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1000/2000/2400 ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

PREFACE

Welcome to the TS3192EN Troubleshooting manual. We make every effort to


keep our service information current and accurate. Because of the time lag
involved with the writing and printing processes, the transmission TCM may
report a code that has not yet been added to this document. If you encounter
a code that is not yet in this publication, please call the Allison Transmission
Technical Assistance Center at 1-800-252-5283.
Click here to go to the table of contents.
TS3192EN

Troubleshooting
Manual

Allison Transmission
ELECTRONIC CONTROLS

1000 Series™
2000 Series™
2000MH Series
2400 Series™

2003 April

Allison Transmission, General Motors Corporation


P.O. Box 894 Indianapolis, Indiana 46202-0894
www.allisontransmission.com

Printed in the U.S.A. Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

FOREWORD — How to Use This Manual

This manual provides troubleshooting information for Allison Transmission Division, 1000 Series™,
2000 Series™, 2000MH Series, and 2400 Series™ transmissions. Service Manual SM3191EN,
Mechanics Tips MT3190EN, 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.

Take time to review the Table of Contents and the manual. Reviewing the Table of Contents will aid you in
quickly locating information.

NOTE: Allison Transmission is providing service of wiring harnesses and wiring harness
components as follows:
• Repair parts for the internal wiring harness will be available through the Allison
Transmission Parts Distribution Center (PDC). Use the P/N from your appropriate
parts catalog or from Appendix E in this manual. Allison Transmission is responsible
for warranty on these parts.
• Repair parts for the external harnesses and external harness components must be
obtained from the vehicle OEM or the OEM is responsible for warranty on these parts.

ii Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

IMPORTANT SAFETY NOTICE

IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings and cautions used in
this manual. These warnings and cautions advise against using specific service procedures
that can result in personal injury, equipment damage, or cause the equipment to become
unsafe. These warnings and cautions are not exhaustive. Allison Transmission could not
possibly know, evaluate, or advise the service trade of all conceivable procedures by which
service might be performed or of the possible hazardous consequences of each procedure.
Consequently, Allison Transmission has not undertaken any such broad evaluation.
Accordingly, ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT
RECOMMENDED BY ALLISON TRANSMISSION MUST first be thoroughly satisfied that
neither personal safety nor equipment safety will be jeopardized by the service procedures
used.

Also, be sure to review and observe WARNINGS, CAUTIONS, and NOTES provided by the
vehicle manufacturer and/or body builder before servicing the Allison transmission in that
vehicle.

Proper service and repair is important to the safe and reliable operation of the equipment. The
service procedures recommended by Allison Transmission and described in this manual are
effective methods for performing troubleshooting operations. Some procedures require using
specially designed tools. Use special tools when and in the manner recommended.

The WARNINGS, CAUTIONS, and NOTES in this manual apply only to the Allison transmission
and not to other vehicle systems which may interact with the transmission. Be sure to review and
observe any vehicle system information provided by the vehicle manufacturer and/or body builder
at all times the Allison transmission is being serviced.

WARNINGS, CAUTIONS, AND NOTES


Three types of headings are used in this manual to attract your attention:

Is used when an operating procedure, practice, etc., which, if not correctly


WARNING! followed, could result in injury or loss of life.

Is used when an operating procedure, practice, etc., which, if not strictly observed,
CAUTION: could result in damage to or destruction of equipment.

NOTE: Is used when an operating procedure, practice, etc., is essential to highlight.

Copyright© 2003 General Motors Corp. iii


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

TRADEMARKS USED IN THIS MANUAL

The following trademarks are the property of the companies indicated:


• 1000 Series™, 2000 Series ™, 2400 Series™ are trademarks of General Motors Corporation.
• Allison DOC™ is a trademark of General Motors Corporation.
• MagiKey™ is a trademark of Micro Processor Systems, Inc.
• LPS® Cleaner is a registered trademark of LPS Laboratories.
• Loctite® is a registered trademark of the Loctite Corporation.
• Teflon® is a registered trademark of the DuPont Corporation.
• Windows™ is a trademark of Microsoft Corporation.

SERVICE LITERATURE
This service literature provides fully illustrated instructions for operation, maintenance, service, overhaul,
and parts support for your transmission. To ensure maximum performance and service life from you unit,
you may order publications from:

SGI, Inc.
Attn: Allison Literature Fulfillment Desk
8350 Allison Avenue
Indianapolis, IN 46268
TOLL FREE: 888-666-5799
INTERNATIONAL: 317-471-4995

1000/2000/2400 Series Service Literature


Publication Name Publication No.
*Mechanic’s Tips MT3190EN
*In-Chassis Maintenance JA3664EN
*Operator’s Manual OM3063EN
*Owner’s Manual (2000MH) OM3364EN
Parts Catalog PC3062EN
Parts Catalog On CD-ROM CD3062EN
Principles Of Operation PO3065EN
Retail Literature Catalog GN2798EN
Service Manual SM3191EN
* Also Available On The Internet At www.allisontransmission.com

iv Copyright© 2003 General Motors Corp.


1000/2000/2400
ALLISON ELECTRONIC
1000/2000/2400 SERIES CONTROLS
ELECTRONIC TROUBLESHOOTING
CONTROLS MANUAL
TROUBLESHOOTING MANUAL
TABLE OF CONTENTS

Page

Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

SAFETY INFORMATION
IImportant Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
Warnings, Cautions, and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
Trademarks Used in This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv
Service Literature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv

SECTION 1. GENERAL DESCRIPTION


1–1. TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
1–2. TRANSMISSION CONTROL MODULE (TCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
1–3. SHIFT SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
A. Shift Selector Range Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
B. Manual Selector Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
C. NSBU Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
1–4. THROTTLE POSITION SENSOR (TPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
1–5. SPEED SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
A. Input (Engine) Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6
B. Turbine Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6
C. Output Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6
1–6. CONTROL VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
1–7. WIRING HARNESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
A. External Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
B. Internal Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9

SECTION 2. DEFINITIONS AND ABBREVIATIONS


2–1. CHECK TRANS LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
2–2. SCAN TOOL INHIBITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
2–3. SCAN TOOL (Allison DOC™) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
2–4. ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4
2–5. RANGE INHIBIT RESPONSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6

SECTION 3. BASIC KNOWLEDGE


3–1. BASIC KNOWLEDGE REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3–2. USING THE TROUBLESHOOTING MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3–3. SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3–4. IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS. . . . . . . . . . . . . 3–2
3–5. BASIC TROUBLESHOOTING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
3–6. TCM REPLACEMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6
3–7. RESETTING OF TCM PARAMETERS TO SUPPORT ENGINE UPDATE. . . . . . . . . . . . . 3–7

Copyright© 2003 General Motors Corp. v


1000/2000/2400
ALLISON ELECTRONIC
1000/2000/2400 SERIES CONTROLS
ELECTRONIC TROUBLESHOOTING
CONTROLS MANUAL
TROUBLESHOOTING MANUAL
T A B L E O F C O N T E N T S (C o n t ' d)

Page

SECTION 4. WIRE CHECK PROCEDURES


4–1. CHECKING OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND . . . . . 4–1
4–2. CHECKING AT TRANSMISSION CONNECTOR AND THE INTERNAL HARNESS
FOR OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND . . . . . . . . . . 4–2

SECTION 5. DIAGNOSTIC TROUBLE CODES (DTC)


5–1. DTC MEMORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
5–2. FAILURE RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
5–3. CODE READING AND DTC CLEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2
A. Clearing DTCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2
B. Clearing Active Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2
5–4. BEGINNING THE TROUBLESHOOTING PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2
A. Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2
B. Solenoid Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
C. Wire/Terminal Numbering Scheme. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
D. Available Diagnostic Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
5–5. DIAGNOSTIC TROUBLE CODES (DTCs — Includes Index) . . . . . . . . . . . . . . . . . . . . . . 5–6

SECTION 6. INPUT AND OUTPUT FUNCTIONS


6–1. SPECIAL INPUT AND OUTPUT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
A. Input Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
B. Output Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1

SECTION 7. GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS . . . . . . . . . . 7–1

APPENDICES
A. DIAGNOSING INTERMITTENT DTCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1
B. MAIN PRESSURE CHECK PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–1
C. SOLENOID AND CLUTCH TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C–1
D. WIRE/CONNECTOR TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–1
E. CONNECTOR REPAIR INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–1
F. THROTTLE POSITION SENSOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F–1
G. WELDING ON VEHICLE/VEHICLE INTERFACE MODULE . . . . . . . . . . . . . . . . . . . . . . . G–1
H. HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H–1
J. WIRING SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J–1
K. RESISTANCE vs. TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K–1
L. ELECTRONIC INTERFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L–1
M. DIAGNOSTIC TOOL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M–1
N. INPUT/OUTPUT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N–1
P. FLUID CHECK PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–1

vi Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

SECTION 1—GENERAL DESCRIPTION

1–1. TRANSMISSION
The 1000 Series™/2000 Series™/2400 Series™ Electronic Controls system features closed-loop clutch control to
provide superior shift quality over a wide range of operating conditions. The 1000/2000/2400 Series configurations
can be programmed to provide five forward speeds, neutral, and reverse. The fifth range has an overdrive gear
ratio. The 1000/2000/2400 Series incorporates a variety of standard and optional design features.

Figure 1–1 is a block diagram of the basic system inputs and outputs.

PRESSURE SWITCH MANIFOLD


NSBU

SPEED SENSORS SOLENOIDS


(VBS, PWM, ON/OFF)
THROTTLE POSITION SENSOR
TCM
VEHICLE/ENGINE TEMPERATURE SENSOR
COMMUNICATION LINKS (SUMP/ENGINE)

INPUTS
OUTPUTS
V05726

Figure 1–1. Transmission Control Module Block Diagram

Figure 1–2 shows the electronic control components.


Electronic Controls consist of the following elements:
• Remote 12V or 24V Sealed Transmission Control Module (TCM)
• Throttle Position Sensor (TPS), electronic engine throttle data, or PWM signal
• Speed Sensors — Input (Engine), Turbine, and Output
• Control Valve Assembly (Electro-Hydraulic Valve Body)
• NSBU Switch
• Pressure Switch Manifold (PSM)
• Wiring Harnesses

NOTE: All external harnesses are OEM-supplied.

Copyright© 2003 General Motors Corp. 1–1


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL DESCRIPTION

TRANSMISSION
CONTROL
MODULE
(TCM)

VEHICLE (J1)
HARNESS “J1”
CONNECTOR
(GRAY)

J1939
TRANSMISSION (J2) CONNECTOR
HARNESS
“J2”
Bulkhead Connector (Optional) CONNECTOR
(RED)

VIW “X”
CONNECTOR

NSBU SWITCH
CONNECTORS

7-PIN
(OEM-SUPPLIED)

12-PIN VIW “Y”


CONNECTOR CONNECTOR
(USED WITH NSBU
P/N 29541852) 4-PIN

THROTTLE POSITION
SENSOR (TPS)
CONNECTOR
(OPTIONAL)

OUTPUT
SPEED SENSOR
THROTTLE CONNECTOR
POSITION
SENSOR (TPS)

TURBINE ENGINE
SPEED SENSOR SPEED SENSOR
CONNECTOR CONNECTOR

MAIN
TRANSMISSION
CONNECTOR

NOTE: Illustration is not to scale. Actual harness


configuration may differ from this illustration.
V06475.01.01

Figure 1–2. Electronic Control Components

1–2 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL DESCRIPTION

1–2. TRANSMISSION CONTROL MODULE (TCM)


The electronic control of the transmission is performed by a microcomputer. The microcomputer is an independent
controller and is referred to as a Transmission Control Module (TCM). TCMs are available in both 12V and 24V
configurations to match the configuration of the vehicle electrical system.
The TCM (Figure 1–3) receives and processes signals from various switches and sensors. The TCM determines
shift sequences, shift timing, and clutch apply and release pressures. The TCM uses the information to control
transmission solenoids and valves, supply system status, and provide diagnostic information.

V05728.01.01

Figure 1–3. Transmission Control Module (TCM)

1–3. SHIFT SELECTOR


The vehicle is equipped with a lever-type shift selector (Figure 1–4). In addition to the lever assembly provided for
the operator, other components associated with the shift selector are the manual selector valve in the main control
valve body and an NSBU switch mounted on the selector shaft. Shift selector components (with the exception of
the transmission selector shaft) are customer-supplied.

A. Shift Selector Range Positions


The operator chooses the transmission range by moving the selector lever to the appropriate
gate position (Figure 1–4). When properly adjusted, the shifter gates prevent inadvertent shifting
between ranges and correspond to the internal transmission detent positions. A positive detent
is provided in the transmission to maintain the selector shaft in the selected position.

SHIFT SELECTOR

P
R
N
OD
D
2
1

TOP VIEW

V06476

Figure 1–4. Typical Lever-Type Shift Selector

Copyright© 2003 General Motors Corp. 1–3


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL DESCRIPTION
The TCM shift calibration determines the available forward ranges for each selector position.
Although specific installations vary, typical selector positions for the 1000/2000/2400 Series are:

P — Park. Parking pawl or parking brake is engaged, if available. This position is not available
on all shift selectors.

R — Reverse.

N — Neutral. May be used when starting the engine and for stationary operations. The NSBU
Switch disables the starter switch if a range other than N (Neutral) or P (Park) is selected before
starting the vehicle.

OD — Overdrive. The highest forward range used for normal driving. The transmission shifts to
first range for starting, then automatically upshifts through the ranges (as operating conditions
permit) until the highest range is attained.

D, 2, 1 — Forward Range. The transmission shifts to first range for starting. The range selected
on the shift selector is the highest range which will be attained during automatic shifting.

B. Manual Selector Valve


The manual shift selector shaft is attached to the manual selector valve within the transmission
main control valve body. The selector valve has three positions: Reverse, Neutral, and Forward.

NOTE: For transmissions equipped with a Park position, the selector valve remains in
the Neutral position when the selector is moved to Park.

The Neutral and Reverse selector valve positions (refer to Appendix H—Hydraulic Schematics)
exhaust the C1 and C2 rotating clutches. By exhausting C1 and C2 clutches, forward range is
inhibited. This provides the capability for the operator to override the electronically commanded
ranges if N (Neutral) is required.

C. NSBU Switch
The installation of a transmission-mounted neutral start/reverse signal switch is required. This
switch, commonly called an “NSBU Switch” (Figure 1–5), mounts directly onto the transmission
housing from the outside and detects the angular position of the shift selector shaft. This
position is communicated to the TCM so that certain vehicle control functions can be
coordinated with the position of the shift controls. The NSBU switch has redundant circuitry to
alert the TCM in the event of a single wire or switch failure.

The neutral signal output of the NSBU switch is typically used as confirmation that the
transmission is in N (Neutral) before the engine starter is engaged. The NSBU switch is
interfaced to the starter circuit with weatherproof electrical connectors. The reverse signal
provision may be used to activate vehicle back-up lights and/or reverse warning devices.

V05729.01.00

Figure 1–5. NSBU Switch

1–4 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL DESCRIPTION

1–4. THROTTLE POSITION SENSOR


The Throttle Position Sensor (TPS) can be mounted to the engine, chassis, or transmission. The TPS (Figure 1–6)
contains a pull actuation cable and a potentiometer. One end of the cable is attached to the engine fuel lever and
the other, inside a protective housing, to the TPS potentiometer. Output voltage from the TPS is directed to the
TCM through the external harness. The voltage signal indicates the throttle position and, in combination with other
input data, determines shift timing.

B
A
C

THROTTLE POSITION
SENSOR (TPS)

V00628.01

Figure 1–6. Throttle Position Sensor

1–5. SPEED SENSORS


There are three speed sensors available for use with 1000/2000/2400 Series transmissions: the input (engine)
speed sensor, the turbine speed sensor, and the output speed sensor (Figure 1–7). The speed sensors provide
rpm information to the TCM. The speed ratios between the various sensors allow the TCM to determine the
transmission operating range. Speed sensor information is also used to control the timing of clutch apply
pressures, resulting in the best possible shift quality.

V04736

Figure 1–7. Typical Speed Sensor

The speed sensors are variable reluctance devices which convert mechanical motion to an AC voltage. Each
sensor consists of a wire coil wrapped around a pole piece that is adjacent to a permanent magnet. These
elements are contained in a housing which is mounted adjacent to a rotating ferrous member (such as a gear
tooth). Two signal wires extend from one end of the housing and an exposed end of the pole piece is at the
opposite end of the housing. The permanent magnet produces lines of flux around the pole piece. As a ferrous
object (such as a gear tooth) approaches and passes through the gap at the end of the pole piece, an AC voltage
pulse is induced in the wire coil. The TCM calculates the frequency of these AC pulses and converts it to a speed
value. The AC voltage generated varies from 150mV at low speed to 15V at high speed. The signal wires from the

Copyright© 2003 General Motors Corp. 1–5


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL DESCRIPTION
sensor are formed as twisted pairs to cancel magnetically induced fields. The cable is also shielded to protect from
voltage-related fields. Noise from other sources is eliminated by using two-wire differential inputs at the TCM.

NOTE: Do not rotate the speed sensor in the retaining bracket. Orientation is fixed, and if changed, may
cause improper operation.

A. Input (Engine) Speed Sensor


The input speed sensor is externally mounted in the torque converter housing directed at the
ribs protruding from the torque converter. The input speed sensor connector should be
positioned at approximately four o’clock, as viewed from the left side of the transmission
(Figure 1–8).

B. Turbine Speed Sensor


The turbine speed sensor is externally mounted in the main housing directed at the tone wheel
or PTO drive gear attached to the rotating clutch module. The turbine speed sensor connector
should be positioned at approximately three o’clock, as viewed from the left side of the
transmission (Figure 1–8).

C. Output Speed Sensor


The output speed sensor is externally mounted in the rear cover and directed at the teeth of a
tone wheel splined to and rotating with the output shaft. The output speed sensor connector
should be positioned at approximately five o’clock, as viewed from the left side of the
transmission (Figure 1–8).

ENGINE SPEED TURBINE SPEED


SENSOR CONNECTOR SENSOR CONNECTOR
ORIENTATION = 4 o'clock ORIENTATION = 3 o'clock

OUTPUT SPEED
SENSOR CONNECTOR
ORIENTATION = 5 o'clock

V06457

Figure 1–8. Speed Sensor Connector Orientation

1–6 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL DESCRIPTION

1–6. CONTROL VALVE ASSEMBLY


The hydraulic control valve assembly (Figure 1–9) governs fluid flow to the clutches (including the torque converter
clutch). Solenoids, actuated by the TCM, control valve movement.
The control valve assembly consists of two components. The main valve body contains the trim valves, the TCC
valve, the exhaust backfill valve, and the control main relief valve. The shift valve body contains the shift valves, the
control main pressure valve, and the manual selector valve. The control valve assembly attaches to the bottom of
the gearbox module and is enclosed by the oil pan. An internal wiring harness connects the solenoids and PSM to
the main transmission connector and external wiring harness.

A. Modulated Main Pressure


Modulated main pressure was added to the 1000/2000/2400 Series product line in the second
quarter of 2003. Starting with DEE software level, the TCM will autodetect if the hardware is
present. Main pressure is reduced by utilizing an additional on/off solenoid (“G”) that is located
in the control valve body assembly. The G solenoid body is bolted to the revised main valve
body. Main pressure will be reduced under various conditions such as low throttle, low torque,
low engine speeds, and low output speeds. The primary benefit of modulating main pressure is
to increase cooler flow at low engine speeds.

A TRIM
B TRIM
E
G D
F
V07476.01.01

Figure 1–9. Control Valve Assembly

1–7. WIRING HARNESSES


A. External Wiring Harness (Figure 1–10)
The external wiring harness requirements are typically met through the use of two separate
harnesses — one connecting the TCM to the transmission, throttle position sensor, NSBU
switch, and speed sensors; another connecting the TCM to the Scan Tool (ST) and other vehicle
interfaces. Each harness may be a single piece or may be divided into two segments joined by
bulkhead connectors. All wiring harnesses and mating connectors are customer-supplied.

Copyright© 2003 General Motors Corp. 1–7


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL DESCRIPTION
NOTE: Allison Transmission is providing for service of wiring harnesses and wiring harness
components as follows:
• Repair parts for the internal wiring harness will be available through the Allison Transmission
Parts Distribution Center (PDC). Use the P/N from your appropriate parts catalog or from
Appendix E in this manual. Allison Transmission is responsible for warranty on these parts.
• Repair parts for the external harnesses and external harness components must be obtained
through the vehicle OEM. The OEM is responsible for warranty on these parts.

VEHICLE (J1)
HARNESS “J1”
CONNECTOR
(GRAY)

TRANSMISSION (J2)
HARNESS J1939
CONNECTOR
“J2”
Bulkhead Connector (Optional) CONNECTOR
(RED)

VIW “X”
CONNECTOR

NSBU SWITCH
CONNECTORS

7-PIN
(OEM-SUPPLIED)

12-PIN
CONNECTOR
(USED WITH NSBU VIW “Y”
P/N 29541852) 4-PIN CONNECTOR

THROTTLE POSITION
SENSOR (TPS)
CONNECTOR
(OPTIONAL)
OUTPUT
SPEED SENSOR
THROTTLE CONNECTOR
POSITION
SENSOR (TPS)

TURBINE ENGINE
SPEED SENSOR SPEED SENSOR
CONNECTOR CONNECTOR

MAIN
TRANSMISSION
NOTE: Illustration is not to scale. Actual harness CONNECTOR
configuration may differ from this illustration.
V06477.01.01

Figure 1–10. Typical External Wiring Harnesses

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ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL DESCRIPTION
B. Internal Wiring Harness (Figure 1–11)
An internal wiring harness connects the shift solenoids, clutch trim solenoids, torque converter
clutch solenoid, pressure switch manifold, and temperature sensor to the external harness
leading to the TCM.

SOL C
13 mm EXTENSION

PSM

SOL G
MAIN
TRANSMISSION
CONNECTOR
SOL A
SOL B
SOL E
SOL D
SOL F V05732.01.02

Figure 1–11. Typical Internal Wiring Harness

Copyright© 2003 General Motors Corp. 1–9


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL DESCRIPTION

NOTES

1–10 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

SECTION 2—DEFINITIONS AND ABBREVIATIONS

2–1. CHECK TRANS LIGHT


The electronic control system is programmed to inform the operator of a problem with the transmission system and
automatically take action to protect the operator, vehicle, and transmission. To do this, the TCM turns on the
CHECK TRANS light on the instrument panel, which notifies the operator that a Diagnostic Trouble Code (DTC)
has been stored.

Each time the engine is started, the TCM will illuminate the CHECK TRANS light, then turn it off after a few
seconds. This is a circuit check to verify that the lamp and wiring are in proper working order. Illumination of the
CHECK TRANS light at any time after start-up indicates that the TCM has set a DTC. The Scan Tool is used to
verify that the TCM has set a DTC (see Paragraph 2–5). While the CHECK TRANS light is on, upshifts and
downshifts may be restricted and direction changes (D–R, R–D) may not occur. The torque converter clutch is
inhibited when transmission shifting is restricted or during any critical transmission malfunction.

The 1000 Series™/2000 Series™/2400 Series™ transmissions DTCs are latching DTCs. When a failure condition
is detected, the DTC set by the TCM remains active for the entire time the ignition is on. When the ignition is turned
off and then on again, the transmission DTCs will reset and the TCM will recheck for the failure condition. If the
failure condition is not present, the previously set DTC will remain in history; the CHECK TRANS light will turn off
after the circuit check, and the transmission will function normally unless another failure occurs. This feature allows
the vehicle to be driven to a service outlet.

2–2. SCAN TOOL INHIBITS


The following inhibit information may be displayed on the Allison DOC™ (Scan Tool), depending on the TCM
software level. If TCM software does not support one of the inhibits listed below, a N/A will be shown in the
information box.
If an inhibit has occurred since the last DTC was cleared, the inhibit state will indicate ON and will stay ON until the
next manual DTC clear with the Scan Tool. These inhibits do not turn OFF after a specified number ignition cycles.
The range inhibit light will illuminate and/or an inhibited state will be shown on the Scan Tool when the transmission
is inhibited to Neutral for the following reasons:

• Low Main Pressure


If the transmission pressure switches do not indicate transmission pressurized at start-up, shifts-to-
range may be inhibited and the range inhibit light will illuminate. The Scan Tool will indicate an active
inhibit.
Common causes are transmission low on fluid, transmission filter has just been changed, or pan has
been removed and fluid recently drained.
May produce P0701.

• Transfer Case Neutral


If the transfer case is shifted into neutral while the transmission is in drive or reverse at a speed above
idle, the transmission will continue to command range until the output speed is reduced to a point where
neutral range is commanded. The range inhibit light will illuminate and the Scan Tool will indicate an
active inhibit.

• Diagnostic Active
This indicates that an active diagnostic code is set and that the CHECK TRANS light should be
illuminated. In some failure modes, Reverse cannot and will not be commanded. If Reverse is selected
during these failure modes a range inhibit light will illuminate in Reverse.
During diagnostic responses, Neutral-to-Range Inhibits and Direction Change Inhibits continue to
operate, but they may latch under certain conditions. In these cases, shutting down ignition and waiting
for at least 5 seconds before re-starting will clear the inhibit condition. The Scan tool will indicate an
active inhibit.

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ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DEFINITIONS AND ABBREVIATIONS


• Auto Neutral for PTO
Neutral-to-Drive and Neutral-to-Reverse shifts will be inhibited to neutral and the Scan Tool will show an
inhibited state when TCM detects that auto neutral function input is active.

• Reverse Enable
Neutral-to-Reverse shifts will be inhibited to neutral and the Scan Tool will show an inhibited state when
no input is detected from dash or floor mounted reverse enable switch when selecting reverse range.
The Scan Tool will indicate an active inhibit.
This function is only used in European transit and tour buses applications.

• Refuse Packer Step Switch


Transmission operation is limited to only 1st range. Neutral-to-reverse shifts will be inhibited to neutral
and the Scan Tool will show an inhibited state when input is detected from a step switch indicating that
personnel is present on rear step platform.

• Auxiliary Function Range Inhibit


Neutral-to-Drive and Neutral-to-Reverse shifts will be inhibited to neutral and the Scan Tool will show an
inhibited state when input is detected from an auxiliary switch or device. This inhibit will remain active
until the auxiliary switch input is shut off and range is reselected.

• PTO Neutral Lockup


The Scan Tool will show an inhibited state when Neutral Lockup is active and range shifts are being
inhibited to neutral. When the selector is moved, lockup is released and the inhibit clears.

• Engine Speed
Neutral-to-Drive and Neutral-to-Reverse shifts will be inhibited to neutral and the range inhibit light
will illuminate if the Engine Speed is greater than a calibrated value (1400 rpm for medium duty
non-emergency vehicles). The Scan Tool will indicate an active inhibit.

• Output Speed
Reverse-to-Drive, Drive-to-Reverse, and Neutral-to-Reverse shifts initiated above 300 rpm of output
speed will be inhibited to neutral and the range inhibit light will illuminate. The Scan Tool will indicate an
active inhibit.

• Throttle
Reverse-to-Drive, Drive-to-Reverse, Neutral-to-Drive, and Neutral-to-Reverse shifts where throttle
position is greater then 25 percent will be inhibited to neutral and the range inhibit light will illuminate.
The Scan Tool will indicate an active inhibit.

• NSBU Function or Alignment


Reverse-to-Drive, Drive-to-Reverse, Neutral-to-Drive, and Neutral-to-Reverse shifts will be inhibited to
neutral and the range inhibit light will illuminate when a NSBU failure or misalignment is detected.
Common cause would be an error in the four-bit NSBU switch input signal that is sent to the TCM. The
Scan Tool will indicate an active inhibit.

• NSBU RPS Disagree


Reverse-to-Drive, Drive-to-Reverse, Neutral-to-Drive, and Neutral-to-Reverse shifts will be inhibited to
neutral and the range inhibit light will illuminate when the reverse pressure switch status is in the
incorrect state when compared to the NSBU switch state. The Scan Tool will indicate an active inhibit.

• MSV Mis-Alignment/Unable to detect ratio after shift to range


If the range verification test fails to detect turbine speed pull-down or valid gear ratio when shifting to
either forward or reverse range from neutral, the transmission will shift back to a neutral condition and
the range inhibit light will illuminate.

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ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DEFINITIONS AND ABBREVIATIONS


Conditions that may cause this include: Attempts to shift the transmission from Neutral-to-Drive or
Neutral-to-Reverse with the transfer case in neutral; transmission low on fluid; misadjustment in the
NSBU or Selector Linkage; turbine or output speed sensor failure that may prevent the pull down test/
ratio test from passing; solenoid A or B hydraulically failures; and possibly failed range clutch (C1 or C5
for 1st, C3 or C5 for Reverse).
The Scan Tool will indicate an active inhibit response.
• Wheel Spin or Lock
When the TCM detects that wheel lock or spin is occurring, the TCC is disengaged and a lock-to-range
response is commanded for 6 seconds. The Scan Tool will indicate an active inhibit response.

2–3. SCAN TOOL (Allison DOC™) (Figure 2–1)


The current Scan Tool (ST) is the PC Tool Software Allison DOC™, which is available through Kent-Moore
Heavy-Duty Division. When installed on a Windows™ 95/98 PC, the Allison DOC™ transmits and receives data to
and from the TCM via the vehicle data communications link, processes the data, and displays appropriate
information. Use Allison DOC™ during installation checkout and troubleshooting.
For more details on Allison DOC™ features, see information in Appendix M.

V05490

Figure 2–1. Scan Tool

Copyright© 2003 General Motors Corp. 2–3


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DEFINITIONS AND ABBREVIATIONS

2–4. ABBREVIATIONS
A/N Assembly Number
ABS Anti-lock Brake System—OEM-provided means to detect and prevent wheel stoppage to
enhance vehicle handling. Retarder and engine brakes will not apply when ABS is active.
Amp Ampere—Unit of electrical current
CAN Controller Area Network—A network for all SAE J1939 communications in a vehicle
(engine, transmission, diagnostics, ABS, etc.)
CC Calibration Compatibility—First two digits of the CIN
CIN Calibration Identification Number—Used to identify transmission controls software level
CT Closed Throttle
DNA Does Not Adapt—Adaptive shift control is disabled.
DNS DO NOT SHIFT—Refers to the DO NOT SHIFT diagnostic response during which the
CHECK TRANS light is illuminated and the transmission will not shift and will not respond
to the Shift Selector.
DTC Diagnostic Trouble Code
DVOM Digital volt/ohmmeter
ECM Engine Controller Module—Available on electronically-controlled engines—provides some
relevant data to TCM.
EMI ElectroMagnetic Interference
GPI General Purpose Input—Input signal to the TCM to request a special operating mode or
condition.
GPO General Purpose Output—Output signal from the TCM to control vehicle components
(such as PTOs, backup lights, etc.) or allow a special operating mode or condition.
IPC Instrument Panel Controller
J1939 High-speed vehicle serial data communications link.
LED Light-Emitting Diode—Electronic device used for illumination.
LRTP Low-Range Torque Protection—A feature limiting engine torque in lower ranges to protect
the transmission from damage when a stall condition occurs.
NNC Neutral No Clutches—Neutral commanded with no clutches applied.
NSBU Switch Neutral Start Backup Switch
NVL Neutral Very Low—The TCM has sensed turbine speed below 150 rpm. This is usually
caused by a dragging C1 or C3 clutch or a failed turbine speed sensor. When attained, the
C4 and C5 clutches are applied to lock the transmission output.
OBD II On Board Diagnostics Second generation. EPA mandated specification for vehicle
diagnostics.
OEM Original Equipment Manufacturer—Maker of vehicle or equipment.
Ohm Unit of electrical resistance.
PC Personal Computer
PCCS Production Calibration Configuration System
PCM Powertrain Controller Module—Electronic device used on some vehicles.
PDM Parallel Data Module

2–4 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DEFINITIONS AND ABBREVIATIONS

2–4. ABBREVIATIONS (cont’d)


PPC Pressure Proportional to Current solenoid. Solenoid control of clutch pressure is
proportional to the current being supplied to the solenoid.
PROM Programmable Read Only Memory
PSM Pressure Switch Manifold—Part of transmission control system located inside the oil pan.
PTO Power Takeoff
PWM Solenoid Pulse Width Modulated Solenoid—Solenoids are controlled by pulse width modulation.
Solenoid control of clutch pressures is based on the solenoid’s duty cycle. Duty cycle is
determined by the ratio of solenoid’s on-time to off-time.
RFI Radio Frequency Interference
RPR Return to Previous Range—Diagnostic response in which the transmission is commanded
to return to previously commanded range.
SEM Shift Energy Management—Currently used on 2000MH Series. Allows the TCM to request
torque reduction from the ECM during upshifts for increased clutch life.
SOL OFF All SOLenoids OFF
ST Scan Tool—Most current version is the Allison DOC™. Diagnostic tool used to interrogate
the TCM for diagnostic information.
TBC Truck Body Controller
TCC Torque Converter Clutch
TCM Transmission Control Module (also commonly referred to as the “computer”)
TFT Transmission Fluid Temperature—Data provided by thermistor that is part of the PSM.
TPS Throttle Position Sensor—Potentiometer for signaling the position of the engine fuel control
lever.
V Version—Abbreviation used in describing TCM software levels.
VBS Variable Bleed Solenoid—Another name for Pressure Proportional to Current (PPC)
solenoid. Solenoid control of clutch pressure is proportional to the current being supplied
to the solenoid.
VDC Volts Direct Current (DC)
VIW Vehicle Interface Wiring—Interfaces TCM programmed input and output functions with the
vehicle wiring.
Volt Unit of electrical force
VOM Volt/ohmmeter
WOT Wide Open Throttle
∞ Infinity—Condition of a circuit with higher resistance than can be measured; effectively an
open circuit.

Copyright© 2003 General Motors Corp. 2–5


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DEFINITIONS AND ABBREVIATIONS

2–5. RANGE INHIBIT RESPONSES


The range inhibit feature is a function of the TCM logic. The TCM senses when certain input variables are
exceeded and takes action to prevent transmission damage. The TCM inhibits neutral-to-range shifts and
illuminates a light on the dash when the inhibit is active.

Listed below are three variables that, when exceeded, cause inhibited shifts (with thresholds listed).
• Engine speed above 1000 rpm
• Throttle setting above 40 percent
• Output speed above 225 rpm

There are two levels of the special logic inhibits.


• Self-clearing inhibit—This inhibit clears itself if one of the above conditions is not present after a
calibrated time. This is three seconds in the case of medium-duty vehicles. If the shift inhibit is active,
but not latched, the bulb will stay lit until self-cleared.
• Latching inhibit — This inhibit latches when one of the conditions listed above is still present after a
calibrated time. This is above three seconds for medium duty vehicles. To clear a latching inhibit, move
the selector into any other position than the one originally selected.

2–6 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

SECTION 3—BASIC KNOWLEDGE

3–1. BASIC KNOWLEDGE REQUIRED

To service 1000/2000/2400 Series Electronic Controls, the technician must understand basic electrical concepts.
Technicians need to know how to use a volt/ohmmeter (VOM) to make resistance and continuity checks. Most
troubleshooting checks consist of checking resistance and continuity, and checking for shorts between wires and to
ground. The technician should be able to use jumper wires and breakout harnesses and connectors. Technicians
unsure of making the required checks should ask questions of experienced personnel or find instruction.
The technician should also have the mechanical aptitude required to connect pressure gauges or transducers to
identified pressure ports used in the troubleshooting process. Pressure tap locations and pressure values are
shown in Appendix B — Main Pressure Check Procedure.

Input power, ground, neutral start circuitry, etc., can cause problems with electronic controls or vehicle functioning
and may not generate a DTC. A working knowledge of 1000/2000/2400 Series Electronic Controls vehicle
installation is necessary in troubleshooting installation-related problems.

Refer to Section 7 for information concerning performance complaints (non-DTC) troubleshooting. A complete
wiring schematic is shown in Appendix J. Refer to the Sales Tech Data Book for information concerning electronic
controls installation and the Installation Checklist. Reliable transmission operation and performance depend upon a
correctly installed transmission. Review the Installation Checklist in the 1000 Series™/2000 Series™/2400 Series™
Sales Tech Data Book to ensure proper installation.

NOTE: Allison Transmission is providing for service of wiring harnesses and wiring harness
components as follows:
• Repair parts for the internal wiring harness will be available through the Allison Transmission
Parts Distribution Center (PDC). Use the P/N from your appropriate parts catalog or from
Appendix E in this manual. Allison Transmission is responsible for warranty on these parts.
• Repair parts for the external harnesses and external harness components must be obtained
through the vehicle OEM. The OEM is responsible for warranty on these parts.

3–2. USING THE TROUBLESHOOTING MANUAL


Use this manual as an aid to troubleshooting the 1000/2000/2400 Series Electronic Controls. Every possible
problem and its solution cannot be encompassed by any manual. However, this manual does provide a starting
point from which most problems can be resolved.
Once a problem solution is discovered in the manual do not look further for other solutions. It is necessary to
determine why a problem occurred. The root cause of a problem as well as the symptom must be corrected to
ensure trouble free operation. For example, taping a wire that has been rubbing on a frame rail will not correct the
problem unless the rubbing contact is eliminated.

3–3. SYSTEM OVERVIEW


1000/2000/2400 Series Electronic Control functions are controlled by the TCM. The TCM reads shift selector range
selection, output speed, and throttle position to determine when to command a shift. When a shift occurs, the TCM
monitors turbine speed, output speed, and throttle position to control the oncoming and off-going clutches during
the shift.
When the TCM detects an electrical fault, it logs a DTC indicating the faulty circuit and may alter the transmission
operation to prevent or reduce damage.

When the TCM detects a non-electrical problem while trying to make a shift, the TCM may try that shift a second or
third time before setting a DTC. Once that shift has been retried, and a fault is still detected, the TCM sets a DTC
and holds the transmission in a fail-to-range mode of operation.

Copyright© 2003 General Motors Corp. 3–1


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

BASIC KNOWLEDGE
The 1000/2000/2400 Series transmission utilizes “clutch to clutch” shift control to achieve range changes. In
every case (except shifts to or from neutral), one clutch is exhausted and another applied to make a range shift.
The “handoff” between exhausting and applying clutches is very precisely controlled by use of two “PPC” (Pressure
Proportional to Current) solenoids. These solenoids are labeled A and B in the transmission, and are referred to as
“trim” solenoids. For example, to make a 1–2 shift, A solenoid is used to trim pressure off C5 clutch, and B solenoid
is used to trim pressure on C4 clutch.

The TCM (transmission control module) modulates the current to both A and B solenoid, which translates to a
proportional level of pressure to the clutch. In order to make a shift, the TCM uses software and calibration settings
of several program parameters to determine the level of current sent to the respective trim solenoids. These
parameters are referred to as “adaptive values”. With a new transmission and TCM calibration, the adaptive
values are set to “base calibration” level. The transmission uses the base calibration to perform the first of each
type of shift. However, once it has performed a shift, the TCM evaluates the actual shift and compares it to an
“ideal” shift in the TCM’s memory. Based on that comparison, the TCM changes the settings of the adaptive values
to a level that it believes will result in a shift closer to the “ideal” shift the next time it makes that type of shift. This is
referred to as “adaptive shifting.”

When the transmission/TCM calibration is new, the TCM is in “fast adaptive” mode. In other words, the TCM is
allowed to make relatively large changes in the adaptive values after each shift. Once the TCM determines that a
given shift is close to its ideal level it switches to “slow adaptive” mode. In slow adaptive the TCM still is evaluating
shifts and changing adaptive values, but is only allowed to do so in smaller increments. When a shift switches from
fast to slow adaptive mode, it is described as “converged”.

The TCM is programmed to try to switch from fast to slow adaptive mode within approximately five shifts. It is
important to understand that there are many different distinct shifts recognized by the TCM, and each of these
shifts has its own adaptive values. For example, there are upshift and downshifts to and from each range, as well
as unique adaptive values for several different throttle regions for each upshift and downshift. The point is, it may
take a significant amount of time before most of the shifts converge from fast to slow adaptive, and thus it is not
unusual to experience somewhat harsh or unpleasant shift quality until these shifts are converged.
TCC engagement is accomplished by a separate PWM (pulse-width modulated) solenoid labeled “F” in the
transmission. There are adaptive values for this as well, and thus it will also require some driving for TCC
engagement to converge.

3–4. IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS


Before beginning the troubleshooting process, read and understand the following:
• Allison recommended wire numbers (i.e. 212) are a combination of the first digit indicating the TCM
connector number (i.e. J2) and the last two digits indicating the pin-out information (i.e. 12).
• Shut off the engine and ignition before any harness connectors are disconnected or connected.
• Remember to do the following when checking for shorts and opens:
— Minimize movement of wiring harnesses when looking for shorts. Shorts involve wire-to-wire or
wire-to-ground contacts and moving the harnesses may eliminate the problem.
— Wiggle connectors, harnesses, and splices when looking for opens. This simulates vehicle
movements which occur during actual operation.
• When disconnecting a harness connector, be sure that pulling force is applied to the connector itself and
not the wires extending from the connector.
• Resistance checks involving the wiring between the TCM connectors and other components adds about
one Ohm of resistance to the component resistance shown.
• Inspect all connector terminals for damage. Terminals may have bent or lost the necessary tension to
maintain firm contact.

3–2 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

BASIC KNOWLEDGE
• Clean dirty terminals or connectors with isopropyl alcohol and a cotton swab, or a good quality, non-
residue, non-lubricating, cleaning solvent such as LPS Electro Contact Cleaner® or LPS NoFlash
Electro Contact Cleaner®.

The cleaning solvent must not be chlorine based, contain petroleum distillates, or conduct
electricity. The cleaning solvent should evaporate quickly to prevent the possibility of
condensation within the connectors. Always blow or shake any excess cleaner from the
CAUTION: connector before assembling it to its mating connector or hardware. Cleaner trapped in
the connector can affect the connector seal. (Refer to SIL 17-TR-94 for detailed
information on the recommended cleaners.)

Care should be taken when welding on a vehicle equipped with electronic controls. Refer
CAUTION: to Appendix G, Paragraph 1–1.

• DTCs displayed after system power is turned on while a harness connector is disconnected can be
ignored and cleared from memory. Refer to Section 5, DTCs, for the DTC clearing procedure.

3–5. BASIC TROUBLESHOOTING INFORMATION


1. Begin troubleshooting by checking the transmission fluid level and ignition voltage. Remember that
some problems may be temperature related. Do troubleshooting, including the fluid level and ignition
voltage checks, at the temperature level where the problem occurs.

NOTE: Fluid level and igniton voltage MUST be checked before any troubleshooting is performed.

NOTE: If you are experiencing harsh shifts, it is important to use the Scan Tool to check whether that
particular shift is converged. If it is not, the TCM is still “learning” how to adapt that shift and
simply needs to be driven further while performing more of that particular type of shift.
If a particular shift is converged but still objectionable, it’s good troubleshooting practice to reset
the adaptive values for that shift back to “base cal” level. This will automatically reset the TCM to
fast adaptive mode. The vehicle should then be driven to allow the TCM to “re-learn” the shift.
Many times this will correct the problem. It is possible to reset individual shifts without affecting
the other shifts.

Whenever a transmission is overhauled, exchanged, or has undergone repairs, the


Transmission Control Module (TCM) must be “RESET TO UNADAPTED SHIFTS.” This
CAUTION: will cause the TCM to erase previous adaptive information and begin to adapt in Fast
Adaptive Mode from the base calibration. Failure to follow this procedure may cause
premature failure of the overhauled, repaired, or replaced transmission.

2. If a transmission has been overhauled, exchanged, or repaired, use the Allison DOC™ to “RESET TO
UNADAPTED SHIFTS”. Accomplish the reset by doing the following:
• Select the Shift Selector icon.
• Select the Reset Adaptives icon.
• Push the Reset All Adaptive Values button.
At the “Are you sure you want to reset all adaptive parameters?” prompt, select “OK.”

Copyright© 2003 General Motors Corp. 3–3


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

BASIC KNOWLEDGE
3. Before using your Allison DOC™ Scan Tool, check the following:
• The desktop or laptop computer must meet the minimum system requirements (see Allison DOC™
User Guide, GN3433EN):
— Microsoft Windows 95B™, Windows ME ™, Windows NT 4.0™ (SP6 or later), Windows
2000™ (SP1 or later), or Windows XP™
— 60 MB free hard drive space (an additional 440 MB of disc space needed if training videos are
stored on hard drive)
— 64 MB of RAM
— Intel® Pentium® II processor
— Available serial port and parallel port
— 1024 x 768 screen resolution
— 256-color palette
— Small fonts
— A media player program (Windows Media Player® is provided on the Allison DOC™ CD)
— Adobe® Acrobat® Reader® (provided on the Allison DOC™ CD)

NOTE: Refer to the CD Readme.txt file for more information.


• The proper driver (electronic file) is installed for the Computer Interface Module.
• Power at the Deutsch 9-pin diagnostic connector (pin A is negative’ pin B is positive).
• The proper connections exist for communicating with Allison DOC™ Scan Tool (Figure 3–1 and
Figure 3–2).
Presently there are two communication standards for Allison DOC™ diagnostic software: J 1939 and
J 1850. Both standards are supported by Allison DOC™ (versions 2.0, 2.05, 3.0, and 3.1).

The Deutsch 9-pin vehicle connector should always be used to establish communication for
troubleshooting. If it is necessary to use the J 43890 T-Adapter Harness, the following conditions
will occur:

• DTC U2105 CAN bus error sets.


• The CHECK TRANS light illuminates (beginning with M04 software, effective March 2000).
• The TCM freezes shift adapts.
• The TCM inhibits TCC engagement.
• Throttle information is defaulted; the TCM estimates throttle data from torque converter slip.

J 42660

RP1210A – COMPLIANT
COMPUTER J 42660-90
INTERFACE BOX
(MPSI MAGIKEY™ SHOWN) V06528.00.02

Figure 3–1. Proper Allison DOC™ Scan Tool Connections — J1939

3–4 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

BASIC KNOWLEDGE

J 44652
DDL ADAPTER
J 1850/OBD II
HEAVY DUTY
(GMC)

SPX J 1850 – VPW


DIAGNOSTIC INTERFACE BOX

V06527.00.01

Figure 3–2. Proper Allison DOC™ Scan Tool Connections — J1850

The J1850 Diagnostic Interface Box (J 44652) utilizes a serial port connection, rather than a parallel
port, and is used only for off-board diagnostic communications. J1939 is still used for on-board
communications such as throttle position; therefore it will necessary to use the J1939 T-Adapter Harness
(J 43890) and MPSI MagiKey™ Interface Box (J 42660) to perform a recalibration (Figure 3–3).

VEHICLE TCM J 43890

J 42660
J1 VEHICLE
HARNESS

MPSI MAGIKEY™
INTERFACE BOX

J 42660-90

V06526.00.01

Figure 3–3. Proper Allison DOC™ Scan Tool Connections Using J1939 T-Adapter Harness (J 43890)

Copyright© 2003 General Motors Corp. 3–5


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

BASIC KNOWLEDGE
4. Check DTCs by using the Scan Tool.

5. When a problem exists but a DTC is not indicated, refer to the General Troubleshooting Section
(Section 7) for a listing of various electrical and hydraulic problems, their causes, and remedies.

6. If a DTC is found in the TCM memory, save all available DTC and failure record information before
clearing the active indicator (refer to Section 5).

7. When certain DTCs are active, a range selection into reverse or forward may not be possible. To
determine if a failure is electrical or hydraulic, perform the following “limp home” test.

Never remove electronic control connectors while the engine is running. Always
WARNING! turn off the ignition, set parking brakes and chock the wheels. Failure to follow this
procedure may result in unexpected vehicle movement.

Limp Home Test

With the ignition in the OFF position (engine not running), the selector in N (Neutral) and the parking
brake set, remove the wiring harness from the main transmission connector. When the engine is
restarted, the transmission will default to a “limp home” capability. In this state, trim solenoid A (de-
energized) allows C3 clutch to be applied. If the selector valve is moved to the reverse range position,
main pressure will be routed to C5 clutch, allowing reverse operation. If the selector valve is moved to
the drive range position, main pressure will be routed to C1 clutch, allowing third range operation.

This allows a technician to use “limp home” capability to determine if a hydraulic or an electrical
problem exists. If reverse and third ranges are available in “limp home,” an electrical failure may be
indicated. If only one of the two ranges or neither was obtainable, this may indicate an internal
hydraulic failure (failed clutch, stuck valve, or solenoid failure). The clutches that could possibly have
an indicated failure in “limp home” are C1, C3, and C5.

NOTE: Removing the main transmission connector will induce several DTCs. Make sure all codes are
cleared before proceeding with further troubleshooting.

8. Test drive the vehicle to confirm a DTC or performance complaint.


• If the DTC reappears, refer to the DTC section (Section 5) and the appropriate DTC table. The
DTC section lists diagnostic codes and their description. Locate the appropriate troubleshooting
table and follow the instructions.
• If the DTC does not reappear and the test has passed, it may be an intermittent problem. Use the
Scan Tool (Allison DOC™) and the DTC (Section 5). The DTC display procedure will identify
possible causes of the problem.
• Appendix A deals with the identification of potential circuit problems. Refer to Appendix A if a circuit
problem is suspected.

NOTE: Information concerning specific items is contained in the appendices located in the back of this
manual. The appendices are referred to throughout the manual.

3–6. TCM REPLACEMENT PROCEDURE


• Using the Scan Tool, verify the current calibration information number (CIN) and record or print a report
of the current customer modifiable constants (CMC) information for later reference.
• Remove the J1 and J2 connectors from the suspect TCM; inspect the J1 and J2 connectors for
damaged or bent pins.

3–6 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

BASIC KNOWLEDGE
• Replace TCM with a new or known good TCM from a similar vehicle.
• If the replacement TCM corrects the original complaint, reinstall the original TCM to verify the complaint
returns. If original complaint is confirmed, reinstall a new TCM.
• If the complaint does not return, leave the original TCM installed. Disconnecting and reconnecting the
TCM can often correct faulty wiring harness connections that may have been present.
• Clear any DTCs that may be present and test drive the vehicle to confirm the repair.

NOTE: All 1000/2000/2400 Series TCMs are designed to be isolated from the vehicle chassis ground. Be
sure that the TCM case is not contacting the vehicle frame or any other point that might provide
a ground connection.

3–7. RESETTING OF TCM PARAMETERS TO SUPPORT ENGINE UPDATE

Shift Energy Management (SEM) Autoselect feature was added to TCM software in the second quarter of
2002.

Autoselect is deactivated following the first 20 engine starts where engine and transmission
communication are present. If during the first 20 engine starts the TCM recognizes an engine to be on its
list of certified engines, it will lock to the SEM active state. If the engine is not supported, the TCM will lock
to a non-SEM state.
TCM Autoselect Certified Engines
Autoselect Functionality
Software Implemented in
CC Level Level TCM Software Engine Type Supported
16 U02 May 2002 Cummins ISB
18 U2A July 2002 Cummins ISB02
19 DEE September 2002 Cummins ISBe (6-cylinder)
N/A N/A Proposed first quarter 2004 Caterpillar C7

ISB engine software since December 2001 should support SEM, as well as most ISBe since
October 2002. ISB02 ECM software started supporting SEM in July 2002.

NOTE: Most engine upgrades are same type/rating; under normal circumstances there should be no
reason to reset the TCM Autoselect.

However, there may be a small chance that transmission performance, shift quality, or codes may result
from the use of different engine models within the same engine family or when a recalibration of engine
software has taken place. If a vehicle receives upgraded engine hardware or software it may become
necessary to reactivate the Autoselect feature to redetect the engines current SEM status.

NOTE: Once TCM Autoselect locks, the only way to reactivate is to perform the power-off data erase
procedure described below.

3–8. RESETTING TCM AUTOSELECT

Verify a new engine rating by checking the engine data tag. The engine must be compatible with the
transmission rating. If the engine rating is not compatible, the vehicle must be returned to the OEM for
engine recalibration. If the rating is correct for the transmission, perform the following steps.

Copyright© 2003 General Motors Corp. 3–7


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

BASIC KNOWLEDGE
PCCS Load Station is used to reset Autoselect function, to do this it is necessary to clear all power-off data
currently stored in the TCM.
• Go to the Maintenance button and select “Erase Power-off Data”
• After selecting “Erase Power-off data”, a message will indicate “PCCS is going to erase Power-off
data”. Select “Yes”. Selecting “No” will abort the clearing of Power-off Data.
• After clearing Power-off Data, there will be a prompt to cycle the ignition.
The TCM is now reset to Autoselect and will start looking for supporting engine software.
Drive the vehicle; confirm DTCs have not returned.

NOTE: Transmission shifts will now be in the unadaptive (base) state, so it will be necessary to drive the
vehicle to allow shifts to converge.
Autoselect reset function will be incorporated into the Allison DOC™ service tool at a later date, along with
an indication of the current SEM Autoselect status.

3–8 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

SECTION 4—WIRE CHECK PROCEDURES

4–1. CHECKING OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND


(Use Digital Volt/Ohmmeter J 34520-A and Jumper Wire Set J 39197)

NOTE: Please refer to Paragraph 3–5 to begin the troubleshooting process.

1. Make sure all connectors are tightly connected and re-check the circuit.

2. Disconnect and inspect all connectors.

3. Thoroughly clean corroded or dirty terminals. If dirty or corroded terminals are the probable cause of
the problems, reconnect the clean connectors and operate the vehicle normally. If the problem recurs,
proceed with Step (4).

The cleaning solvent must not be chlorine based, contain petroleum distillates, or
conduct electricity. The cleaning solvent should evaporate quickly to prevent the
possibility of condensation within the connectors. Always blow or shake any excess
CAUTION: cleaner from the connector before assembling it to its mating connector or hardware.
Cleaner trapped in the connector can affect the connector seal. (Refer to SIL 17-TR-94
for detailed information on the recommended cleaners.)

4. Review the wire numbering system described in Paragraph 3–4.

5. If all connectors are clean and properly seated, determine which wires in the chassis harness are in-
dicated by the DTC. For example, DTC P0748, indicates an open or a short-to-ground in the
solenoid A circuit — wires 222 and 223.
a. Check continuity of wires 222 and 223 by performing the following (Figure 4–1):
(1) Disconnect the red (J2) connector from the TCM and disconnect the harness from the
transmission main connector. At one end of the harness, using jumper wire kit J 39197 and
connector probes in J 39775-CP, connect wire 222 and 223 to each other, being careful not to
distort the terminals. Jumping the wires together creates a circuit between wires 222 and 223.

TRANSMISSION CONNECTOR

WIRING HARNESS
JUMPER
TCM
“J2” CONNECTOR

0
VOLT/OHM-
– METER –
+ (VOM) +
0 OHMS OHMS
Circuit has continuity. Jumper Circuit does not have continuity due
from 222 or 223 to another wire to a broken wire (open circuit).
produces a complete circuit. VOM VOM reading is very high
reading is near zero Ohms. (infinite Ohms or OL – overlimit). V06478

Figure 4–1. Checking Continuity (External Harness)

Copyright© 2003 General Motors Corp. 4–1


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

WIRE CHECK PROCEDURES


(2) On the opposite end of the harness, check the continuity of the jumpered pair. No continuity in
a jumpered pair circuit (infinite resistance reading) indicates an open in the wire being tested.
Refer to OEM wiring harness repair procedure.
b. If the continuity check is good (0–2 Ohms resistance), remove the jumpers. Check the harness for
shorts between wires and shorts-to-ground by performing the following (refer to Figure 4–2):
(1) At the TCM end of the harness, touch one VOM probe to one wire of the circuit being tested
and touch the other probe to each terminal in the same connector, then touch the probe to
chassis ground and to the transmission main housing. Do this for both wires in the circuit
being tested.
(2) If at any time the VOM shows zero to low resistance, or the meter’s continuity beeper sounds,
there is a short between the two points being probed — wire-to-wire or wire-to-ground. Isolate
and repair the short.

TRANSMISSION CONNECTOR

WIRING HARNESS

TCM
“J2” CONNECTOR
Wires shorted
together
Shorted to
ground on
metal frame
rail

Ground
to metal
frame rail
0 0
VOLT/OHM-
METER
– (VOM) –
+ +
0 OHMS 0 OHMS
Two wires have frayed and are shorted Harness has been chafed and one or more
together. Continuity beeper of VOM will wires are shorted-to-ground. VOM continuity
sound, or reading will go to zero Ohms beeper will sound, or reading will go to zero
when these two wires are probed with Ohms when meter is probing between this wire
the VOM. and chassis ground. V05734

Figure 4–2. Short Between Wires and to Ground (External Harness)

4–2. CHECKING AT TRANSMISSION CONNECTOR AND THE INTERNAL HARNESS


FOR OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND
1. Disconnect the external wiring harness from the transmission.

2. Inspect the connectors. Any terminals which are corroded or dirty must be thoroughly cleaned.

The cleaning solvent must not be chlorine based, contain petroleum distillates, or
conduct electricity. The cleaning solvent should evaporate quickly to prevent the
possibility of condensation within the connectors. Always blow or shake any excess
CAUTION: cleaner from the connector before assembling it to its mating connector or hardware.
Cleaner trapped in the connector can affect the connector seal. (Refer to SIL 17-TR-94
for detailed information on the recommended cleaners.)

4–2 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

WIRE CHECK PROCEDURES


3. If the connectors are clean and properly seated, determine which wires in the harness to test. Use
the diagnostic code system schematic to locate the wire terminals. For this example, DTC P0748
indicates an open or a short-to-ground in the solenoid “A” circuit — wires 222 and 223 (refer to
Figure 4–3 and Figure 4–4).
a. At the transmission connector, check the resistance of the A solenoid circuit. Resistance of a
solenoid circuit should be 5.5–8 Ohms — covering a temperature range of –18°C to 149°C
(0°F to 300°F). Refer to Solenoid Resistance vs. Temperature chart in Appendix K. No continuity
in the circuit (infinite resistance) indicates an open in the internal harness, the feedthrough
connector, or the solenoid coil. Replace the internal harness, replace the feedthrough connector,
or replace the solenoid.

SOLENOID
MAIN
TRANSMISSION
CONNECTOR

3.5

– –
+ +

VOLT/OHM-
METER
(VOM)
INFINITE ( ) OHMS
5.5–8 OHMS Circuit does not have continuity due to a
AT NORMAL OPERATING broken wire (open circuit). VOM reading is
TEMPERATURE* very high (infinite ohms or OL–overlimit).
Circuit has continuity. This could also be due to an open solenoid
coil or bad connection.
* Refer to Appendix K V05735

Figure 4–3. Checking Continuity (Internal Harness)

b. If the resistance check is good, check the harness for shorts between wires and to ground by per-
forming the following (refer to Figure 4–4):
(1) At the transmission connector, touch one probe of the VOM to one wire of the circuit being
tested and touch the other probe to each terminal in the connector and to chassis ground and
the transmission main housing. Do this for both wires in the circuit being tested.
(2) If the VOM shows zero to low resistance, or the continuity beeper sounds, there is a short
between the two points being probed, wire-to-wire or wire-to-ground. An indication of a short
may be caused by a splice to the wire being checked. Check the wiring diagram in Appendix J
for splice locations. If the short is not a splice, then isolate and repair the short.

Copyright© 2003 General Motors Corp. 4–3


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

WIRE CHECK PROCEDURES

Shorted
to metal

MAIN
TRANSMISSION SOLENOIDS
CONNECTOR
Bare wires
touching
each other

0
0
VOLT/OHM- –

METER +
+ (VOM)

0 OHMS 0 OHMS
Two wires have frayed and are shorted Harness has been chafed and one or more
together. Continuity beeper of VOM will wires are shorted to ground. VOM continuity
sound, or reading will go to zero Ohms beeper will sound or meter reading will go
when these two wires are probed with to zero Ohms when meter is probing between
the VOM. this wire and chassis ground. V05736

Figure 4–4. Short Between Wires and to Ground (Internal Harness)

NOTE: When conducting circuit checks that include the external harness, add one (1) Ohm to the values
shown. Speed sensor resistance is 2304–2815 Ohms at 20°C (68°F).

4–4 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

SECTION 5 — DIAGNOSTIC TROUBLE CODES (DTC)


5–1. DTC MEMORY
Diagnostic Trouble Codes (DTCs) are logged in a list in TCM memory. The DTCs contained in the list have
information recorded as shown in Table 5–1 (DTCs are examples). The TCM is capable of displaying all historical
and active DTCs.
Table 5–1. DTC List
Active CHECK
Code DTC Description Indicator TRANS Light
P0562 System Voltage Low Y Y
P0875 Transmission Pressure Switch Reverse Circuit N N
P0743 Torque Converter Clutch PWM Solenoid Circuit N Y
P1892 Throttle Position Sensor PWM Signal High Input N N
The following paragraphs define the different parts of the DTC list.
A. Code. The number assigned to a given fault condition in accordance with SAE J2012.
B. DTC Description. Name assigned to a given fault condition in accordance with SAE J2012.
C. Active Indicator. Indicates when a DTC is active. If a DTC is active, the Scan Tool displays Y (Yes). If
DTC is not active, N (No) is displayed.
D. CHECK TRANS Light. Indicates if CHECK TRANS Light/Malfunction Indicator Lamp (MIL) is
illuminated.

5–2. FAILURE RECORDS


Failure records contain a snapshot of transmission data that is stored in the TCM when DTCs are logged. A limit of
five failure records can be stored. When an additional DTC is logged, the new failure record pushes the oldest
record from the TCM memory. Table 5–2 illustrates the failure record data stored in the TCM when a DTC is set.

Table 5–2. Failure Record Data


Data Description
Gear Selected
Gear Commanded
Current Gear
Previous Gear
Ignition Voltage
Trans Fluid Temperature (TFT)
Trans Input Shaft Speed
Trans Output Shaft Speed
Turbine Speed
Present Gear Ratio
Normalized TPS
Force Motor Solenoid A Actual Current
Force Motor Solenoid B Actual Current
Force Motor Solenoid A Pressure
Force Motor Solenoid B Pressure
TCC PWM Duty Cycle
PSM C
PSM D

Copyright© 2003 General Motors Corp. 5–1


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Table 5–2. Failure Record Data (cont’d)
Data Description
PSM E
PSM R
Shift Solenoid C
Shift Solenoid D
Shift Solenoid E
Engine Run Time

5–3. DTC READING AND DTC CLEARING


DTCs can be read and cleared by using the Allison DOC™ scan tool. The use of Allison DOC™ is described in the
instruction manual furnished with each tool and briefly in Appendix M of this manual.
A. Clearing DTCs
• DTCs will automatically clear after 40 code-free warm-up cycles.
• DTCs can be manually cleared by the Allison DOC™.
B. Clearing Active Indicators
• A DTC’s active indicator can be cleared, which removes the DTC’s shift inhibitions while the DTC
remains in the queue as inactive.
• The active indicator clearing method is to power down (all active indicators are cleared at TCM
power down).

If an active indicator is cleared while the transmission is locked in a forward range or


CAUTION: reverse (fail-to-range), the transmission will remain in the forward range or reverse after the
clearing procedure is completed. N (Neutral) must be manually selected.

5–4. BEGINNING THE TROUBLESHOOTING PROCESS


A. Starting Procedure
NOTE: Review Paragraph 3–5, “Basic Troubleshooting Information” and check fluid level and ignition
voltage before any troubleshooting is performed.
1. Begin troubleshooting by reading Paragraph 3–5, checking the transmission fluid level and the
TCM input voltage. Check for DTCs by using the Allison DOC™ diagnostic tool.
2. When a problem exists, but a DTC is not indicated, refer to Section 7 — General Troubleshooting
Performance Complaint for a listing of various electrical and hydraulic problems, their causes, and
remedies.
3. If a DTC is found in the TCM memory, record all available DTC information and failure record data
before clearing the DTC (refer to Paragraph 5–3).
4. Test drive the vehicle to confirm a DTC or performance complaint.
• If the DTC reappears, refer to the DTC paragraph (Paragraph 5–5) and the appropriate DTC
table. The DTC section lists DTCs and their description. Locate the appropriate troubleshooting
table and follow the instructions.
• If the DTC does not reappear, it may be an intermittent problem. Use the Allison DOC™ and the
DTC display procedure described in Section 5. Refer to the troubleshooting table for possible
causes of the problem.
• Appendix A deals with the identification of potential circuit problems. Refer to Appendix A if a
circuit problem is suspected.

5–2 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


NOTE: Information concerning specific items is contained in the appendices located in the back of this
manual. The appendices are referred to throughout the manual.
B. Solenoid Locations
Solenoid locations in the control module are as illustrated in Figure 5–1. Refer to Figure 5–1 as
necessary when using the DTC schematics.

A TRIM
B TRIM
E
G D
F
V07476.01.01

Figure 5–1. Solenoid Locations

C. Wire/Terminal Numbering Scheme


Allison Transmission recommended wire numbers (i.e. 212) consist of three digits, where the first digit
indicates the TCM connector number (i.e. J2=2), and the last two digits indicate the pin-out
information (i.e. 12).
D. Available Diagnostic Adapters
Figures 5–2 and 5–3 show the J 43799 and J 44722 Adapters that are available for use with the
J 39700 Breakout Box.

Copyright© 2003 General Motors Corp. 5–3


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)

J 43799 ADAPTER CABLE


1 2 3 4 5 6 7 8
J 39700 BREAKOUT BOX
9 10 11 12 13 14 15 16

17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32

Detail of
Magnetic Overlay
for use with
J 43799
Adapter Box

To
Ground

Existing
E
L
R 9

B
E 9

x)
A

0
T 7

70 Bo
C
P 43

-39 ut
A J-

h J ako
wit re
se l B
(U ersa
J1 and J2
D
A

iv
Un
Harnesses
“J2”
CONNECTOR
(RED)

TRANSMISSION
CONTROL
MODULE
(TCM)
“J1”
CONNECTOR
(GRAY)

“J1”
CONNECTOR
(GRAY)

“J2”
CONNECTOR V06827.00.00
(RED)

Figure 5–2. J 39700 Breakout Box And J 43799 Adapter

5–4 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)

J 39700 BREAKOUT BOX 1000/2000/2400 SERIES TM

ENGINE SPEED TURBINE SPEED OUTPUT SPEED


SENSOR SENSOR SENSOR

A B A B A B
DOUBLE 4A 4B 4C 4D
CONNECTOR SINGLE
NSBU CONNECTOR
5 6 8 4 NSBU
MAIN TRANSMISSION CONNECTOR

A B C D E F G H

J K L M N P R S

T U V W
SPEED SENSORS PIN A + B 2500 Ω @ 68˚ F

Shift selector pre-select ranges


are calibration dependent. 5 4 3 1
5 4 2 1
PIN SWA P R N 5 3 2 1
A A OFF OFF ON ON OFF OFF ON
NSBU SWITCH D B ON OFF OFF OFF OFF ON ON
OPEN ON C C ON ON ON OFF OFF OFF OFF
CLOSE/GROUNDED OFF G P OFF ON OFF ON OFF ON OFF

- NSBU TERMINAL REFERENCE -


DOUBLE CONNECTOR NSBU USES ALPHA-NUMERIC.
SINGLE CONNECTOR NSBU USES NUMERIC.

SOL A PIN M + L 5-6 Ω @ 68˚ F


SOL B PIN N + P 5-6 Ω @ 68˚ F
SOL C PIN A + C 21 - 23 Ω @ 68˚ F
SOL D PIN B + C 21 - 23 Ω @ 68˚ F
SOL E PIN W + C 21 - 23 Ω @ 68˚ F
SOL F PIN J + S 10 - 11 Ω @ 68˚ F
SOL G PIN J + R 21 - 23 Ω @ 68˚ F
PIN SWA R N 1 2 3 4 5
PRESSURE SWITCH A B OFF ON ON OFF OFF — ON
MANIFOLD B C ON ON OFF OFF OFF — OFF
C P OFF OFF OFF ON OFF — ON
OPEN OFF D B ON OFF ON ON OFF — OFF
CLOSE/GROUNDED – Switch C Off in Rev. starting with
ON TCM software level NO4 or later.

SUMP TEMP PIN G + H 3088-3942 Ω @ 68˚ F

J-44722-A
FORM 1B

Detail of
Magnetic Overlay
for use with
J 44722-A
Transmission
Breakout Harness

To Existing
Harness
To Engine
To Speed Sensor
Existing
NSBU

To 4-Pin
Connector Harness
To Existing
Harness
To Existing 12-Pin
Single Harness To Turbine
Speed Sensor
J 46971 Harness for use with
Single Connector NSBU Switch

To Existing
Harness
To Output
Speed Sensor

To Existing To Main Case


4-Pin Harness Connector
To NSBU To Existing
4-Pin Connector 32-Pin Harness V06828.01.01

Figure 5–3. J 39700 Breakout Box And J 44722 Adapter

Copyright© 2003 General Motors Corp. 5–5


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


5–5. DIAGNOSTIC TROUBLE CODES (DTCs)
DTC LIST AND DESCRIPTION INDEX
CHECK
TRANS
DTC Description Light Page
P0122 Pedal Position Sensor Circuit Low Voltage Yes 5–16
P0123 Pedal Position Sensor Circuit High Voltage Yes 5–20
P0218 Transmission Fluid Over Temperature Condition No 5–24
P0561 Unrealistic Variations In Vehicle System Voltage Yes 5–27
P0562 System Voltage Low Yes 5–31
P0563 System Voltage High Yes 5–34
P0602 TCM Not Programmed Yes 5–37
P0606 Controller Internal Performance—Not enabled for Pickups or med duty “04” Yes 5–38
P0614 Torque Control Data Mismatch—ECM/TCM Yes 5–39
P0701 Transmission Control System Performance No 5–41
P0703 Brake Switch Circuit Malfunction—GMT800 only No 5–43
Transmission Range Sensor Circuit (PNRDL input)
P0705✝ N/A
Not production enabled/could be in development cals
Transmission Range Sensor Circuit (Performance)
P0706✝ N/A
Not production enabled/could be in development cals
P0708 Transmission Range Sensor Circuit High Input Yes 5–46
Transmission Fluid Temperature Sensor Circuit
P0710✝ N/A
Not production enabled/could be in development cals
P0711 Transmission Fluid Temperature Sensor Circuit Performance No 5–50
P0712 Transmission Fluid Temperature Sensor Circuit Low Input (High Temperature) No 5–54
P0713 Transmission Fluid Temperature Sensor Circuit High Input (Low Temperature) No 5–58
P0716 Turbine Speed Sensor Circuit Performance Yes 5–62
P0717 Turbine Speed Sensor Circuit No Signal Yes 5–65
P0719 Brake Switch ABS Input Low N/A 5–69
P0721 Output Speed Sensor Circuit Performance Yes 5–71
P0722 Output Speed Sensor Circuit No Signal Yes 5–75
P0726 Engine Speed Input Circuit Performance No 5–79
P0727 Engine Speed Input Circuit No Signal No 5–82
P0731 Incorrect 1st Gear Ratio Yes 5–85
P0732 Incorrect 2nd Gear Ratio Yes 5–88
P0733 Incorrect 3rd Gear Ratio Yes 5–91
P0734 Incorrect 4th Gear Ratio Yes 5–94
P0735 Incorrect 5th Gear Ratio Yes 5–97
P0736 Incorrect Reverse Ratio Yes 5–100
P0741 Torque Converter Clutch System Stuck Off Yes 5–104
P0742 Torque Converter Clutch System Stuck On Yes 5–107
P0743 Torque Converter Clutch PWM Solenoid Circuit—Electrical (Previously P1860) Yes 5–110
P0746 Solenoid A Controlled Clutch Stuck Off (Previously P1720) Yes 5–115
P0747 Solenoid A Controlled Clutch Stuck On (Previously P1723) Yes 5–118
P0748 Pressure Control Solenoid A Electrical Yes 5–121
P0763 Shift Solenoid C Electrical Yes 5–126

5–6 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC LIST AND DESCRIPTION INDEX (cont’d)
CHECK
TRANS
DTC Description Light Page
P0768 Shift Solenoid D Electrical Yes 5–131
P0773 Shift Solenoid E Electrical Yes 5–135
P0776 Solenoid B Controlled Clutch Stuck Off (Previously P1721) Yes 5–139
P0777 Solenoid B Controlled Clutch Stuck On (Previously P1724) Yes 5–142
P0778 Pressure Control Solenoid B Electrical Yes 5–145
P0840 Transmission Pressure Switch Solenoid C Circuit Yes 5–150
P0841 Transmission Pressure Switch Solenoid C Circuit Stuck Open Yes 5–155
P0842 Transmission Pressure Switch Solenoid C Circuit Stuck Closed Yes 5–160
P0843 Transmission Pressure Switch Solenoid C Circuit High Yes 5–165
P0845 Transmission Pressure Switch Solenoid D Circuit Yes 5–170
P0846 Transmission Pressure Switch Solenoid D Circuit Stuck Open Yes 5–175
P0847 Transmission Pressure Switch Solenoid D Circuit Stuck Closed Yes 5–180
P0848 Transmission Pressure Switch Solenoid D Circuit High Yes 5–185
P0870 Transmission Pressure Switch Solenoid E Circuit (Previously P1709) Yes 5–190
P0871 Transmission Pressure Switch Solenoid E Circuit Stuck Open (Previously P1710) Yes 5–195
P0872 Transmission Pressure Switch Solenoid E Circuit Stuck Closed (Previously P1711) Yes 5–200
P0873 Transmission Pressure Switch Solenoid E Circuit High (Previously P1712) Yes 5–205
P0875 Transmission Reverse Pressure Switch Circuit Malfunction (Previously P1713) Yes 5–210
Transmission Reverse Pressure Switch Circuit Stuck Open (Previously P1714)
P0876 Yes 5–215
Not production enabled/could be in development cals
Transmission Reverse Pressure Switch Circuit Stuck Closed (Previously P1715)
P0877✝ N/A
Not production enabled/could be in development cals
Transmission Reverse Pressure Switch Circuit High (Previously P1716)
P0878✝ N/A
Not production enabled/could be in development cals
P0880 TCM Supply Voltage (Previously P1760) No 5–220
Pressure Control Solenoid Control Circuit
P0960✝ N/A
Not production enabled/could be in development cals
P1688 Unmanaged Engine Torque Delivered To TCM Signal See Note 5–223
P1709 See DTC P0870 5–190
P1710 See DTC P0871 5–195
P1711 See DTC P0872 5–200
P1712 See DTC P0873 5–205
P1713 See DTC P0875 5–210
P1714 See DTC P0876 5–215
P1715 See DTC P0877
P1716 See DTC P0878
P1720 See DTC P0746 5–115
P1721 See DTC P0776 5–139
P1723 See DTC P0747 5–118
P1724 See DTC P0777 5–142
P1760 See DTC P0880 5–220
P1779 Engine Torque Delivered To TCM Signal See Note 5–225

Copyright© 2003 General Motors Corp. 5–7


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC LIST AND DESCRIPTION INDEX (cont’d)
CHECK
TRANS
DTC Description Light Page
P1860 See DTC P0743 5–110
P1891 Throttle Position Sensor Pulse Width Modulation (PWM) Signal Low Input No 5–227
P1892 Throttle Position Sensor Pulse Width Modulation (PWM) Signal High Input No 5–230
P2771 Four-Wheel Drive Switch Circuit (Previously P0836, P1875 ) Yes 5–233
P2773 Torque Control Request Ignored—ECM/TCM Yes 5–237
P2810 Solenoid G Electrical Yes 5–239
U0031 J1850 (Class 2) Serial Data Communication Link Low (Previously U1300) No 5–243
U0032 J1850 (Class 2) Serial Data Communication Link High (Previously U1301) No 5–246
U0073 CAN Bus Reset Counter Overrun (Previously U2104) Yes 5–249
U0100 CAN Bus ECM Error (Previously U2105) Yes 5–252
U1000 Class 2 Loss of Serial Data Communication 5–255
U1016 J1850 (Class 2) Powertrain Controller State of Health Failure No * 5–255
U1041 J1850 (Class 2) ABS Controller State of Health Failure No * 5–255
U1064 J1850 (Class 2) TBC Controller State of Health Failure No * 5–255
U1096 J1850 (Class 2) IPC Controller State of Health Failure No * 5–255
U1300 See DTC U0031 5–243
U1301 See DTC U0032 5–246
U2104 See DTC U0073 5–249
U2105 See DTC U0100 5–252
* Enabled for MY2001 Non-OBD Vehicles.
✝ Call Technical Assistance Center (TAC) at 1-800-252-5283 for further information.

NOTE: Used with GM gasoline engine applications only—CHECK TRANS light will illuminate.

DTC REFERENCE TABLES


Gear Ratio Table
Range 1000 Series™ Gear Ratio 2000 Series™/2400 Series™ Gear Ratio
1 3.10:1 3.51:1
2 1.81:1 1.90:1
3 1.41:1 1.44:1
4 1.00:1 1.00:1
5 0.71:1 0.74:1
R –4.49:1 –5.09:1

Main Pressure Schedule Table (Used Prior To S/N 6310004116)

Range Main Pressure @ 600 rpm Main Pressure @ 2100 rpm


Forward Converter 800–1380 kPa (115–200 psi) 1515–1795 kPa (220–260 psi)
Forward Lockup — 1000–1170 kPa (145–170 psi)
Reverse 800–1380 kPa (115–200 psi) 1515–1795 kPa (220–260 psi)
Neutral/Park 900–1655 kPa (130–240 psi) 1515–1795 kPa (220–260 psi)

5–8 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)

Main Pressure Schedule Table (Used Starting With S/N 6310004116)

Range Main Pressure @ 600 rpm Main Pressure @ 2100 rpm


Forward Converter 700–1380 kPa (102–200 psi) 1515–1795 kPa (220–260 psi)
Forward Lockup — 1000–1170 kPa (145–170 psi)
Reverse 700–1380 kPa (102–200 psi) 1515–1795 kPa (220–260 psi)
Neutral/Park 800–1655 kPa (116–240 psi) 1515–1795 kPa (220–260 psi)

Modulated Main Pressure Schedule (Transmissions with Modulated Main G Solenoid)

Range Main Pressure @ 600 rpm Main Pressure @ 2100 rpm


Forward/Reverse Converter with G Solenoid 590–720 kPa (85–105 psi) 634–758 kPa (92–110 psi)
Active (viewable in Allison DOC™)
Forward Converter with G Solenoid Inactive 700–1380 kPa (101–200 psi) 1515–1795 kPa (220–260 psi)
Forward Lockup with G Solenoid Active* — 510–627 kPa (74–91 psi)
Forward Lockup with G Solenoid Inactive* — 1000–1170 kPa (145–170 psi)
Neutral/Park with G Solenoid Active 590–720 kPa (85–105 psi) —
Neutral/Park 800–1655 kPa (130–240 psi) 1515–1795 kPa (220–260 psi)
* Medium duty gasoline engines only.

NSBU Switch Table

Selector Position A B C P
P OFF ON ON OFF
R OFF OFF ON ON
N ON OFF ON OFF
5 5 5 ON OFF OFF ON
3 4 4 OFF OFF OFF OFF
2 2 3 OFF ON OFF ON
1 1 1 ON ON OFF OFF
ON = Open Circuit
OFF = Grounded Circuit
The NSBU Switch has only four positions available in the forward ranges. Therefore, one range
position will be omitted at the selector. This position may be 2nd, 3rd, 4th, or 5th range
depending upon chosen calibration.

Copyright© 2003 General Motors Corp. 5–9


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Solenoid and Clutch Table — Software Levels Prior To N04

Clutch To Trim Solenoids Shift Solenoids TCC Sol


Range Status Logic Main A B C D E F
Steady State R — De-energized; Energized; ON ON ON OFF
C3 Applied C5 Applied
Garage Shift R–N — De-energizing; Energizing; ON ON ON OFF
C3 Trimming Off C5 Applied
Garage Shift N–R — Energizing; Energizing; ON ON ON OFF
C3 Trimming On C5 Applied
Steady State N — De-energized; De-energized; ON ON ON OFF
C5 Applied Exhausted
Garage Shift N–1 — De-energizing; Energizing; ON ON ON OFF
C5 Applied C1 Trimming On
Garage Shift 1–N — De-energizing; Energizing; ON ON ON OFF
C5 Applied C1 Trimming Off
Steady State 1 C1 De-energized; De-energized; OFF ON OFF OFF
C5 Applied C4 Exhausted
Upshift 1–2 C1 Energizing; Energizing; OFF ON OFF OFF
C5 Trimming Off C4 Trimming On
Downshift 2–1 C1 Energizing; Energizing; OFF ON OFF OFF
C5 Trimming On C4 Trimming Off
Steady State 2 C1 Energized; Energized; OFF OFF OFF ON or
C3 Exhausted C4 Applied OFF *
Upshift 2–3 C1 De-energizing; De-energizing; OFF OFF OFF ON
C3 Trimming On C4 Trimming Off
Downshift 3–2 C1 De-energizing; De-energizing; OFF OFF OFF ON
C3 Trimming Off C4 Trimming On
Steady State 3 C1 De-energized; De-energized; ON OFF OFF ON
C3 Applied C2 Exhausted
Upshift 3–4 C1 Energizing; Energizing; ON OFF OFF ON
C3 Trimming Off C2 Trimming On
Downshift 4–3 C1 Energizing; Energizing; ON OFF OFF ON
C3 Trimming On C2 Trimming Off
Steady State 4 C2 Energized; Energized; ON OFF ON ON
C3 Exhausted C1 Applied
Upshift 4–5 C2 De-energizing; De-energizing; ON OFF ON ON
C3 Trimming On C1 Trimming Off
Downshift 5–4 C2 De-energizing; De-energizing; ON OFF ON ON
C3 Trimming Off C1 Trimming On
Steady State 5 C2 De-energized; De-energized OFF OFF ON ON
C3 Applied
* Depending upon output speed

5–10 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Solenoid and Clutch Table — Software Level N04 And Later
ClutchTo Trim Solenoids Shift Solenoids TCC Sol
Range Status Logic Main A B C D E F
Steady State R — De-energized; Energized; ON ON ON OFF
with Throttle C3 Applied C5 Applied
Steady State R — De-energized; Energized; OFF ON ON OFF
at Closed C5 Applied C3 Applied
Throttle
Garage Shift R–N — De-energizing; Energizing; OFF ON ON OFF
C3 Trimming Off C5 Applied
Garage Shift N–R — Energizing; Energizing; OFF ON ON OFF
C3 Trimming On C5 Applied
Steady State N — De-energized; De-energized; ON ON ON OFF
C5 Applied Exhausted
Garage Shift N–1 — De-energizing; Energizing; ON ON ON OFF
C5 Applied C1 Trimming On
Garage Shift 1–N — De-energizing; Energizing; ON ON ON OFF
C5 Applied C1 Trimming Off
Steady State 1 C1 De-energized; De-energized; OFF ON OFF OFF
C5 Applied C4 Exhausted
Upshift 1–2 C1 Energizing; Energizing; OFF ON OFF OFF
C5 Trimming Off C4 Trimming On
Downshift 2–1 C1 Energizing; Energizing; OFF ON OFF OFF
C5 Trimming On C4 Trimming Off
Steady State 2 C1 Energized; Energized; OFF OFF OFF ON or
C3 Exhausted C4 Applied OFF **
Upshift 2–3 C1 De-energizing; De-energizing; OFF OFF OFF ON
C3 Trimming On C4 Trimming Off
Downshift 3–2 C1 De-energizing; De-energizing; OFF OFF OFF ON
C3 Trimming Off C4 Trimming On
Steady State 3 C1 De-energized; De-energized; ON OFF OFF ON
C3 Applied C2 Exhausted
Upshift 3–4 C1 Energizing; Energizing; ON OFF OFF ON
C3 Trimming Off C2 Trimming On
Downshift 4–3 C1 Energizing; Energizing; ON OFF OFF ON
C3 Trimming On C2 Trimming Off
Steady State 4 C2 Energized; Energized; ON OFF ON ON
C3 Exhausted C1 Applied
Upshift 4–5 C2 De-energizing; De-energizing; ON OFF ON ON
C3 Trimming On C1 Trimming Off
Downshift 5–4 C2 De-energizing; De-energizing; ON OFF ON ON
C3 Trimming Off C1 Trimming On
Steady State 5 C2 De-energized; De-energized OFF OFF ON ON
C3 Applied
Beginning with N04 software level, the following throttle-dependent conditions occur in Reverse range:
At closed throttle (idle), C solenoid is OFF, A trim solenoid controls C-5 clutch, and B solenoid controls C-3 clutch.
Above 20 percent throttle*, C solenoid is ON, A trim solenoid controls C-3 clutch, and B solenoid controls C-5.
Under 10 percent throttle*, the TCM reverts to the closed throttle (idle) schedule.
* Values are calibration dependent ** Depending upon output speed

Copyright© 2003 General Motors Corp. 5–11


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)

Pressure Switch Status Table — Software Levels Prior To N04

Pressure Switch C Pressure Switch D Pressure Switch E Pressure Switch R


(N/O) (N/O) (N/O) (N/C)
Switch Scan Tool Switch Scan Tool Switch Scan Tool Switch Scan Tool
Range Status Status Status Status Status Status Status Status
R Closed ON Closed ON Closed ON Closed ON
N Closed ON Closed ON Closed ON Open OFF
1 Open OFF Closed ON Open OFF Open OFF
2 Open OFF Open OFF Open OFF Open OFF
3 Closed ON Open OFF Open OFF Open OFF
4 Closed ON Open OFF Closed ON Open OFF
5 Open OFF Open OFF Closed ON Open OFF
N/O = Normally OpenN/C = Normally Closed

Pressure Switch Status Table — Software Level N04 And Later

Pressure Switch C Pressure Switch D Pressure Switch E Pressure Switch R


(N/O) (N/O) (N/O) (N/C)
Switch Scan Tool Switch Scan Tool Switch Scan Tool Switch Scan Tool
Range Status Status Status Status Status Status Status Status
R Open OFF* Closed ON Closed ON Closed ON
N Closed ON Closed ON Closed ON Open OFF
1 Open OFF Closed ON Open OFF Open OFF
2 Open OFF Open OFF Open OFF Open OFF
3 Closed ON Open OFF Open OFF Open OFF
4 Closed ON Open OFF Closed ON Open OFF
5 Open OFF Open OFF Closed ON Open OFF
N/O = Normally OpenN/C = Normally Closed
* C pressure switch reverts to the CLOSED/ON state with throttle applied in Reverse.

Solenoid Resistance vs. Temperature Table

Solenoid A, B Solenoid C, D, E, G Solenoid F


Sump Temperature Resistance Resistance Resistance
(°C) (°F) (Ω) (Ω) (Ω)
0 32 4.5 20.0 9.5
20 68 5.5 22.0 10.5
40 104 6.5 24.5 11.5
80 176 7.5 27.0 12.5
120 248 8.5 29.5 13.5

5–12 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)

Speed Sensor Resistance vs. Temperature Table

Temperature
Temperature ( Minimum Resistance Nominal Resistance Maximum Resistance
(°C) F) (Ω) (Ω) (Ω)
–25 –13 1929 2143 2358
0 32 2157 2397 2637
25 77 2340 2600 2860
50 122 2614 2904 3195
75 167 2842 3158 3474
100 212 3071 3412 3753
125 257 3299 3666 4032
150 302 3483 3870 4257

Transmission Fluid Temperature (TFT) Sensor Resistance vs. Temperature Table

Temperature Temperature Minimum Resistance Nominal Resistance Maximum Resistance


(°C) (°F) (Ω) (Ω) (Ω)
–45 –49 128 565 141 951 155 338
–40 –40 95 826 100 735 105 644
–35 –31 68 952 72 315 75 679
–30 –22 50 153 52 480 54 807
–25 –13 36 854 38 478 40 103
–20 –4 27 345 28 488 29 631
–15 5 20 476 21 286 22 097
–10 14 15 467 16 045 16 624
–5 23 11 781 12 197 12 612
0 32 9045 9345 9646
5 41 6998 7219 7441
10 50 5458 5623 5787
15 59 4291 4413 4536
20 68 3398 3490 3582
25 77 2710 2779 2849
30 86 2173 2228 2282
35 95 1754 1797 1840
40 104 1424 1459 1493
45 113 1163 1191 1218
50 122 955.0 977.1 999.2
55 131 788.6 806.5 824.5

Copyright© 2003 General Motors Corp. 5–13


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Transmission Fluid Temperature (TFT) Sensor Resistance vs. Temperature Table (cont’d)

Temperature Temperature Minimum Resistance Nominal Resistance Maximum Resistance


(°C) (°F) (Ω) (Ω) (Ω)
60 140 654.7 669.3 683.9
65 149 546.3 558.3 570.2
70 158 458.1 467.9 477.8
75 167 385.9 394.1 402.2
80 176 326.6 333.3 340.1
85 185 277.5 283.2 288.9
90 194 236.5 241.6 246.7
95 203 202.4 206.9 211.5
100 212 173.8 177.9 182.0
105 221 149.8 153.6 157.3
110 230 129.7 133.0 136.4
115 239 112.6 115.6 118.7
120 248 98.17 100.88 103.6
125 257 85.87 88.29 90.71
130 266 75.35 77.52 79.69
135 275 66.34 68.27 70.21
140 284 58.58 60.31 62.04
145 293 51.88 53.42 54.97
150 302 46.08 47.46 48.84
155 311 41.04 42.27 43.50
160 320 36.65 37.74 38.84

TPS Table (Distance (mm) of Travel vs. Volts)


mm Volts mm Volts mm Volts mm Volts
0 0 12 1.317 24 2.634 36 3.951
1 0.110 13 1.427 25 2.744 37 4.061
2 0.220 14 1.537 26 2.854 38 4.171
3 0.329 15 1.646 27 2.964 39 4.281
4 0.439 16 1.756 28 3.073 40 4.390
5 0.549 17 1.866 29 3.183 41 4.500
6 0.659 18 1.976 30 3.293 42 4.610
7 0.768 19 2.085 31 3.403 43 4.720
8 0.878 20 2.195 32 3.512 44 4.829
9 0.988 21 2.305 33 3.622 45 4.939
10 1.098 22 2.415 34 3.732 46 5.049
11 1.207 23 2.524 35 3.842

5–14 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)

Clutch Test Failure Table


Range — Clutches
Applied C1 Failure C2 Failure C3 Failure C4 Failure C5 Failure
*Reverse / C3 and C5 NT > 0 in 3rd NT > 0 in 1st
and 5th only

First / C1 and C5 NT > 0 in 1st NT > 0 in 1st


and 4th only

Second / C1 and C4 NT > 0 in 1st NT > 0 in 4th


and 4th only

Third / C1 and C3 NT > 0 in 1st NT > 0 in 3rd


and 4th only

Fourth / C1 and C2 NT > 0 in 1st NT > 0 in 4th


and 4th and 5th

Fifth / C 2 and C3 NT > 0 in 4th NT > 0 in 3rd


and 5th and 5th

* CAUTION: Reverse is not attainable in clutch test mode. Do not stall transmission in Reverse or driveline
damage may occur.

NOTE: NT is transmission turbine speed observed during clutch test

Copyright© 2003 General Motors Corp. 5–15


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0122 Pedal Position Sensor Circuit Low Voltage

J2 HARNESS CONNECTOR
(RED)
J2-9

TCM
TPS
CONNECTOR
J2-20 J2-19

J2

J1
A
B
C

219
C J2-19 5V
TCM
THROTTLE 209 ANALOG
POSITION B J2-9
INTERFACE
SENSOR
(TPS) 220
A J2-20

V06225.01.00

Circuit Description

The Transmission Control Module (TCM) receives input on throttle position from either a Throttle Position Sensor
(TPS) or a signal transmitted by the engine electronic controls.

Vehicles not equipped with electronically-controlled engines have a TPS attached to the engine fuel control linkage.
The TPS continuously sends the exact throttle position to the transmission TCM.

The TPS is a sliding resistor sensor (potentiometer) actuated by a mechanical linkage. The TCM delivers a
constant voltage to one terminal of the TPS resistive strip. The other TPS terminal connects to ground. The resistor
contacts of the TPS are connected to provide a regulated voltage signal input to the TCM.

When actuated by the mechanical throttle cable, the contacts of the resistor move along the resistive strip. As the
contacts slide along the resistive strip, a voltage is sent to the TCM. At each increment of 0.178 mm (0.007 inch)
along the resistive strip, the contacts deliver a different voltage to the TCM. The different voltages are interpreted as
throttle sensor movement. The TCM converts travel distance (mm) into throttle opening percentage.

Conditions for Running the DTC


• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• DTC P0123 Pedal Position Sensor Circuit High Voltage is not active.

5–16 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Conditions for Setting the DTC
DTC P0122 sets when the TCM detects a throttle position sensor voltage less than 0.55V for 5 seconds.

Action Taken When the DTC Sets


• DTC P0122 is stored in the TCM history.
• The TCM uses the default throttle value.
• The TCM freezes shift adapts (DNA).
• The TCM inhibits TCC engagement.
• The CHECK TRANS light is illuminated.

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
• You may have to drive the vehicle in order to experience a fault.

Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests for the proper adjustment of TPS.
3. This step tests for the proper ignition voltage.
4. This step tests for the proper reference voltage from TCM.
5. This step tests for dead spots in the TPS rheostat.
6. This step tests for a high or low resistance in the TPS internal circuit.
7. This step tests for a harness-wiring problem.

DTC P0122 Pedal Position Sensor Circuit Low Voltage


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Refer to Appendix F to check for proper TPS — Go to Step 3 Adjust TPS to
adjustment. proper setting.
Is the TPS adjusted properly? Go to Step 11

Copyright© 2003 General Motors Corp. 5–17


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0122 Pedal Position Sensor Circuit Low Voltage
Step Action Value(s) Yes No
3 1. Install the Scan Tool. 9–18V Go to Step 4 Resolve
2. Start the engine. (12V TCM); voltage problem
3. Record the DTC Failure Record data. 18–32V (Refer to
4. Using the Scan Tool, measure ignition (24V TCM) DTC P0562
voltage. and P0563)
Is voltage within the specified value?
4 1. Turn the ignition OFF. 4.75–5.0V Go to Step 5 Go to Step 10
2. Disconnect the J2 connector from the TCM
and install the J43799 adapter box.
3. Reconnect the J2 connector to the adapter
box. With the engine OFF, turn the ignition to
the ON position.
4. Using a DVOM, measure the voltage
between pins 19 and 20.
Is the voltage within the specified value?
5 1. With the engine OFF and the ignition in the — Go to Step 6 Go to Step 7
ON position, monitor throttle percentage with
the Scan Tool.
2. Slowly increase the throttle from Idle to the
full throttle position.
3. Watch for a steady increase in throttle
percentage.
Was the throttle percentage steady and without
interruptions?
6 1. Turn the ignition OFF. 9,000–15,000 Go to Step 7 Go to Step 9
2. Disconnect the TPS connector. Ohms
3. Using a DVOM, measure the resistance at
pins A and C.
Is resistance within the specified value?
7 1. Reconnect the TPS connector. 9,000–15,000 Go to Diagnostic Go to Step 8
2. Disconnect J2 connector from the TCM. Ohms Aids
3. Using a DVOM, measure resistance at
connector J2 pins 19 and 20.
Is resistance within the specified value?
8 NOTE: The vehicle OEM has responsibility — Go to Step 10 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?
9 Replace the throttle position sensor. — Go to Step 11 —
Is the replacement complete?

5–18 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0122 Pedal Position Sensor Circuit Low Voltage
Step Action Value(s) Yes No
10 NOTE: In most cases, the TCM is not at fault. — Go to Step 11 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM.
Is the replacement complete?
11 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under normal driving Go to Step 1
conditions.
Did the DTC return?

Copyright© 2003 General Motors Corp. 5–19


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0123 Pedal Position Sensor Circuit High Voltage

J2 HARNESS CONNECTOR
(RED)
J2-9

TCM
TPS
CONNECTOR
J2-20 J2-19

J2

J1
A
B
C

219
C J2-19 5V
TCM
THROTTLE 209 ANALOG
POSITION B J2-9
INTERFACE
SENSOR
(TPS) 220
A J2-20

V06225.01.00

Circuit Description
The Transmission Control Module (TCM) receives input on throttle position from either a Throttle Position Sensor
(TPS) or a signal transmitted by the engine electronic controls.

Vehicles not equipped with electronically-controlled engines have a TPS attached to the engine fuel control linkage.
The TPS continuously sends the exact throttle position to the transmission TCM.

The TPS is a sliding resistor sensor (potentiometer) actuated by a mechanical linkage. The TCM delivers a
constant voltage to one terminal of the TPS resistive strip. The other TPS terminal connects to ground. The resistor
contacts of the TPS are connected to provide a regulated voltage signal input to the TCM.

When actuated by the mechanical throttle cable, the contacts of the resistor move along the resistive strip. As the
contacts slide along the resistive strip, a voltage is sent to the TCM. At each increment of 0.178 mm (0.007 inch)
along the resistive strip, the contacts deliver a different voltage to the TCM. The different voltages are interpreted as
throttle sensor movement. The TCM converts travel distance (mm) into throttle opening percentage.

Conditions for Running the DTC


• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• DTC P0122 Throttle/Pedal Position Sensor/Switch A Circuit Low Input is not active.

5–20 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Conditions for Setting the DTC
DTC P0123 sets when the TCM detects a throttle position sensor voltage greater than 4.75 for 5 seconds.

Action Taken When the DTC Sets


• DTC P0123 is stored in the TCM history.
• The TCM uses the default throttle value.
• The TCM freezes shift adapts (DNA).
• The TCM inhibits TCC engagement.
• The CHECK TRANS light is illuminated.

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
• You may have to drive the vehicle in order to experience a fault.

Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests for the proper adjustment of TPS.
3. This step tests for the proper ignition voltage.
4. This step tests for the proper reference voltage from TCM.
5. This step tests for dead spots in the TPS rheostat.
6. This step tests for a high or low resistance in the TPS internal circuit.
7. This step tests for a harness-wiring problem.

DTC P0123 Pedal Position Sensor Circuit High Voltage


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Refer to Appendix F to check for proper TPS — Go to Step 3 Adjust TPS to
adjustment. proper setting.
Is the TPS adjusted properly? Go to Step 11

Copyright© 2003 General Motors Corp. 5–21


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0123 Pedal Position Sensor Circuit High Voltage
Step Action Value(s) Yes No
3 1. Install the Scan Tool. 9–18V Go to Step 4 Resolve
2. Start the engine. (12V TCM); voltage problem
3. Record the DTC Failure Record data. 18–32V (Refer to
4. Using the Scan Tool, measure ignition (24V TCM) DTC P0562
voltage. and P0563)
Is voltage within the specified value?
4 1. Turn the ignition OFF. 4.75–5.0V Go to Step 5 Go to Step 10
2. Disconnect the J2 connector from the TCM
and install the J43799 adapter box.
3. Reconnect the J2 connector to the adapter
box. With the engine OFF, turn the ignition to
the ON position.
4. Using a DVOM, measure the voltage
between pins 19 and 20.
Is the voltage within the specified value?
5 1. With the engine OFF and the ignition in the — Go to Step 6 Go to Step 7
ON position, monitor throttle percentage with
the Scan Tool.
2. Slowly increase the throttle from Idle to the
full throttle position.
3. Watch for a steady increase in throttle
percentage.
Was the throttle percentage steady and without
interruptions?
6 1. Turn the ignition OFF. 9,000–15,000 Go to Step 7 Go to Step 9
2. Disconnect the TPS connector. Ohms
3. Using a DVOM, measure the resistance at
pins A and C.
Is resistance within the specified value?
7 1. Reconnect the TPS connector. 9,000–15,000 Go to Diagnostic Go to Step 8
2. Disconnect J2 connector from the TCM. Ohms Aids
3. Using a DVOM, measure resistance at
connector J2 pins 19 and 20.
Is resistance within the specified value?
8 NOTE: The vehicle OEM has responsibility — Go to Step 10 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?
9 Replace the throttle position sensor. — Go to Step 11 —
Is the replacement complete?

5–22 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0123 Pedal Position Sensor Circuit High Voltage
Step Action Value(s) Yes No
10 NOTE: In most cases, the TCM is not at fault. — Go to Step 11 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM.
Is the replacement complete?
11 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under normal driving Go to Step 1
conditions.
Did the DTC return?

Copyright© 2003 General Motors Corp. 5–23


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0218 Transmission Fluid Over Temperature Condition

PRE-BLOCK 1
GAIN VALVE
AND A TRIM A Trim Accumulator
SOLENOID N/C
Solenoid
W/O SPRING
B
N/C Solenoid
F Trim Filter
Solenoid

N/C

CONTROL MAIN
EBF
CONV – IN
MAIN

A TRIM
PRESSURE

CONV – OUT

MAIN

TCC SIGNAL
MAIN

EXHAUST

Control
Main
Main Valve
Regulator
Valve

OVERDRIVE
KNOCKDOWN

OVERAGE TCC

Converter CONV – OUT TO COOLER


Relief
Valve OVERAGE
Charging
Pump
CONV – IN
TCC SIGNAL
SUMP Cooler

LUBE Converter
Flow
Valve
Lube
Regulator
Valve

Main Filter

V07737.00.00.eps

Circuit Description
The flow of transmission fluid starts in the transmission pan. Fluid is then drawn through the filter and internal
passages into the oil pump assembly. The oil pump pressurizes the fluid into main-pressure that is regulated at the
main-pressure regulator valve. From this point, fluid is directed to the F trim solenoid and to the control-main
regulator and control-main relief valve into the control-main filter assembly and on to all solenoids for use as control
pressure. Hot fluid leaving the torque converter is routed through the converter flow valve to cooler lines and into
the cooler assembly. The transmission oil cooler is located in the radiator. The vehicle may be equipped with an
auxiliary oil cooler. The cooled fluid is returned to the transmission through the return cooler line and to the
transmission lube circuit. The automatic transmission fluid temperature (TFT) sensor, which is part of the PSM, is
located in the oil pan.

If the Transmission Control Module (TCM) detects a high TFT for an extended period of time, then DTC P0218 sets.

5–24 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Conditions for Running the DTC
• DTCs P0711, P0712, P0713 are not active.
• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• Engine speed is greater than 200 rpm for more than 5 seconds.

Conditions for Setting the DTC


DTC P0218 sets when the TCM detects a transmission sump temperature greater than 126°C (252°F) for
10 seconds.

Action Taken When the DTC Sets


• The TCM does not illuminate the CHECK TRANS light.
• The TCM freezes shift adapts (DNA).
• The TCM records the operating conditions when the conditions for setting the DTC are met. The TCM stores
this information as Failure Records.
• DTC P0218 is stored in the TCM history.
• The TCM defaults to “hot mode” shift schedule where 4th-range is held and TCC is inhibited to increase engine
speed and improve cooler flow.

Conditions for Clearing the DTC/CHECK TRANS Light


• A Scan Tool may be used to clear the code from the TCM history.
• The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles
without the DTC recurring.
• The TCM cancels the DTC default actions when the fault no longer exists and the DTC passes test.

Diagnostic Aids
• Verify the customer’s driving habits, such as trailer towing, etc.
• The Scan Tool transmission fluid temperature (TFT) should rise steadily during warm-up cycles and then
stabilize.
• DTC P0218 may set after DTC P0711 (not active) has set. Follow the diagnostic table for DTC P0711 before
proceeding to the diagnostic for DTC P0218. Repairing the condition that set DTC P0711 will likely eliminate
DTC P0218.

Test Description
The numbers below refer to the step numbers on the diagnostic table.
3. This step inspects for air restriction and loss of transmission fluid flow, causing an extremely high TFT.
4. This step tests main-pressure.
5. This step inspects for a stuck torque converter stator.

DTC P0218 Transmission Fluid Over Temperature Condition


Step Action Yes No
1 Was the Beginning The Troubleshooting Process Go to Step 2 Go to Beginning The
(Paragraph 5–4A) performed? Troubleshooting
Process
(Paragraph 5–4A)

Copyright© 2003 General Motors Corp. 5–25


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0218 Transmission Fluid Over Temperature Condition (cont’d)


Step Action Yes No
2 1. Install the Scan Tool. Go to Step 3 Go to A/T Fluid
2. Turn ON the ignition, with the engine OFF. Checking Procedure.
3. Record the Failure Record data. (Appendix P)
4. Clear the DTC.
5. Perform the A/T Fluid Checking Procedure (Appendix P).
Was the A/T fluid level check performed?
3 1. Inspect the engine cooling system for the following Go to Step 6 Go to Step 4
conditions:
• Air flow restrictions
• Air flow blockage
• System fluid level and condition
• Debris
2. Inspect the transmission cooling system for the following
conditions:
• Air flow restrictions
• Air flow blockage
• System fluid level and condition
• Debris
• Damaged cooler lines or hoses
Did you find and correct the condition?
4 Perform the Main Pressure Check Procedure. Refer to Go to Step 6 Go to Step 5
Appendix B.
Did you find and correct a pressure problem?
5 Check for a possible torque converter stator malfunction. Go to Step 6 Go to General
A stuck stator would be indicated by no cool-down in neutral Troubleshooting
after stalling the transmission. Refer to Section 7. (Section 7)
Did you find and correct the condition?
6 Perform the following procedure in order to verify your Begin the diagnosis System OK
repair: again.
1. Clear the DTC. Go to Step 1
2. Using the Scan Tool, monitor the transmission fluid
temperature.
3. Operate the vehicle under the following conditions.
4. Turn ON the ignition, with the engine OFF.
5. The TFT must be less than 126°C (258°F) for at least
10 seconds.
6. Using the Scan tool, verify that the test to detect this code
has run.
Has the test run and passed?

5–26 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0561 Unrealistic Variations in Vehicle System Voltage

J1 HARNESS CONNECTOR TCM


(GRAY)
J1-4
J1-5 J1-3
J1-2
J1-1

J2

J1

102
J1-2

104 IGNITION
J1-4
POWER
10a 103 BATTERY
J1-3 POWER TCM
10a 101
J1-1 GND
IGN 105
SWITCH J1-5 GND

+ —
12V/24V
BATTERY
V06215.01.00

Circuit Description
The Transmission Control Module (TCM) requires a switched ignition voltage input and a direct battery voltage
input. This switched ignition voltage signal originates from the ignition switch or an ignition relay to supply voltage to
pins 102 and 104 in the J1 connector at the TCM. Battery direct voltage is supplied to pin 103 at the J1 connector.

Conditions for Running the DTC


• The test becomes enabled when the engine has been running above 400 rpm for at least 0.5 seconds.
• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).

Conditions for Setting the DTC


P0561 sets when the TCM detects a large variation in ignition voltage or battery direct voltage. When an ignition or
battery direct voltage variation of 4.0V or greater is detected for 0.5 seconds, a fault pending is reported. After
1.0 second of 4.0V or greater variation, a DTC is set with a failure response.

Action Taken When the DTC Sets


When DTC P0561 is active, the following conditions will occur:
• DTC P0561 is stored in the TCM history.
• Hydraulic default is commanded. Shift selector position and hydraulic state of logic valves determine the range
attained.
• The CHECK TRANS light illuminates.

Copyright© 2003 General Motors Corp. 5–27


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


• The TCM inhibits TCC engagement.
• The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• You may have to drive the vehicle in order to experience a fault.
• This DTC indicates a variation in ignition voltage or battery direct voltage. Common ignition circuit problems for
this DTC are a fault in the feed wires to the TCM, a defective ignition switch, or a large vehicle accessory load
on the ignition circuit. Battery direct voltage problems may be due to loose or corroded battery cables, a bad
connection at the battery direct feed terminal (103), or an internal TCM failure due to a burnt trace.
• A vehicle charging system failure may cause this DTC under certain circumstances.
• This code may indicate that an internal voltage problem has occurred inside the TCM. The use of a substitute
TCM would be a good way to diagnose this problem.
• A defective vehicle battery may induce this DTC.
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.

Test Description
The numbers below refer to the step numbers on the diagnostic table.

2. This step tests for an active DTC after clearing.


3. This step tests for the proper battery direct input voltage.
4. This step tests for the proper ignition input voltage.
5. This step tests for shorts or open conditions at battery direct input circuit.
6. This step tests for shorts or open conditions at ignition input circuit.
DTC P0561 Unrealistic Variations in Vehicle System Voltage
Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)

5–28 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0561 Unrealistic Variations in Vehicle System Voltage
Step Action Value(s) Yes No
2 1. Install the Scan Tool. — Go to Step 3 Go to Step 4
2. Turn ON the ignition, with the engine OFF.
3. Record the failure records.
4. Clear the DTC.
5. Start vehicle and test drive.
6. Duplicate same operating conditions
observed in failure records.
NOTE: This DTC indicates that a voltage
variation exists in the ignition voltage or at
the battery direct input. This variation is
measured from min. and max. voltage
values. If the voltage variation is present for
a pre-determined amount of time, this DTC
sets.
Did DTC P0561 return?
3 1. Turn the ignition OFF. 11.5–12.5V Go to Step 4 Go to Step 5
2. Disconnect TCM connector J1 (gray) at the
TCM.
3. Install J 39700 Breakout Box and J 43799
Adapter box at the J1 connector.
4, Using a digital multimeter (DVOM), measure
voltage at J1 connector pin 1 and pin 3.
Is the voltage within the specified value?
4 1. Using a digital multimeter (DVOM), 11.5–12.5V Go to Diagnostic Go to Step 6
sequentially measure voltage at J1 Aids
connector pins 2 and 4 using J1 connector
pins 1 or 5 as ground return.
2. Turn ON the ignition, with the engine OFF.
Is the voltage within the specified value?
5 NOTE: The vehicle OEM has responsibility — Go to Step 8 Go to Step 7
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Inspect battery direct circuit 103 for one of the
following conditions:
• Intermittent open or short.
• Loose or corroded connections at battery
or connection points.
• Defective battery.
Was one of these conditions discovered and
repaired?

Copyright© 2003 General Motors Corp. 5–29


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0561 Unrealistic Variations in Vehicle System Voltage
Step Action Value(s) Yes No
6 NOTE: The vehicle OEM has responsibility — Go to Step 8 Go to Step 7
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Inspect the TCM ignition input circuit for one of
the following conditions:
• Intermittent open or short at ignition input
circuits 101, 102, 103, or 104.
• Loose or corroded connections at ignition
switch or ignition relay assembly.
• Defective ignition switch or relay.
• Loading of ignition circuit by defective
vehicle accessories.
Was one of these conditions discovered and
repaired?
7 NOTE: In most cases, the TCM is not at fault. — Go to Step 8 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM.
Is the replacement complete?
8 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under conditions shown in Go to Step 1
failure records.
Did the DTC return?

5–30 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0562 System Voltage Low

J1 HARNESS CONNECTOR TCM


(GRAY)
J1-4
J1-5 J1-3
J1-2
J1-1

J2

J1

102
J1-2

104 IGNITION
J1-4
POWER
10a 103 BATTERY
J1-3 POWER TCM
10a 101
J1-1 GND
IGN 105
SWITCH J1-5 GND

+ —
12V/24V
BATTERY
V06215.01.00

Circuit Description

The Transmission Control Module (TCM) requires a switched ignition voltage input to operate. This switched
ignition voltage signal originates from the ignition switch or an ignition relay to supply voltage to pins 102 and 104 in
the J1 connector at the TCM.

Conditions for Running the DTC

• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).

• The engine speed is greater than 450 rpm for 10 seconds.

Conditions for Setting the DTC

DTC P0562 sets when the TCM detects the following condition:

• 12 volt TCM — Ignition voltage is detected below 8V at 0°C (32°F) for a total of 5 out of 7 seconds. The voltage
threshold is temperature dependent varying from 5V at –60°C (–75°F) to 9V at 20°C (68°F).

• 24 volt TCM — Ignition voltage is detected below 17V at 0°C (32°F) for a total of 5 out of 7 seconds. The
voltage threshold is temperature dependent varying from 14V at –60°C (–75°F) to 18V at 20°C (68°F).

Copyright© 2003 General Motors Corp. 5–31


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Action Taken When the DTC Sets
• If the DTC is active while vehicle is in a forward range, transmission shifts to neutral, 1st, 3rd, or 5th range.
• If the DTC is active while in reverse or neutral, transmission shifts to neutral.
• If the shift selector is moved to forward range, transmission shifts to neutral, 1st, 3rd, or 5th range.
• If the shift selector is moved to reverse or neutral, transmission shifts to neutral. Diagnostic response honors
the inhibit latched at the time the DTC is set. If a latched inhibit is present and PRNDL is incorrect,
transmission shifts to neutral range. If PRNDL is correct, GPI request is responded to.
• The CHECK TRANS light is illuminated.
• The TCM inhibits TCC engagement.
• The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• A defective vehicle battery may allow this DTC to set. Test the vehicle battery to verify proper voltage and load
capacity.
• A defective vehicle charging system may cause this DTC.
• Vehicle components such as an ignition switch or TCM ignition relay may cause this DTC to set and not be
active, this indicates that an intermittent condition may exist in these components.
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.

Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests for the proper ignition input voltage.
3. This step tests for an active DTC after clearing.
4. This step tests vehicle battery per OEM guidelines.
5. This step tests vehicle charging system per OEM guidelines.

DTC P0562 System Voltage Low


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)

5–32 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0562 System Voltage Low (cont’d)
Step Action Value(s) Yes No
2 1. Install the Scan Tool. Voltage should Go to Step 4 Go to Step 3
2. Turn ON the ignition, with the engine OFF. be above 9V
3. Record the failure records. (12V TCM) or
4. Clear the DTC. 18V (24V TCM)
5. Inspect the ignition voltage value on the at 20°C (68°F).
Scan Tool. See conditions
for setting the
NOTE: This DTC sets when ignition voltage DTC.
drops below a predetermined level that is
temperature dependent for 5 out of 7
seconds.
Is the ignition voltage below specified value?
3 1. Start the vehicle, if possible. — Go to Step 4 Go to Diagnostic
2. If the DTC is not active, drive the vehicle. Aids
Attempt to duplicate the same operating
conditions observed in the failure records.
Did the DTC return?
4 Test the vehicle battery per OEM instructions. See OEM for Go to Step 5 Replace the
This should include a voltage test and a load correct battery vehicle battery
test. specifications and go to Step 6
Does test indicate the battery is good?
5 Test the vehicle charging system per the OEM See OEM for Go to Diagnostic Repair the
recommended testing procedure. correct charging Aids charging system
Is the charging system operating properly? system and go to Step 6
specifications
6 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under conditions shown in Go to Step 1
the failure records when the DTC set.
Did the DTC return?

Copyright© 2003 General Motors Corp. 5–33


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0563 System Voltage High

J1 HARNESS CONNECTOR TCM


(GRAY)
J1-4
J1-5 J1-3
J1-2
J1-1

J2

J1

102
J1-2

104 IGNITION
J1-4
POWER
10a 103 BATTERY
J1-3 POWER TCM
10a 101
J1-1 GND
IGN 105
SWITCH J1-5 GND

+ —
12V/24V
BATTERY
V06215.01.00

Circuit Description
The Transmission Control Module (TCM) requires a switched ignition voltage input to operate. This switched
ignition voltage signal originates from the ignition switch or an ignition relay to supply voltage to pins 102 and 104 in
the J1 connector at the TCM.

Conditions for Running the DTC


• The engine speed is greater than 450 rpm for one second.
• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).

Conditions for Setting the DTC


DTC P0563 sets when the TCM detects the following condition:
• 12 volt TCM — Ignition voltage is above 18V for 6 out of 10 seconds.
• 24 volt TCM — Ignition voltage is above 32V for 6 out of 10 seconds.

5–34 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Action Taken When the DTC Sets
• If the DTC is active while the vehicle is in a forward range, the transmission shifts to neutral, 1st, 3rd, or 5th
range.
• If the DTC is active while in reverse or neutral, the transmission shifts to neutral.
• If the shift selector is moved to a forward range, the transmission shifts to neutral, 1st, 3rd, or 5th range. If the
shift selector is moved to reverse or neutral, the transmission shifts to neutral. Diagnostic response honors the
inhibit latched at the time the DTC is set. If a latched inhibit is present and PRNDL is incorrect, the
transmission shifts to neutral range. If PRNDL is correct, the GPI request is responded to.
• The CHECK TRANS light is illuminated.
• The TCM inhibits TCC engagement.
• The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• A defective vehicle charging system that is overcharging may cause this DTC.
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.

Test Description
The numbers below refer to the step numbers on the diagnostic table.

2. This step tests for the proper ignition input voltage.


3. This step tests for an active DTC after clearing.
5. This step tests vehicle charging system per OEM guidelines.

DTC P0563 System Voltage High


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)

Copyright© 2003 General Motors Corp. 5–35


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0563 System Voltage High (cont’d)
Step Action Value(s) Yes No
2 1. Install the Scan Tool. See Conditions for Go to Step 4 Go to Step 3
2. Turn ON the ignition, with the engine OFF. Setting the DTC
3. Record the failure records.
4. Clear the DTC.
5. Start vehicle engine and inspect the ignition
voltage value on the Scan Tool.
NOTE: This DTC sets when ignition voltage
is detected above 18V for 12V systems or
32V for 24V systems for 6 out of 10 seconds.
Is the ignition voltage above specified value?
3 1. Start the vehicle, if possible. — Go to Step 4 Go to Diagnostic
2. If the DTC is not active, drive the vehicle. Aids
Attempt to duplicate the same operating
conditions observed in failure records.
Did the DTC return?
4 Test the vehicle charging system per the OEM — Go to Diagnostic Repair the
recommended testing procedure. Aids charging system
Is the charging system operating properly? and go to Step 5
5 In order to verify your repair: — Begin the System OK
1. Clear DTC. diagnosis again.
2. Drive vehicle under conditions shown in Go to Step 1
failure records when DTC set.
Did the DTC return?

5–36 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0602 TCM Not Programmed

NO SCHEMATIC FOR THIS DTC


Circuit Description
At the power up and after clearing codes, the Transmission Control Module (TCM) performs a self-test to determine
if the calibration in memory is valid.

Conditions for Running the DTC


• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• This test will run before any TCM functions.

Conditions for Setting the DTC


DTC P0602 sets if the TCM determines the present calibration is invalid.

Action Taken When the DTC Sets


• DTC P0602 is stored in the TCM history.
• The CHECK TRANS light illuminates.
• The TCM returns to the boot program, and then waits to be recalibrated.
• The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light


TCM must be recalibrated.

DTC P0602 TCM Not Programmed


Step Action Yes No
1 Was the Beginning The Troubleshooting Process Go to Step 2 Go to
(Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. Go to Step 4 —
2. If DTC P0602 is present, the TCM must be recalibrated.
Is recalibration complete?
3 NOTE: In most cases, the TCM is not at fault. Investigate Go to Step 4 —
thoroughly before replacing the TCM. Refer to TCM
Replacement Procedure (Section 3–6).
Replace the TCM.
Is replacement complete?
4 1. Install the Scan Tool. Go to Step 3 System OK
2. Start the vehicle.
Did the DTC return?

Copyright© 2003 General Motors Corp. 5–37


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0606 Controller Internal Performance

NO SCHEMATIC FOR THIS DTC


Circuit Description
The Transmission Control Module (TCM) completes numerous scheduled tasks during normal operation. If one of
the scheduled tasks fails to complete within a specific time limit the TCM will re-attempt this task.
NOTE: The presence of DTC P0606 indicates a TCM software error has occurred and the Allison
Transmission Service Department should be contacted at 1-800-252-5283.

Conditions for Running the DTC


The components are powered and ignition voltage is greater than 9V and less than 18V for a 12V TCM, or greater
than 18V and less than 32V for a 24V TCM.
This test is run during the entire ignition cycle.

Conditions for Setting the DTC


DTC P0606 sets if a task fails to complete after two consecutive attempts.

Action Taken When the DTC Sets


• When DTC P0606 is active, the transmission will lock in N (Neutral).
• DTC P0606 is stored in the TCM history.
• The CHECK TRANS light illuminates.
• The TCM freezes shift adapts (DNA).
• The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool can clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history
if the vehicle completes 40 warm-up cycles without failure.

5–38 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0614 Torque Control Data Mismatch — ECM/TCM

NO SCHEMATIC FOR THIS DTC


Circuit Description
Shift Energy Management (SEM) allows the Transmission Control Module (TCM) to request torque reduction from
the engine controller. By reducing torque, shifts can be made quicker, at a more consistent output torque which
reduces clutch temperatures and increases clutch life. When an engine torque rating exceeds 580 lb ft, Lower
Range Torque Protection (LRTP) is used. This feature limits engine torque in lower ranges to protect the
transmission from damage if a stall condition occurs.

Conditions for Running the DTC


• No DTC U2105 CAN bus error.
• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
• This test runs for 30 seconds for the first 20 engine starts after the engine is detected on the J1939 CAN.
• Engine must be identified by the TCM as an approved make and model.
• Engine’s torque configuration message (peak torque) must be greater than allowed without SEM (above
580 lb ft gross input torque).

NOTE: Unapproved engines or low torque engines will operate without setting a P0614.

Conditions for Setting the DTC

P0614 sets when the TCM detects one of the following conditions:

• TCM detects a valid engine having the proper torque rating but ECM software is not supporting all the
messaging necessary for SEM.
• TCM detects a valid engine having a torque rating exceeding 580 lb ft that does not support Lower Range
Torque Protection (LRTP) messaging.

NOTE: Valid engines with a torque rating exceeding 580 lb ft must have software that is compatible with
LRTP or a P0614 is set.

Action Taken When the DTC Sets


• DTC P0614 is stored in the TCM history.
• The CHECK TRANS light illuminates.
• If the TCM and engine ECM software are not compatible, the transmission will be restricted to reverse, neutral,
first range, or third range.
• The TCM inhibits TCC engagement.
• The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Copyright© 2003 General Motors Corp. 5–39


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Test Description
The numbers below refer to the step numbers on the diagnostic table.
3. This step tests for an incompatible engine calibration.
5. This step tests for the proper engine torque limit.

DTC P0614 Torque Control Data Mismatch — ECM/TCM


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 If a DTC U2105 is present, troubleshoot and — Go to DTC Go to Step 3
resolve before going to the next step. U2105 and
Is a DTC U2105 present? resolve before
proceeding to
Step 7
3 Using the Scan tool, refer to the Transmission/ Scan Tool Go to Step 4 Go to Step 5
Engine shift energy management (SEM) indicates with Yes
compatibility and the Lower Range Torque or No Answer
Protection compatibility display.
Is the ECM shown as being incompatible with
TCM request for SEM or LRTP?
4 This indicates that engine software does not — Go to Step 7 —
support shift energy management for either
SEM or LRTP.
Have the OEM install the proper engine
software and calibration to support SEM.
Is the proper software and calibration installed?
5 Using Scan Tool, refer to the engine torque Scan Tool Go to Step 7 Go to Step 6
rating display. indicates with Yes
Is the torque rating displayed as acceptable? or No Answer
6 This indicates that engine torque values are — Go to Step 7 —
above the transmission ratings set in the TCM
calibration. Inspect the TCM for proper software
and calibration to support SEM. If the proper
TCM software and calibration are installed, the
engine rating is too high for the transmission.
Recalibrate the engine to a lower torque rating.
Was one of the above conditions found and
resolved?
7 In order to verify your repair: — Begin the System OK
1. Connect the Scan Tool. diagnosis again.
2. Clear the DTC. Go to Step 1
3. Drive the vehicle under normal operating
conditions.
Did the DTC return?

5–40 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0701 Transmission Control System Performance

NO SCHEMATIC FOR THIS DTC


Circuit Description
The Transmission Control Module (TCM) monitors the status of the pressure switches at start-up to detect the
presence of hydraulic pressure.

Conditions for Running the DTC


• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM).
• Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
• This test is run after engine start-up and runs as part of the transmission hydraulic initialization.

Conditions for Setting the DTC


DTC P0701 sets when transmission fluid temperature is above –25°C (–13°F) with an engine speed above
500 rpm for 6 seconds or 400 rpm for 15 seconds and forward or reverse range is selected and all the pressure
switches do not indicate pressure.

Action Taken When the DTC Sets


• DTC P0701 is stored in the TCM history.
• The TCM inhibits TCC engagement.

Conditions for Clearing the MIL/DTC


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without failure.

Diagnostic Aids
• DTC P0701 may be logged if a forward or reverse range is selected immediately after the engine is started and
before the TCM detects pressure at the switches (2 to 6 seconds after engine start).
• A plugged control main filter may cause this code to set. The control main filter is to be changed after the first
8000 km (5,000 miles). Failure to change the filter at this interval may cause this code and other pressure
switch codes to set.
• A cracked internal suction filter tube or damaged tube seal may cause this DTC to set.
• A stuck lube regulator valve (located in the front support) may cause this DTC to set. A high static oil level with
the vehicle running is often a good indication of this complaint. Often pressure switch DTCs are set in this
scenario.
• You may have to drive the vehicle in order to experience a fault.

Test Description
The numbers below refer to the step numbers on the diagnostic table.

2. This step tests for proper fluid level.


5. This step tests for main pressure.

Copyright© 2003 General Motors Corp. 5–41


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0701 Transmission Control System Performance
Step Action Yes No
1 Was the Beginning The Troubleshooting Process Go to Step 2 Go to
(Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. Go to Step 3 Go to Step 4
2. Turn the ignition to ON, with the engine OFF.
3. Record the DTC Failure Record data.
4. Clear the DTC.
5. Start the engine; Check the Transmission Fluid Level.
Is the fluid at the appropriate level?
3 This DTC can be set after performing fluid service and Go to Step 7 Go to Step 5
filter change, after replacement of the PSM, or after a long
period of storage.
Have any of these conditions occurred?
4 Add fluid to the proper level. Go to Step 5 —
Is the fluid at the appropriate level?
5 Check main pressure (refer to Main Pressure Check Go to Step 7 Go to Step 6
Procedure — Appendix B).
Is the pressure within the specified value?
6 No main pressure at idle may be an indication of the Go to Step 7 Go to General
following: Troubleshooting
• Stuck or sticking lube regulator valve (Section 7)
• Stuck or sticking main pressure regulator valve
• Loose or damaged suction filter
• Defective suction filter seal
Was the reason for no main pressure condition found and
repaired?
7 In order to verify your repair: Go to Step 1 System OK
1. Clear the DTC.
2. Start the vehicle.
3. Use the Scan Tool, in the test passed section, to confirm
the diagnostic test was run.
Did the DTC return?

5–42 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0703 Brake Switch Circuit Malfunction

TCM
J1 HARNESS CONNECTOR
(GRAY)
J1-14* J1-7**

J2

J1-28* J1

TCM
114 DIGITAL
J1-14 INTERFACE

128
J1-28

*NOTE: Brake signal provides ground

TCM
SWITCHED
POWER 107 DIGITAL
J1-7 INTERFACE

**NOTE: Brake signal provides power


V06216.01.00

Circuit Description

A mechanical switch attached to the brake pedal sends a signal to the Transmission Control Module (TCM)
indicating the service brake has been applied. This signal is either ignition voltage or a ground signal depending on
the calibration installed in the TCM.

P0703 is a type C DTC.

Conditions for Running the DTC


• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM).
• No DTC P0721 or P0722.

Conditions for Setting the DTC

The TCM sets a DTC when either of the following conditions occur:

• The vehicle has accelerated 10 or more times with TCM input indicating brakes applied.
• Decelerated 10 or more times with TCM input indicating brakes released.

Copyright© 2003 General Motors Corp. 5–43


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Action Taken when the DTC Sets
• No Grade Braking allowed.
• Use the default assumption that the brake is off.
• TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light

A Scan Tool can clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history
if the vehicle completes 40 warm-up cycles without the DTC active.

Diagnostic Aids

Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:

• A bent terminal.
• A backed-out.
• A damaged terminal.
• Poor terminal tension.
• A chafed wire.
• A broken wire inside the insulation.

When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment
for a change.
DTC P0703 Brake Switch Circuit Malfunction
Step Action Value Yes No
1 Was the Beginning The Troubleshooting Go to Step 2 Go to Beginning
Process (Section 5-4A) Performed? The
Troubleshooting
Process
(Paragraph 5–4a)
2 1. Install the Scan Tool. Go to Go to Step 3
2. Turn the ignition ON, with the engine OFF. Diagnostic Aids
3. Record the DTC Failure Record Data.
4. Apply and release the service brake.
Does the Scan Tool indicate that brake switch is
toggling off and on?
3 1. Using a DVOM, probe pin 5 and pin 7 on the Battery + Go to Step 8 Go to Step 4
C1 connector.
2. Apply and release the service brake.
3. There should be no voltage reading at pin 7
when the brake is applied, with the brake
released there should be 12V.
Was voltage reading proper according to brake
status?
4 1. Go to the Stop Lamp Switch, with a DVOM Battery + Go to Step 6 Go to Step 5
probe pin C at the switch, supply a ground
connection at other lead.
2. Apply and release the service brake.
Is the switch turning voltage ON and OFF?

5–44 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0703 Brake Switch Circuit Malfunction
Step Action Value Yes No
5 Using a DVOM, check the voltage at pin D on Go to Step 7 Resolve voltage
the input side of the Stop Lamp Switch. problem
Is voltage available at the input side of the Stop
Lamp Switch?
6 Replace the TCC Brake Switch/Cruise Control Go to Step 9
harness.
Is repair complete?
7 Repair or replace the Stop Lamp Switch Go to Step 9
assembly.
Is repair complete?
8 NOTE: In most cases, the TCM is not at fault. Go to Step 9
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM.
Is the replacement complete?
9 In order to verify your repair: Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle making at lease 10 Go to Step 1
accelerations and decelerations cycles.
Did the test run and pass?

Copyright© 2003 General Motors Corp. 5–45


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0708 Transmission Range Sensor Circuit High Input

J2 HARNESS CONNECTOR
(RED) TCM
J2-7 J2-6
J2-8 J2-5

J2

J2-20 J1

4-PIN AND 7-PIN

NSBU SWITCH TCM


208
P 4C 8 J2-8
207
C 4B 6 J2-7
DIGITAL
206 INTERFACE
B 4D 4 J2-6
205
A 4A 5 J2-5
220
7D 7 J2-20 GND

12-PIN
SINGLE CONNECTOR
NSBU
FORMER CURRENT
NSBU SWITCH NSBU SWITCH
4- AND 7-PIN 12-PIN

V06217.01.00

Circuit Description
The installation of a transmission-mounted Neutral Start/Back-Up (NSBU) switch is required. This switch mounts
directly onto the transmission housing from the outside and detects the angular position of the shift selector shaft.
This position is communicated to the Transmission Control Module (TCM) so that certain vehicle control functions
can be coordinated with the position of the shift controls. The NSBU switch has redundant circuitry to alert the TCM
in the event of a single wire or switch failure.

The neutral signal output of the NSBU switch is typically used as confirmation that the transmission is in
N (Neutral) before the engine starter is engaged. The NSBU switch is interfaced to the starter circuit with
weatherproof electrical connectors. The reverse signal provision may be used to activate vehicle back-up lights
and/or reverse warning devices.

Conditions for Running the DTC


• The components are powered and ignition voltage is greater than 9V and less than 18V.
• Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.

5–46 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Conditions for Setting the DTC — Software Levels Prior To N11
DTC P0708 sets when the TCM detects an invalid condition or parity errors occurring over consecutive ignition
cycles.

Actions Taken When the DTC Sets — Software Levels Prior To N11
• The diagnostic response is to shut all solenoids off and allow the transmission to operate in hydraulic default
mode or “limp home”. Shift selector and hydraulic state of logic valves determines range attained.
• DTC P0708 is stored in the TCM history.
• The CHECK TRANS light illuminates.
• The TCM inhibits TCC engagement.
• Due to this failure and associated responses, P0722 and P0845 may also set.

Action Taken When the DTC Sets — Software Level N11 And Later
• The CHECK TRANS light illuminates but no diagnostic response is implemented until after 50 warm-up cycles
occur when a NSBU switch parity error is active. A warm-up cycle is defined as a 20 degree change in
transmission temperature.
• The diagnostic response is to shut all solenoids off and allow the transmission to operate in hydraulic default
mode or “limp home.” Shift selector and hydraulic state of logic valves determines range attained.
• DTC P0708 is stored in the TCM history.
• The TCM inhibits TCC engagement.
• Due to this failure and associated responses, P0722 and P0845 may also set.
• A shift to R (Reverse) will allow reverse range if a P0876 (previously P1714) is not active.

Conditions for Clearing the MIL/DTC


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without failure.

Diagnostic Aids
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
• You may have to drive the vehicle in order to experience a fault.
• When a P0708 is shown in failure records, this indicates that conditions to set a P0708 were present at one
time. If the condition was due to moisture intrusion, the moisture may no longer be present, and thus you may
not be able to reproduce the DTC. In such case, variables such as vehicle mileage, external physical condition
of the switch should be factored in when making a decision to replace the NSBU switch.
NOTE: Due to the TCM logic used to detect and set a P0708, this code can remain active even after a
NSBU switch replacement is complete and the ignition has been cycled. It is important to clear all
active DTCs from the TCM after servicing the NSBU switch.

Copyright© 2003 General Motors Corp. 5–47


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Test Description

The numbers below refer to the step numbers on the diagnostic table.

3. This step tests NSBU switch status.

4. This step tests for proper TCM input response.

5. This step tests the wiring harness for opens or shorts.

DTC P0708 Transmission Range Sensor Circuit High Input


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Is the NSBU switch and shift linkage properly — Go to Step 3 Go to
adjusted? Mechanic’s Tips
3 1. Install the Scan Tool. Refer to NSBU Go to Go to Step 4
2. Turn the ignition ON with the engine OFF. Switch Table Diagnostic Aids
3. Record the DTC Failure Record data. (Page 5–9)
4. Using the Scan Tool, monitor PRNDL A, B, C,
P status while moving the shift selector
through each range.
Does each switch toggle ON and OFF in the
correct sequence, and does the range selected
displayed on the Scan Tool match the actual
physically selected range?
4 1. Turn the ignition OFF. A=pin 5 Go to Step 5 Go to Step 10
2. Disconnect J2 connector from the TCM and B=pin 6
install J 39700 Breakout Box and J 43799 C=pin 7
Breakout Box Adapter. P=pin 8
3. Disconnect the NSBU 4-pin connector and
the NSBU 7-pin connector. Scan Tool Status
4. Turn the ignition ON. ON=Open circuit
5. In sequence, connect J2 connector pin 20 to OFF=Grounded
circuit
J2 pins 5, 6, 7, and 8.
6. Monitor the switch status on the Scan Tool.
Does each switch toggle ON and OFF in the
correct sequence as each pin is grounded?
5 Inspect the NSBU switch connector assembly. Go to Step 6 Go to Step 7
Does the NSBU have two connectors—a seven
pin and four pin connector?
6 1. Turn the ignition OFF. Scan Tool Status Go to Step 8 Go to Step 9
2. Reconnect J2 connector to the TCM. ON=Open circuit
3. In sequence, connect pins 4A, 4B, 4C, and OFF=Grounded
4D at the 4-pin NSBU connector to pin 7D** circuit
on the NSBU 7-pin connector. *
4. Monitor the switch status on the Scan Tool. 7D=wire 220
Does the Scan Tool indicate the proper switch
status for each switch when grounded?

5–48 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0708 Transmission Range Sensor Circuit High Input (cont’d)
Step Action Value(s) Yes No
7 1. Turn the ignition OFF. Scan Tool Status Go to Step 8 Go to Step 9
2. Reconnect J2 connector to the TCM. ON=Open circuit
3. At the NSBU connector in sequence, OFF=Grounded
connect pins 4, 5, 6, and 8 to pin 7** at the circuit
12 pin connector.
4. Monitor the switch status on the Scan Tool. 7D=wire 220
Does the Scan Tool indicate the proper switch
status for each switch when grounded?
8 Replace the NSBU switch (refer to Mechanic’s — Go to Step 11 —
Tips).
Is the replacement complete?
9 Repair the vehicle wiring harness. — Go to Step 11 —
NOTE: The vehicle OEM has responsibility
for all external wiring, wherefore the OEM
should perform vehicle harness repairs.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Is the repair complete?
10 NOTE: In most cases, the TCM is not at fault. — Go to Step 11 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM.
Is the replacement complete?
11 In order to verify your repair: Refer to NSBU Begin the System OK
1. Clear the DTC. Switch Table diagnosis again.
2. Drive the vehicle under normal operating (Page 5–9) Go to Step 1
conditions.
3. Using the Scan Tool, monitor PRNDL switch
status while moving selector through all
positions.
Does each switch toggle according to switch
table?
* If J 39700 Breakout Box and J 44722 Transmission Harness are available, they may be used to perform this
operation.
** Use pin H at the magnetic overlay to provide a ground source when J 44722 Harness is used.

Copyright© 2003 General Motors Corp. 5–49


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0711 Transmission Fluid Temperature Sensor Circuit Performance

TRANSMISSION
HARNESS
CONNECTOR J2 HARNESS CONNECTOR
(RED)
H J2-10

J2-20 TCM
TRANSMISSION
BULKHEAD
CONNECTOR
H

J2
G
J1
NOTE: Letters I, O, and Q are not used.

C A
D B
E C 210
G J2-10 HI
R D TCM
TRANSMISSION
E
F 220 LO
H J2-20

NOTE: Switches C, D, and E are N/O. Switch R is N/C.


PRESSURE SWITCH
MANIFOLD
R E D
C

F E D C B A
V06214.01.00

Circuit Description

The Transmission Fluid Temperature (TFT) sensor is part of the Pressure Switch Manifold (PSM) which is located
in the transmission oil pan. The TFT sensor is a thermistor that changes its resistance value based on the
temperature of the transmission fluid. The Transmission Control Module (TCM) supplies a 5V reference signal to
the TFT sensor and measures the voltage drop in the circuit. When the transmission is cold, the sensor resistance
is high and the TCM detects high signal voltage. As the transmission fluid temperature warms to a normal
operating temperature, the resistance becomes less and the signal voltage decreases. The TCM uses this
information to control shift quality and to determine torque converter clutch applies.

If the TCM detects the TFT sensor resistance has no change, an unrealistic change in a short amount of time, or
multiple changes within seconds, DTC P0711 sets.

5–50 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Conditions for Running the DTC
• No DTC P0721, P0722, P0717, P0716, P0713, or P0712.
• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• The engine speed is greater than 200 rpm for more than 5 seconds.
• The engine speed is greater than 450 rpm for more than 2 seconds with output speed of 100 rpm or above.
This would indicate that a range is selected.
• A valid start-up temperature is detected.

Conditions for Setting the DTC


DTC P0711 sets when the TCM detects one of the following conditions:

• The TCM detects a temperature change that is under a set limit when compared to samples of the minimum
and maximum temperature values.
• The TFT has an unrealistic temperature change of more than 10°C (50°F) for 10 occurrences.
• The temperature from start up decreases 40°C (104°F) or more within duration of 6 or more seconds.

Action Taken When the DTC Sets


• The TCM does not illuminate the CHECK TRANS light.
• The TCM stores DTC P0711 in TCM history.
• The TCM uses calibration default for temperature values.

Conditions for Clearing the DTC/CHECK TRANS Light


• A Scan Tool may be used to clear the code from the TCM history.
• The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles
without the DTC recurring.
• The TCM cancels the DTC default actions when the fault no longer exists and the ignition has been cycled.

Diagnostic Aids
• The Scan Tool transmission fluid temperature (TFT) should rise steadily during warm-up cycles and then
stabilize.
• DTC P0218 may set after DTC P0711 has set. Follow the diagnostic table for DTC P0711 before proceeding to
the diagnostic for DTC P0218.

Test Description
The numbers below refer to the step numbers on the diagnostic table.

2. This step tests for proper AT fluid level and condition.


3. This step tests for the proper reference voltage.
4. This step verifies which condition has set DTC P0711.
5. This step tests the resistance value of the internal wiring harness and TFT sensor.
6. This step tests for opens and shorts in the main wiring harness.
8. This step tests the resistance value of the internal TFT sensor.

Copyright© 2003 General Motors Corp. 5–51


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0711 Transmission Fluid Temperature Sensor Circuit Performance


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Perform the A/T Fluid Checking Procedure — Go to Step 4 Go to A/T Fluid
(Appendix P). Checking
Is the transmission fluid level correct? Procedure
(Appendix P)
3 1. Turn the ignition OFF. 4.75–5.25V Go to Step 4 Go to Step 11
2. Disconnect J2 connector at the TCM and
install J 39700 Breakout Box and J 43799
Breakout Box Adapter.
3. With the engine OFF, turn the ignition to the
ON position, Measure voltage between J2
connector pins 10 and 20.
Is voltage within the specified value?
4 1. Install the Scan Tool. 1.5°C (2.7°F) Go to Step 5 Go to
2. With the engine OFF, turn the ignition to the Diagnostic Aids
ON position.
3. Record the failure records.
4. Clear the DTCs.
5. Monitor the TFT on the Scan Tool.
6. Drive the vehicle and observe the Scan Tool
for one of the following conditions:
• No transmission temperature change.
• An unrealistic transmission temperature
change of greater than 1.5°C in (2.7°F) in
one second.
Did either of these conditions occur?
5 1. Disconnect the wiring harness from the main 3398–3582 Ohms Go to Step 6 Go to Step 8
transmission connector. at 20°C (68°F)
2. Using a DVOM, measure resistance at main Refer to
transmission connector pins G and H.* TFT Sensor
Is resistance within the specified values? Resistance Table
Page 5–13)
6 1. Reconnect the wiring harness to the main 3398–3582 Ohms Go to Go to Step 7
transmission connector. at 20°C (68°F) Diagnostic Aids
2. Disconnect connector J2 from the TCM. Refer to
3. Using a DVOM, measure resistance at TFT Sensor
connector J2 pins 10 and 20.* Resistance Table
Is resistance within the specified values? Page 5–13)

5–52 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0711 Transmission Fluid Temperature Sensor Circuit Performance (cont’d)
Step Action Value(s) Yes No
7 NOTE: The vehicle OEM has responsibility — Go to Step 12 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Have the vehicle wiring harness repaired.
Is the repair complete?
8 1. Remove the oil pan. 3398–3582 Ohms Go to Step 9 Go to Step 10
2. Disconnect the PSM from the internal wiring at 20°C (68°F)
harness. Refer to
3. Using a DVOM, measure PSM resistance at TFT Sensor
pins E and F. Resistance Table
Is resistance within the specified values? Page 5–13)
9 Replace the internal wiring harness (refer to — Go to Step 12 —
Mechanic’s Tips).
Is the replacement complete?
10 Replace the PSM (refer to Mechanic’s Tips). — Go to Step 12 —
Is the replacement complete?
11 NOTE: In most cases, the TCM is not at fault. — Go to Step 12 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM.
Is the replacement complete?
12 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Using the Scan Tool, monitor the Go to Step 1
transmission fluid temperature.
3. Drive the vehicle under normal operating
conditions. Look for significant changes in
TFT.
Did the DTC return?
* If J 39700 and J 44722 are available, they may be used to perform this operation.

Copyright© 2003 General Motors Corp. 5–53


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0712 Transmission Fluid Temperature Sensor Circuit Low Input
(High Temperature)

TRANSMISSION
HARNESS
CONNECTOR J2 HARNESS CONNECTOR
(RED)
H J2-10

J2-20 TCM
TRANSMISSION
BULKHEAD
CONNECTOR
H

J2
G
J1
NOTE: Letters I, O, and Q are not used.

C A
D B
E C 210
G J2-10 HI
R D TCM
TRANSMISSION
E
F 220 LO
H J2-20

NOTE: Switches C, D, and E are N/O. Switch R is N/C.


PRESSURE SWITCH
MANIFOLD
R E D
C

F E D C B A
V06214.01.00

Circuit Description

The Transmission Fluid Temperature (TFT) sensor is part of the Pressure Switch Manifold (PSM) which is located
in the transmission oil pan. The TFT sensor is a thermistor that changes its resistance value based on the
temperature of the transmission fluid. The Transmission Control Module (TCM) supplies a 5V reference to the
thermistor. The TCM’s internal impedance provides resistance at the TCM so that voltage drop can be measured
between the TCM and the thermistor. When the transmission is cold, the sensor resistance is high and the TCM
detects high signal voltage. As the transmission fluid temperature warms to a normal operating temperature, the
resistance becomes less and the signal voltage decreases. The TCM uses this information to control shift quality
and to determine torque converter clutch applies.

If the TCM detects a continuous short to ground in the TFT sensor or signal circuit, DTC P0712 is set.

5–54 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Conditions for Running the DTC
• No TFT sensor DTC P0711 or P0713.
• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• The engine is greater than 200 rpm for more than 5 seconds.
• The engine has been running for 20 seconds with a coolant temperature above 20°C (68°F).

Conditions for Setting the DTC


DTC P0712 sets when the TFT sensor indicates a voltage of less than 313mV for 2.5 seconds.

Action Taken When the DTC Sets


• The TCM does not illuminate the CHECK TRANS light.
• The TCM stores DTC P0712 in TCM history.
• TCM uses calibration default for temperature values.

Conditions for Clearing the DTC/CHECK TRANS Light


• A Scan Tool may be used to clear the code from the TCM history.
• The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles
without the DTC recurring.
• The TCM cancels the DTC default actions when the fault no longer exists and the ignition has been cycled.

Diagnostic Aids
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
• A short to ground on wire 210 may allow a code P0712 to set. A default value of 160°C (320°F) TFT on the
Scan Tool would be a good indication this has occurred.

Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests for proper AT fluid level and condition.
3. This step tests for the proper reference voltage.
4. This step verifies which condition has set DTC P0712.
5. This step tests the resistance value of the internal wiring harness and TFT sensor.
6. This step tests for opens and shorts in the main wiring harness.
8. This step tests the resistance value of the internal TFT sensor.

Copyright© 2003 General Motors Corp. 5–55


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0712 Transmission Fluid Temperature Sensor Circuit Low Input


(High Temperature)
Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Perform the A/T Fluid Checking Procedure — Go to Step 3 Go to A/T Fluid
(Appendix P). Checking
Is the transmission fluid level correct? Procedure
(Appendix P)
3 1. Turn the ignition OFF. 4.75–5.25V Go to Step 4 Go to Step 11
2. Disconnect J2 connector at the TCM and
install J 39700 Breakout Box and J 43799
Breakout Box Adapter at J2 connector.
3. With the engine OFF, turn the ignition to the
ON position. Measure voltage at J2
connector pins 10 and 20.
Is voltage within the specified value?
4 1. Install the Scan Tool. 150°C (302°F) Go to Step 5 Go to
2. With the engine OFF, turn the ignition to the Diagnostic Aids
ON position.
3. Record the Failure Record data.
4. Clear the DTC.
5. Select TFT on the Scan Tool. Drive the
vehicle and inspect for unrealistic TFT
readings.
Is the TFT reading at or above the specified
value?
This DTC may indicate a short to ground at wire
210.
5 1. Disconnect the wiring harness from the main 3398–3582 Ohms Go to Step 6 Go to Step 8
transmission connector. at 20°C (68°F)
2. Using a DVOM, measure resistance at main Refer to
transmission connector pins G and H.* TFT Sensor
Is resistance within the specified values? Resistance Table
Page 5–13)
6 1. Reconnect the wiring harness to the main 3398–3582 Ohms Go to Go to Step 7
transmission connector. at 20°C (68°F) Diagnostic Aids
2. Disconnect J2 connector from the TCM. Refer to
3. Using a DVOM, measure resistance at J2 TFT Sensor
connector pins 10 and 20. Resistance Table
Is the resistance within the specified values? Page 5–13)

5–56 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0712 Transmission Fluid Temperature Sensor Circuit Low Input
(High Temperature) (cont’d)
Step Action Value(s) Yes No
7 NOTE: The vehicle OEM has responsibility — Go to Step 12 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Have the vehicle wiring harness repaired.
Is the repair complete?
8 1. Remove the oil pan. 3398–3582 Ohms Go to Step 9 Go to Step 10
2. Disconnect the PSM from the internal wiring at 20°C (68°F)
harness. Refer to
3. Using a DVOM, measure PSM resistance at TFT Sensor
pins E and F. Resistance Table
Is resistance within the specified values? Page 5–13)
9 Replace the internal wiring harness (refer to — Go to Step 12 —
Mechanic’s Tips).
Is the replacement complete?
10 Replace the PSM (refer to Mechanic’s Tips). — Go to Step 12 —
Is the replacement complete?
11 NOTE: In most cases, the TCM is not at fault. — Go to Step 12 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM.
Is the replacement complete?
12 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Using the Scan Tool, monitor the Go to Step 1
transmission fluid temperature.
3. Drive the vehicle under normal operating
conditions making sure coolant temperature
is over 20°C (68°F).
4. Watch for significant change in TFT.
Did the DTC return?
* If J 39700 and J 44722 are available, they may be used to perform this operation.

Copyright© 2003 General Motors Corp. 5–57


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0713 Transmission Fluid Temperature Sensor Circuit High Input
(Low Temperature)

TRANSMISSION
HARNESS
CONNECTOR J2 HARNESS CONNECTOR
(RED)
H J2-10

J2-20 TCM
TRANSMISSION
BULKHEAD
CONNECTOR
H

J2
G
J1
NOTE: Letters I, O, and Q are not used.

C A
D B
E C 210
G J2-10 HI
R D TCM
TRANSMISSION
E
F 220 LO
H J2-20

NOTE: Switches C, D, and E are N/O. Switch R is N/C.


PRESSURE SWITCH
MANIFOLD
R E D
C

F E D C B A
V06214.01.00

Circuit Description

The Transmission Fluid Temperature (TFT) sensor is part of the Pressure Switch Manifold (PSM) which is located
in the transmission oil pan. The TFT sensor is a thermistor that changes its resistance value based on the
temperature of the transmission fluid. The Transmission Control Module (TCM) supplies a 5V reference to the
thermistor. The TCM’s internal impedance provides resistance at the TCM so that voltage drop can be measured
between the TCM and the thermistor. When the transmission is cold, the sensor resistance is high and the TCM
detects high signal voltage. As the transmission fluid temperature warms to a normal operating temperature, the
resistance becomes less and the signal voltage decreases. The TCM uses this information to control shift quality
and to determine torque converter clutch applies.

If the TCM detects a continuous open or short-to-power in the TFT sensor or signal circuit, DTC P0713 sets.

5–58 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Conditions for Running the DTC
• No DTC P0711 or P0712.
• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• Engine speed is greater than 200 rpm for more than 5 seconds.
• The engine has been running for 20 seconds with a coolant temperature above 20°C (68°F).

Conditions for Setting the DTC


DTC P0713 sets when the TCM detects a voltage greater than 4.84V for 2.5 seconds.

Action Taken When the DTC Sets


• The TCM does not illuminate the CHECK TRANS light.
• The TCM stores DTC P0713 in TCM history.
• TCM uses calibration default for temperature values.

Conditions for Clearing the DTC/CHECK TRANS Light


• A Scan Tool may be used to clear the code from the TCM history.
• The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles
without the DTC recurring.
• The TCM cancels the DTC default actions when the fault no longer exists and the ignition has been cycled.

Diagnostic Aids
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
• An open or a short to power at wire 210 may allow DTC P0713 to set. A default value of –60°C (–76°F) would
be a good indication this has occurred.

Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests for proper AT fluid level and condition.
3. This step tests for the proper reference voltage.
4. This step verifies which condition has set DTC P0713.
5. This step tests the resistance value of the internal wiring harness and TFT sensor.
6. This step tests for opens and shorts in the main wiring harness.
8. This step tests the resistance value of the internal TFT sensor.

Copyright© 2003 General Motors Corp. 5–59


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0713 Transmission Fluid Temperature Sensor Circuit High Input


(Low Temperature)
Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Perform the A/T Fluid Checking Procedure — Go to Step 3 Go to A/T Fluid
(Appendix P). Checking
Is the transmission fluid level correct? Procedure
(Appendix P)
3 1. Turn the ignition OFF. 4.75–5.25V Go to Step 4 Go to Step 11
2. Disconnect J2 connector at the TCM and
install J 39700 Breakout Box and J 43799
Breakout Box Adapter.
3. With the engine OFF, turn the ignition to the
ON position. Measure voltage between J2
connector pins 10 and 20.
Is voltage within the specified value?
4 1. Install the Scan Tool. –36°C (–32.8°F) Go to Step 5 Go to
2. With the engine OFF, turn the ignition to the Diagnostic Aids
ON position.
3. Record the Failure Record data.
4. Clear the DTC.
5. Select TFT on the Scan Tool. Drive the
vehicle and inspect for unrealistic TFT
readings.
Is the TFT reading at or below the specified
value?
This DTC may indicate an open or short to
power at wire 210.
5 1. Disconnect the wiring harness from the main 3398–3582 Ohms Go to Step 6 Go to Step 8
transmission connector. at 20°C (68°F)
2. Using a DVOM, measure resistance at main Refer to
transmission connector pins G and H.* TFT Sensor
Is resistance within the specified values? Resistance Table
Page 5–13)
6 1. Reconnect the wiring harness to the main 3398–3582 Ohms Go to Go to Step 7
transmission connector. at 20°C (68°F) Diagnostic Aids
2. Disconnect the J2 connector from the TCM. Refer to
3. Using a DVOM, measure resistance at TFT Sensor
connector J2 pins 10 and 20. Resistance Table
Is resistance within the specified values? Page 5–13)

5–60 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0713 Transmission Fluid Temperature Sensor Circuit High Input
(Low Temperature) (cont’d)
Step Action Value(s) Yes No
7 NOTE: The vehicle OEM has responsibility — Go to Step 12 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?
8 1. Remove the oil pan. 3398–3582 Ohms Go to Step 9 Go to Step 10
2. Disconnect the PSM from the internal wiring at 20°C (68°F)
harness. Refer to
3. Using a DVOM, measure PSM resistance at TFT Sensor
pins E and F. Resistance Table
Is resistance within the specified values? Page 5–13)
9 Replace the internal wiring harness (refer to — Go to Step 12 —
Mechanic’s Tips).
Is the repair or replacement complete?
10 Replace the PSM (refer to Mechanic’s Tips). — Go to Step 12 —
Is the replacement complete?
11 NOTE: In most cases, the TCM is not at fault. — Go to Step 12 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM.
Is the replacement complete?
12 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Using the Scan Tool, monitor the Go to Step 1
transmission fluid temperature.
3. Drive the vehicle under normal operating
conditions making sure coolant temperature
is over 20°C (68°F).
Did the DTC return?
* If J 39700 and J 44722 are available, they may be used to perform this operation.

Copyright© 2003 General Motors Corp. 5–61


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0716 Turbine Speed Sensor Circuit Performance

J2 HARNESS CONNECTOR
J2-13 (RED)
J2-14
TCM

J2

J1

A TCM
B
TURBINE 213
A J2-13 TURBINE SPEED HI
SPEED 214
SENSOR B J2-14 TURBINE SPEED LO

SPEED SENSOR CIRCUITS


Use twisted pairs of wires

NOTE: Typical speed sensor resistance 2304 Ω – 2815 Ω at 20°C (68°F)


V06219.01.00

Circuit Description
The speed sensors are variable reluctance devices which convert mechanical motion to an AC voltage. Each sensor
consists of a wire coil wrapped around a pole piece that is adjacent to a permanent magnet. These elements are
contained in a housing which is mounted adjacent to a rotating ferrous member. Two signal wires extend from one end
of the housing and an exposed end of the pole piece is at the opposite end of the housing. The permanent magnet
produces lines of flux around the pole piece. As a ferrous object (such as a gear tooth) approaches and passes
through the gap at the end of the pole piece, an AC voltage pulse is induced in the wire coil. The Transmission Control
Module (TCM) calculates the frequency of these AC pulses and converts it to a speed value. The AC voltage
generated varies from 150mV at low speed to 15V at high speed. The signal wires from the sensor are formed as
twisted pairs to cancel magnetically induced fields. The cable is also shielded to protect from voltage-related fields.
Noise from other sources is eliminated by using two-wire differential inputs at the TCM.

Conditions for Running the DTC


• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• DTC P0717, P0721, or P0722 is not active.
• Turbine speed is above 200 rpm.
• Shift is complete and range attained is not neutral.

Conditions for Setting the DTC


DTC P0716 is set when one of the following conditions occur:
• Unrealistic large change in turbine speed. Failure is set if an unrealistic change in transmission turbine speed is
detected at or above 800 rpm for 0.15 seconds.

5–62 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


• Noisy turbine speed signal. Noise is determined with two counters. A low counter is incremented when turbine
speed change is below 800 rpm for 2.0 seconds. A high counter is incremented when turbine speed change is
above 800 rpm. When both counters accumulate 5 events, a failure is set.

Action Taken When the DTC Sets


• When DTC P0716 is active, the following conditions will occur:
— If failure occurs while in a forward range and a shift has been completed, the transmission will remain in the
current range.
— If failure occurs while in a forward range and a shift is in progress, the transmission will return to the
previous range, except in post-shift state; then the transmission will continue to the commanded range.
• DTC P0716 is stored in the TCM history.
• The CHECK TRANS light illuminates.
• The TCM inhibits TCC engagement.
• The TCM freezes shift adapts.

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• You may have to drive the vehicle in order to experience a fault.
• If the condition is intermittent, connect the Scan Tool and select the speed sensor indicated by the code. If the
signal is erratic, investigate and eliminate the following:
— Intermittent wiring connection.
— Excessive vibration (driveline or engine torsionals).
— Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel).
• Install a known good speed sensor and see if normal function is restored to rule out an internal short or open in
the sensor removed.
• Check that the speed sensor wiring consists of twisted pairs at the rate of 12 to 16 twists per 300 mm. These
twists must extend the entire length of the wiring harness to within at least 50 mm of the speed sensor
connector.
• Inspect the turbine speed tone wheel/PTO gear for possible damage.

Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests ignition voltage.
3. This step tests for proper turbine speed sensor resistance at the TCM side of the harness.
4. This step tests turbine speed sensor resistance.

Copyright© 2003 General Motors Corp. 5–63


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0716 Turbine Speed Sensor Circuit Performance


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. 9–18V Go to Step 3 Resolve
2. Start the engine. (12V TCM); voltage problem
3. Record the DTC Failure Record data. 18–32V (Refer to
4. Using the Scan Tool, measure ignition (24V TCM) DTC P0562
voltage. and P0563)
Is voltage within the specified value?
3 1. Turn the ignition OFF. Refer to Go to Diagnostic Go to Step 4
2. Disconnect the J2 connector at the TCM. Speed Sensor Aids
3. Using a DVOM, measure the resistance Resistance Table
between connector J2 pin 13 and Page 5–13)
connector J2 pin 14.
Is the speed sensor resistance within the
specified values?
4 1. Disconnect the wiring harness from the Refer to Go to Step 5 Go to Step 6
turbine speed sensor. Speed Sensor
2. Using a DVOM, check the resistance Resistance Table
between the speed sensor terminals.* Page 5–13)
Is resistance within the specified values?
5 NOTE: The vehicle OEM has responsibility — Go to Step 7 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?
6 NOTE: Do not rotate the speed sensor in the — Go to Step 7 —
retaining bracket. Orientation is fixed, and if
changed, may cause improper operation.
Replace the turbine speed sensor (refer to
Mechanic’s Tips).
Is the replacement complete?
7 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under normal operating Go to Step 1
conditions.
3. Using the Scan Tool, monitor turbine speed
sensor operation.
Did the DTC return?
* If J 39700 and J 44722 are available, they may be used to perform this operation.

5–64 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0717 Turbine Speed Sensor Circuit No Signal

J2 HARNESS CONNECTOR
J2-13 (RED)
J2-14
TCM

J2

J1

A TCM
B
TURBINE 213
A J2-13 TURBINE SPEED HI
SPEED 214
SENSOR B J2-14 TURBINE SPEED LO

SPEED SENSOR CIRCUITS


Use twisted pairs of wires

NOTE: Typical speed sensor resistance 2304 Ω – 2815 Ω at 20°C (68°F)


V06219.01.00

Circuit Description
The speed sensors are variable reluctance devices which convert mechanical motion to an AC voltage. Each sensor
consists of a wire coil wrapped around a pole piece that is adjacent to a permanent magnet. These elements are
contained in a housing which is mounted adjacent to a rotating ferrous member. Two signal wires extend from one
end of the housing and an exposed end of the pole piece is at the opposite end of the housing. The permanent
magnet produces lines of flux around the pole piece. As a ferrous object (such as a gear tooth) approaches and
passes through the gap at the end of the pole piece, an AC voltage pulse is induced in the wire coil. The
Transmission Control Module (TCM) calculates the frequency of these AC pulses and converts it to a speed value.
The AC voltage generated varies from 150mV at low speed to 15V at high speed. The signal wires from the sensor
are formed as twisted pairs to cancel magnetically induced fields. The cable is also shielded to protect from voltage-
related fields. Noise from other sources is eliminated by using two-wire differential inputs at the TCM.

Conditions for Running the DTC


• Components are powered and the ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V or less than 32V (24V TCM).
• DTC P0721, P0722, P0731, P0732, P0733, P0734, P0735, P0736, or P1718 is not active.
• When unrealistic large change in turbine speed is detected.
— Engine is running.
— Shift is not in process.
— Range attained is not neutral.
— Transmission fluid temperature is above –25°C (–13°F).

Copyright© 2003 General Motors Corp. 5–65


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DIAGNOSTIC TROUBLE CODES (DTC)


• When unrealistic low turbine speed is detected.
— Engine is running.
— Shift is not in process.
— Range attained is not neutral.
— Transmission fluid temperature is above –25°C (–13°F).
— Transmission output speed is at or above 150 rpm or engine speed is at or above 400 rpm.

Conditions for Setting the DTC

DTC P0717 is set when one of the following conditions occur:


• Unrealistic large change in turbine speed. A Failure pending is set if an unrealistic change in transmission
turbine speed is detected at or above 800 rpm. The failure pending response is to lock in the current range.
• Unrealistic low value in turbine speed. A failure pending is set if turbine speed is detected below 61 rpm. A
failure is set when turbine speed is below 61 rpm and output speed is detected above 500 rpm for more than
1 second.

Action Taken When the DTC Sets


• When DTC P0717 is active, the following conditions will occur:
— If failure occurs while in a forward range and a shift has been completed, the transmission will remain in the
current range.
— If failure occurs while in a forward range and a shift is in progress, the transmission will return to the
previous range, except in post-shift state; then the transmission will continue to the commanded range.
— If failure occurs under other conditions, the transmission shifts to 1st, 3rd, or 5th.
— If the shift selector is moved to N (Neutral), R (Reverse), or any other forward range, the transmission will
lock in N (Neutral).
• DTC P0717 is stored in the TCM history.
• The CHECK TRANS light illuminates.
• The TCM freezes shift adapts (DNA).
• The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• You may have to drive the vehicle in order to experience a fault.

5–66 Copyright© 2003 General Motors Corp.


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DIAGNOSTIC TROUBLE CODES (DTC)


• If the condition is intermittent, connect the Scan Tool and select the speed sensor indicated by the code. If the
signal is erratic, investigate and eliminate the following:
— Intermittent wiring connection
— Excessive vibration (driveline or engine torsionals)
— Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel)
• Install a known good speed sensor and see if normal function is restored to rule out an internal short or open in
the sensor removed.
• Check that the speed sensor wiring consists of twisted pairs at the rate of 12 to 16 twists per 300 mm. These
twists must extend the entire length of the wiring harness to within at least 50 mm of the speed sensor
connector.
• Install a known good TCM, if available. If the DTC does not return, reinstall the old TCM to verify the repair.

Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests ignition voltage.
3. This step tests for proper turbine speed sensor resistance at the TCM side of the harness.
4. This step tests turbine speed sensor resistance at the sensor.

DTC P0717 Turbine Speed Sensor Circuit No Signal


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. 9–18V Go to Step 3 Resolve
2. Start the engine. (12V TCM); voltage problem
3. Record the DTC Failure Record data. 18–32V (Refer to
4. Using the Scan Tool, measure ignition (24V TCM) DTC P0562
voltage. and P0563)
Is voltage within the specified value?
3 1. Turn the ignition OFF. Refer to Go to Go to Step 4
2. Disconnect connector J2 from the TCM. Speed Sensor Diagnostic Aids
3. Using a DVOM, measure resistance at Resistance Table
connector J2 pins 13 and 14. Page 5–13)
Is resistance within the specified values?
4 1. Disconnect the wiring harness from the Refer to Go to Step 5 Go to Step 6
turbine speed sensor. Speed Sensor
2. Using a DVOM, measure resistance at the Resistance Table
speed sensor terminals.* Page 5–13)
Is resistance within the specified values?
5 NOTE: The vehicle OEM has responsibility — Go to Step 7 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?

Copyright© 2003 General Motors Corp. 5–67


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0717 Turbine Speed Sensor Circuit No Signal (cont’d)
Step Action Value(s) Yes No
6 NOTE: Do not rotate the speed sensor in the — Go to Step 7 —
retaining bracket. Orientation is fixed, and if
changed, may cause improper operation.
Replace the turbine speed sensor (refer to
Mechanic’s Tips).
Is the replacement complete?
7 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under normal operating Go to Step 1
conditions.
3. Using the Scan Tool, monitor turbine speed
sensor operation.
Did the DTC return?
* If J 39700 and J 44722 are available, they may be used to perform this operation.

5–68 Copyright© 2003 General Motors Corp.


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DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0719 Brake Switch ABS Input Low

TCM
J1 HARNESS CONNECTOR
(GRAY)
J1-13

J2

J1-28 J1

ANTI-LOCK
BRAKE TCM
CONTROLS 113
J1-13 DIGITAL
INTERFACE
Customer–furnished
relay is shown
de-energized
128
J1-28
SWITCHED
POWER
NOTE: ABS System provides ground (–) signal when active.

ANTI-LOCK
BRAKE TCM
CONTROLS 113
J1-13 DIGITAL
INTERFACE
Customer–furnished
relay is shown
de-energized
128
J1-28

NOTE: ABS System provides power (+) signal when active.


V08118.00.00

Circuit Description

If the vehicle is equipped with anti-lock brake system (ABS), an interface between the ABS and TCM is required.
This interface allows disengagement of the Torque Converter Clutch (TCC) when the ABS is activated.

This ABS action is initiated with a discrete input from the ABS system, when the ABS is activated a ground signal is
sent to TCM input wire 113. This may be a ground signal direct from the ABS controller or a positive signal from the
ABS controller that powers a relay field coil to supply a ground through the relay contacts. (Some ABS systems
require that the ground signal be switched through a relay.)

Conditions for Running the DTC


• Components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than
18V and less than 32V (24V TCM).
• DTCs P0721, P0722 are not active.

Conditions for Setting the DTC

DTC P0719 will set after the TCM detects one or more vehicle acceleration cycles where the TCM ABS brake
switch input is in the “ON” activated state.

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DIAGNOSTIC TROUBLE CODES (DTC)


Action Taken when DTC sets
• The TCM uses the default assumption that the ABS is OFF.
• DTC P0719 is stored in the TCM history.
• The CHECK TRANS light illuminates.

Conditions for Clearing the DTC/CHECK TRANS Light

A Scan Tool can be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
• ABS system interface to the TCM input can be wired one of three different ways, check with the OEM for proper
wiring information concerning ABS applied input before troubleshooting.

DTC P0719 Brake Switch ABS Input Low


Step Action Value Yes No
1 Was the Beginning the Troubleshooting — Go to Step 2 Go to
Process (Section 5-4A) Performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Remove ABS input wire (113) from J1 — Go to Step 4 Go to Step 3
connector. Clear code and test-drive vehicle.
Did the code return?
3 Return vehicle to OEM for troubleshooting of — Go to Step 5 —
wiring leading to ABS controller.
Was the problem found and corrected?
4 NOTE: In most cases, the TCM is not at — Go to Step 5 —
fault. Investigate thoroughly before
replacing the TCM. Refer to TCM
Replacement Procedure (Section 3–6).
Replace the TCM.
Is the replacement complete?
5 In order to verify your repair: — Begin the System OK
Clear the DTC. diagnosis again.
1. Operate the vehicle under normal driving Go to Step 1.
conditions. Check for proper operation of
ABS.
Did the DTC return?

5–70 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0721 Output Speed Sensor Circuit Performance

J2 HARNESS CONNECTOR
J2-15 (RED)
J2-16
TCM

J2

J1

A TCM
B
OUTPUT 215
A J2-15 OUTPUT SPEED HI
SPEED 216
SENSOR B J2-16 OUTPUT SPEED LO

SPEED SENSOR CIRCUITS


Use twisted pairs of wires

NOTE: Typical speed sensor resistance 2304 Ω – 2815 Ω at 20°C (68°F) V06220.01.00

Circuit Description

The speed sensors are variable reluctance devices which convert mechanical motion to an AC voltage. Each
sensor consists of a wire coil wrapped around a pole piece that is adjacent to a permanent magnet. These
elements are contained in a housing which is mounted adjacent to a rotating ferrous member. Two signal wires
extend from one end of the housing and an exposed end of the pole piece is at the opposite end of the housing.
The permanent magnet produces lines of flux around the pole piece. As a ferrous object (such as a gear tooth)
approaches and passes through the gap at the end of the pole piece, an AC voltage pulse is induced in the wire
coil. The Transmission Control Module (TCM) calculates the frequency of these AC pulses and converts it to a
speed value. The AC voltage generated varies from 150mV at low speed to 15V at high speed. The signal wires
from the sensor are formed as twisted pairs to cancel magnetically induced fields. The cable is also shielded to
protect from voltage-related fields. Noise from other sources is eliminated by using two-wire differential inputs at
the TCM.

Conditions for Running the DTC


• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• DTC P0716, P0717, or P0722 is not active.
• Turbine speed is above 200 rpm.
• Shift is complete and range attained is not neutral.

Copyright© 2003 General Motors Corp. 5–71


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Conditions for Setting the DTC

DTC P0721 is set when one of the following conditions occur:


• Unrealistic large change in output speed. A Failure pending is set if an unrealistic change in transmission
output speed is detected at or above 500 rpm. The failure pending response is to lock in the current range.
• Noisy output speed signal. Noise is determined with two counters. A low counter is incremented when output
speed change is below 500 rpm for 2.5 seconds. A high counter is incremented when output speed change is
above 500 rpm. When both counters accumulate 5 events, a failure is set.
Action Taken When the DTC Sets
• When DTC P0721 is active, the following conditions will occur:
— If failure occurs while in a forward range and a shift has been completed, the transmission will remain in the
current range.
— If failure occurs while in a forward range and a shift is in progress, the transmission will return to the
previous range, except in post-shift state; then the transmission will continue to the commanded range.
— If failure occurs under other conditions, the transmission shifts to 1st, 3rd, or 5th.
— If the shift selector is moved to N (Neutral), R (Reverse), or any other forward range, the transmission will
lock in N (Neutral).
— If a latched inhibit is present, the transmission locks to neutral.
• DTC P0721 is stored in the TCM history.
• The CHECK TRANS light illuminates.
• The TCM freezes shift adapts (DNA).
• The TCM inhibits TCC engagement.
Conditions for Clearing the DTC/CHECK TRANS Light
A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.
Diagnostic Aids
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• You may have to drive the vehicle in order to experience a fault.
• If the condition is intermittent, connect the Scan Tool and select the speed sensor indicated by the code. If the
signal is erratic, investigate and eliminate the following:
— Intermittent wiring connection
— Excessive vibration (driveline or engine torsionals)
— Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel
• Install a known good speed sensor and see if normal function is restored to rule out an internal short or open in
the sensor removed.
• Check that the speed sensor wiring consists of twisted pairs at the rate of 12 to 16 twists per 300 mm. These
twists must extend the entire length of the wiring harness to within at least 50 mm of the speed sensor
connector.

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DIAGNOSTIC TROUBLE CODES (DTC)


Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests ignition voltage.
3. This step tests for proper output speed sensor resistance.
4. This step tests for proper resistance at the output speed sensor.
.

DTC P0721 Output Speed Sensor Circuit Performance


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. 9–18V Go to Step 3 Resolve
2. Start the engine. (12V TCM); voltage problem
3. Record the DTC Failure Record data. 18–32V (Refer to
4. Using the Scan Tool, measure ignition (24V TCM) DTC P0562
voltage. and P0563)
Is voltage within the specified value?
3 1. Turn the ignition OFF. Refer to Go to Go to Go to Step 4
2. Disconnect connector J2 from the TCM. Speed Sensor Diagnostic Aids
3. Using a DVOM, measure resistance at Resistance Table
connector J2 pins 15 and 16. Page 5–13)
Is resistance within the specified values?
4 1. Disconnect the wiring harness from the 2304–2815 Ohms Go to Step 5 Go to Step 6
output speed sensor. at 20°C (68°F)
2. Using a DVOM, measure resistance at the Refer to
speed sensor terminals.* Speed Sensor
Is resistance within the specified values? Resistance Table
Page 5–13)
5 NOTE: The vehicle OEM has responsibility — Go to Step 7 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?
6 NOTE: Do not rotate the speed sensor in the — Go to Step 7 —
retaining bracket. Orientation is fixed, and if
changed, may cause improper operation.
Replace the output speed sensor (refer to
Mechanic’s Tips).
Is the replacement complete?

Copyright© 2003 General Motors Corp. 5–73


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0721 Output Speed Sensor Circuit Performance (cont’d)
Step Action Value(s) Yes No
7 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under normal operating Go to Step 1
conditions.
3. Using the Scan Tool, monitor output speed
sensor operation.
Did the DTC return?
* If J 39700 and J 44722 are available, they may be used to perform this operation.

5–74 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0722 Output Speed Sensor Circuit No Signal

J2 HARNESS CONNECTOR
J2-15 (RED)
J2-16
TCM

J2

J1

A TCM
B
OUTPUT 215
A J2-15 OUTPUT SPEED HI
SPEED 216
SENSOR B J2-16 OUTPUT SPEED LO

SPEED SENSOR CIRCUITS


Use twisted pairs of wires

NOTE: Typical speed sensor resistance 2304 Ω – 2815 Ω at 20°C (68°F) V06220.01.00

Circuit Description

The speed sensors are variable reluctance devices which convert mechanical motion to an AC voltage. Each
sensor consists of a wire coil wrapped around a pole piece that is adjacent to a permanent magnet. These
elements are contained in a housing which is mounted adjacent to a rotating ferrous member. Two signal wires
extend from one end of the housing and an exposed end of the pole piece is at the opposite end of the housing.
The permanent magnet produces lines of flux around the pole piece. As a ferrous object (such as a gear tooth)
approaches and passes through the gap at the end of the pole piece, an AC voltage pulse is induced in the wire
coil. The Transmission Control Module (TCM) calculates the frequency of these AC pulses and converts it to a
speed value. The AC voltage generated varies from 150mV at low speed to 15V at high speed. The signal wires
from the sensor are formed as twisted pairs to cancel magnetically induced fields. The cable is also shielded to
protect from voltage-related fields. Noise from other sources is eliminated by using two-wire differential inputs at
the TCM.

Conditions for Running the DTC

• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• DTC P0716, P0717, P0721, P0731, P0732, P0733, P0734, P0735, P0736, or P1718 is not active.
• When unrealistic large change in output speed is detected, output speed is at or above 600 rpm for more than
1 second.

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ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


• When unrealistically low output speed is detected.
— Engine is running.
— Shift is not in process.
— Range attained is not neutral.
— Transmission fluid temperature is above –25°C (–13°F).
— Transmission turbine speed is at or above 1050 rpm.
— Manual selector valve is not being moved to a forward range.

Conditions for Setting the DTC


DTC P0722 is set when one of the following conditions occur:
• Unrealistic large change in output speed. A failure pending is set if an unrealistic change in transmission output
speed is detected at or above 600 rpm. A failure is set if neutral range is attained.
• Unrealistic low value in output speed. A failure pending is set if output speed is detected below 61 rpm. A
failure is set when output speed is below 61 rpm and transmission range is 3rd, 4th, or 5th for more than
1 second.

Action Taken When the DTC Sets


• When DTC P0722 is active, the following conditions will occur:
— If failure occurs while in a forward range and a shift has been completed, the transmission will remain in the
current range.
— If failure occurs while in a forward range and a shift is in progress, the transmission will return to the
previous range, except in post-shift state; then the transmission will continue to the commanded range.
— If failure occurs under other conditions, the transmission shifts to 1st, 3rd, or 5th.
— If the shift selector is moved to N (Neutral), R (Reverse), or any other forward range while the diagnostic
response is active, the transmission will lock in N (Neutral).
— If a latched inhibit is present, the transmission locks in neutral.
• DTC P0722 is stored in the TCM history.
• The CHECK TRANS light illuminates.
• The TCM freezes shift adapts (DNA).
• The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• You may have to drive the vehicle in order to experience a fault.

5–76 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


• If the condition is intermittent, connect the Scan Tool and select the speed sensor indicated by the code. If the
signal is erratic, investigate and eliminate the following:
— Intermittent wiring connection
— Excessive vibration (driveline or engine torsionals)
— Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel
• Install a known good speed sensor and see if normal function is restored to rule out an internal short or open in
the sensor removed.
• Check that the speed sensor wiring consists of twisted pairs at the rate of 12 to 16 twists per 300 mm. These
twists must extend the entire length of the wiring harness to within at least 50 mm of the speed sensor
connector.
• Install a known good TCM, if available. If the DTC does not return, reinstall the old TCM to verify the repair.

Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests ignition voltage.
3. This step tests for proper output speed sensor resistance at the TCM side of the wiring harness.
4. This step tests for proper output speed sensor resistance.

DTC P0722 Output Speed Sensor Circuit No Signal


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. 9–18V Go to Step 3 Resolve
2. Start the engine. (12V TCM); voltage problem
3. Record the DTC Failure Record data. 18–32V (Refer to
4. Using the Scan Tool, measure ignition (24V TCM) DTC P0562
voltage. and P0563)
Is voltage within the specified value?
3 1. Turn the ignition OFF. Refer to Go to Diagnostic Go to Step 4
2. Disconnect connector J2 from the TCM. Speed Sensor Aids
3. Using a DVOM, measure resistance at Resistance Table
connector J2 pins 15 and 16. Page 5–13)
Is resistance within the specified values?
4 1. Disconnect the wiring harness from the Refer to Go to Step 5 Go to Step 6
output speed sensor. Speed Sensor
2. Using a DVOM, measure resistance at the Resistance Table
speed sensor terminals.* Page 5–13)
Is resistance within the specified values?
5 NOTE: The vehicle OEM has responsibility — Go to Step 7 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?

Copyright© 2003 General Motors Corp. 5–77


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0722 Output Speed Sensor Circuit No Signal (cont’d)
Step Action Value(s) Yes No
6 NOTE: Do not rotate the speed sensor in the — Go to Step 7 —
retaining bracket. Orientation is fixed, and if
changed, may cause improper operation.
Replace the output speed sensor (refer to
Mechanic’s Tips).
Is the replacement complete?
7 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under normal operating Go to Step 1
conditions.
3. Using the Scan Tool, monitor output speed
sensor operation.
Did the DTC return?
* If J 39700 and J 44722 are available, they may be used to perform this operation.

5–78 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0726 Engine Speed Input Circuit Performance

J2 HARNESS CONNECTOR
(RED)
TCM

J2-17
J2-18
J2

J1

A TCM
B
ENGINE 217
A J2-17 ENGINE SPEED HI
SPEED 218
SENSOR B J2-18 ENGINE SPEED LO

SPEED SENSOR CIRCUITS


Use twisted pairs of wires
NOTE: Typical speed sensor resistance 2304 Ω – 2815 Ω at 20°C (68°F) V06221.01.00

Circuit Description

The speed sensors are variable reluctance devices which convert mechanical motion to an AC voltage. Each
sensor consists of a wire coil wrapped around a pole piece that is adjacent to a permanent magnet. These
elements are contained in a housing which is mounted adjacent to a rotating ferrous member. Two signal wires
extend from one end of the housing and an exposed end of the pole piece is at the opposite end of the housing.
The permanent magnet produces lines of flux around the pole piece. As a ferrous object (such as a gear tooth)
approaches and passes through the gap at the end of the pole piece, an AC voltage pulse is induced in the wire
coil. The Transmission Control Module (TCM) calculates the frequency of these AC pulses and converts it to a
speed value. The AC voltage generated varies from 150mV at low speed to 15V at high speed. The signal wires
from the sensor are formed as twisted pairs to cancel magnetically induced fields. The cable is also shielded to
protect from voltage-related fields. Noise from other sources is eliminated by using two-wire differential inputs at
the TCM.

Conditions for Running the DTC

• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• DTC P0716, P0717, P0721, or P0727 is not active.
• Engine speed is above 600 rpm for 1 second.
• Shift is complete and range attained is not neutral.

Copyright© 2003 General Motors Corp. 5–79


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Conditions for Setting the DTC

DTC P0726 is set when one of the following conditions occur:


• Unrealistic large change in engine speed. Failure is set if an unrealistic change in transmission engine speed is
detected at or above 600 rpm.
• Noisy input speed signal. Noise is determined with two counters. A low counter is incremented when engine
speed change is below 650 rpm for 2.5 seconds. A high counter is incremented when engine speed change is
above 650 rpm. When both counters accumulate 5 events, a failure is set.

Action Taken When the DTC Sets


• DTC P0726 is stored in the TCM history.
• The TCM defaults engine speed to turbine speed. Turbine speed is used to determine the missing engine
speed.

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• You may have to drive the vehicle in order to experience a fault.
• If the condition is intermittent, connect the Scan Tool and select the speed sensor indicated by the code. If the
signal is erratic, investigate and eliminate the following:
— Intermittent wiring connection.
— Excessive vibration (driveline or engine torsionals).
— Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel.
• Install a known good speed sensor and see if normal function is restored to rule out an internal short or open in
the sensor removed.
• Check that the speed sensor wiring consists of twisted pairs at the rate of 12 to 16 twists per 300 mm. These
twists must extend the entire length of the wiring harness to within at least 50 mm of the speed sensor
connector.

Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests ignition voltage.
3. This step tests for proper engine speed sensor resistance at the TCM side of the wiring harness.
4. This step tests for proper resistance value at the engine speed sensor.

5–80 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0726 Engine Speed Input Circuit Performance


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. 9–18V Go to Step 3 Resolve
2. Start the engine. (12V TCM); voltage problem
3. Record the DTC Failure Record data. 18–32V (Refer to
4. Using the Scan Tool, measure ignition (24V TCM) DTC P0562
voltage. and P0563)
Is voltage within the specified value?
3 1. Turn the ignition OFF. Refer to Go to Diagnostic Go to Step 4
2. Disconnect connector J2 from the TCM. Speed Sensor Aids
3. Using a DVOM, measure resistance at Resistance Table
connector J2 pins 17 and 18. Page 5–13)
Is resistance within the specified values?
4 1. Disconnect the wiring harness from the Refer to Go to Step 5 Go to Step 6
engine speed sensor. Speed Sensor
2. Using a DVOM, measure resistance at the Resistance Table
speed sensor terminals.* Page 5–13)
Is resistance within the specified values?
5 NOTE: The vehicle OEM has responsibility — Go to Step 7 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?
6 NOTE: Do not rotate the speed sensor in the — Go to Step 7 —
retaining bracket. Orientation is fixed, and if
changed, may cause improper operation.
Replace the engine speed sensor (refer to
Mechanic’s Tips).
Is the replacement complete?
7 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under normal operating Go to Step 1
conditions.
3. Using the Scan Tool, monitor engine speed
sensor operation.
Did the DTC return?
* If J 39700 and J 44722 are available, they may be used to perform this operation.

Copyright© 2003 General Motors Corp. 5–81


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0727 Engine Speed Input Circuit No Signal

J2 HARNESS CONNECTOR
(RED)
TCM

J2-17
J2-18
J2

J1

A TCM
B
ENGINE 217
A J2-17 ENGINE SPEED HI
SPEED 218
SENSOR B J2-18 ENGINE SPEED LO

SPEED SENSOR CIRCUITS


Use twisted pairs of wires
NOTE: Typical speed sensor resistance 2304 Ω – 2815 Ω at 20°C (68°F) V06221.01.00

Circuit Description
The speed sensors are variable reluctance devices which convert mechanical motion to an AC voltage. Each
sensor consists of a wire coil wrapped around a pole piece that is adjacent to a permanent magnet. These
elements are contained in a housing which is mounted adjacent to a rotating ferrous member. Two signal wires
extend from one end of the housing and an exposed end of the pole piece is at the opposite end of the housing.
The permanent magnet produces lines of flux around the pole piece. As a ferrous object (such as a gear tooth)
approaches and passes through the gap at the end of the pole piece, an AC voltage pulse is induced in the wire
coil. The Transmission Control Module (TCM) calculates the frequency of these AC pulses and converts it to a
speed value. The AC voltage generated varies from 150mV at low speed to 15V at high speed. The signal wires
from the sensor are formed as twisted pairs to cancel magnetically induced fields. The cable is also shielded to
protect from voltage-related fields. Noise from other sources is eliminated by using two-wire differential inputs at
the TCM.

Conditions for Running the DTC


• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• DTC P0716, P0717, or P0726 is not active.
• Unrealistically low engine speed detected.
• Engine is running.
• Transmission turbine speed is at or above 400 rpm.
• Ignition is in the ON position.

5–82 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Conditions for Setting the DTC

DTC P0727 is set when one of the following conditions occur:


• Unrealistic large change in engine speed. Failure pending is set if an unrealistic change in engine speed is
detected at or above 1140 rpm.
• Unrealistic low value in engine speed. Failure is set if engine speed is detected below 61 rpm for 4 seconds.

Action Taken When the DTC Sets


• The TCM defaults engine speed to turbine speed. Turbine speed is used to determine missing engine speed.
• TCM inhibits TCC momentarily.
• DTC P0727 is stored in TCM history

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• You may have to drive the vehicle in order to experience a fault.
• If the condition is intermittent, connect the Scan Tool and select the speed sensor indicated by the code. If the
signal is erratic, investigate and eliminate the following:
— Intermittent wiring connection.
— Excessive vibration (driveline or engine torsionals).
— Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel.
• Install a known good speed sensor and see if normal function is restored to rule out an internal short or open in
the sensor removed.
• Check that the speed sensor wiring consists of twisted pairs at the rate of 12 to 16 twists per 300 mm. These
twists must extend the entire length of the wiring harness to within at least 50 mm of the speed sensor
connector.
• Install a known good TCM, if available. If the DTC does not return, reinstall the old TCM to verify the repair.

Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests ignition voltage.
3. This step tests for proper engine speed sensor resistance at the TCM side of the wiring harness.
4. This step tests for proper resistance value at the engine speed sensor.

Copyright© 2003 General Motors Corp. 5–83


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0727 Engine Speed Input Circuit No Signal


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. 9–18V Go to Step 3 Resolve
2. Start the engine. (12V TCM); voltage problem
3. Record the DTC Failure Record data. 18–32V (Refer to
4. Using the Scan Tool, measure ignition (24V TCM) DTC P0562
voltage. and P0563)
Is voltage within the specified value?
3 1. Turn the ignition OFF. Refer to Go to Go to Step 4
2. Disconnect connector J2 from the TCM. Speed Sensor Diagnostic Aids
3. Using a DVOM, measure resistance at Resistance Table
connector J2 pins 17 and 18. Page 5–13)
Is resistance within the specified values?
4 1. Disconnect the wiring harness from the Refer to Go to Step 5 Go to Step 6
engine speed sensor. Speed Sensor
2. Using a DVOM, measure resistance at the Resistance Table
speed sensor terminals.* Page 5–13)
Is resistance within the specified values?
5 NOTE: The vehicle OEM has responsibility — Go to Step 7 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?
6 NOTE: Do not rotate the speed sensor in the — Go to Step 7 —
retaining bracket. Orientation is fixed, and if
changed, may cause improper operation.
Replace the engine speed sensor (refer to
Mechanic’s Tips).
Is the replacement complete?
7 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under normal operating Go to Step 1
conditions.
3. Using the Scan Tool, monitor engine speed
sensor operation.
Did the DTC return?
* If J 39700 and J 44722 are available, they may be used to perform this operation.

5–84 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0731 Incorrect 1st Gear Ratio

REFER TO
1st RANGE HYDRAULIC SCHEMATIC
(APPENDIX H)
Circuit Description
The Transmission Control Module (TCM) uses input from the turbine speed sensor and output speed sensor to
determine gear ratios. The TCM then compares the known gear ratio to the calculated gear ratio for the current
range.

Conditions for Running the DTC


• Output speed exceeds 200 rpm.
• First range is selected and attained.
• DTC P0716, P0717, P0721, or P0722 is not active.

Conditions for Setting the DTC

DTC P0731 sets when the calculated first range ratio (steady state) differs from the known first range ratio.

Action Taken When the DTC Sets


• When DTC P0731 is active, the following conditions will occur:
— The transmission will fail to 2nd or 5th range.
— If the shift selector is moved to N (Neutral), the transmission will shift to N (Neutral).
— If the shift selector is moved to R (Reverse), the transmission will shift to R (Reverse) unless the
transmission is compromised by overspeeding or a direction change; then it will lock in N (Neutral).
• DTC P0731 is stored in the TCM history.
• The CHECK TRANS light illuminates.
• The TCM freezes shift adapts (DNA).
• The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• Incorrect ratio codes typically indicate mechanical problems with specific clutches, i.e. C1 or C5 for 1st range.
• An incorrect ratio code could indicate a hydraulically failed solenoid. Check the DTC information for the specific
solenoid.
• You may have to drive the vehicle to experience the fault. Clutch test mode can be used to check stall speed.
• Incorrect TCM calibrations will cause this DTC to set. Verify that the proper TCM calibration is being used with
the correct transmission series (there are different gear ratios for the 1000 Series™ and 2000 Series™/
2400 Series™ transmissions).

Copyright© 2003 General Motors Corp. 5–85


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Test Description
The numbers below refer to the step numbers on the diagnostic table.
3. This step tests ignition voltage.
4. This step tests for current first range ratio.
5. This step tests speed sensor readings.
6. This step tests for clutch slippage in first range.
7. This step checks for evidence of clutch failure.

DTC P0731 Incorrect 1st Gear Ratio


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Perform the A/T Fluid Checking Procedure — Go to Step 3 Go to A/T Fluid
(Appendix P) and correct the fluid level if Checking
necessary. Procedure
Did you perform the procedure? (Appendix P)
3 1. Start the engine. 9–18V Go to Step 4 Resolve
2. Record the DTC Failure Record data. (12V TCM); voltage problem
3. Using the Scan Tool, measure ignition 18–32V (Refer to
voltage. (24V TCM) DTC P0562
Is voltage within the specified value? and P0563)
4 1. Install the Scan Tool. 3.1 for 1000 Go to Step 5 Go to
2. Monitor the gear ratio. 3.51 for 2000/ Diagnostic Aids
Is the correct first range ratio shown? 2400
5 1. Turn the ignition ON and drive the vehicle — Go to the Go to Step 6
under normal operating conditions. appropriate
2. Using the Scan Tool, monitor engine, turbine, speed sensor
and output speed readings. DTC
Is speed sensor data erratic or are signal
dropouts detected?

5–86 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0731 Incorrect 1st Gear Ratio (cont’d)
Step Action Value(s) Yes No
6 — Go to Go to Step 7
WARNING: To help avoid injury or property Diagnostic Aids
damage caused by sudden and
unexpected vehicle movement, do not
start a stationary stall test until you:
• Put the transmission in N (Neutral)...and
• Apply the parking brake and service
brake...and
• Chock the vehicle wheels and take any
other steps necessary to prevent the
vehicle from moving...and
Warn personnel to keep clear of the vehicle
and its path.

CAUTION: Do not perform a clutch test In


fourth or fifth range under stall conditions
(above 1400 rpm with brakes held), or
possible clutch damage could occur.

1. Using the Scan Tool, select clutch test mode.


2. With brakes applied, move the selector lever
to D (Drive).
3. With engine at idle, select and attain the
range indicated by the DTC. Turbine speed
should go to zero.
4. Monitor turbine speed while increasing
engine speed to 1400 rpm.
Did turbine speed remain at zero?
7 Remove the dipstick and inspect the — Go to Step 8 Go to Step 9
transmission fluid for clutch debris or burnt
odor. If necessary, drain a small amount of fluid
for this inspection.
Are there signs of a clutch failure?
8 Remove the transmission for overhaul or — Go to Step 11 —
replacement (refer to Mechanic’s Tips).
Is replacement complete?
9 Inspect the control valve body for stuck or — Go to Step 11 Go to Step 10
sticking trimmer valves (refer to Mechanic’s
Tips).
Was a valve problem found and repaired?
10 Replace A solenoid (refer to Mechanic’s Tips). — Go to Step 11 —
Is replacement complete?
11 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle in all ranges under Go to Step 1
normal driving conditions.
Did the DTC return?

Copyright© 2003 General Motors Corp. 5–87


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0732 Incorrect 2nd Gear Ratio

REFER TO
2nd RANGE HYDRAULIC SCHEMATIC
(APPENDIX H)
Circuit Description
The Transmission Control Module (TCM) uses input from the turbine speed sensor and output speed sensor to
determine gear ratios. The TCM then compares the known gear ratio to the calculated gear ratio for the current
range.

Conditions for Running the DTC


• Output speed exceeds 200 rpm.
• Second range is selected and attained.
• DTC P0716, P0717, P0721, or P0722 is not active.

Conditions for Setting the DTC

DTC P0732 sets when the calculated second range ratio (steady state) differs from the known second range ratio.

Action Taken When the DTC Sets


• When DTC P0732 is active, the following conditions will occur:
— The transmission will fail to 3rd range.
— If the shift selector is moved to N (Neutral), the transmission will shift to N (Neutral).
— If the shift selector is moved to R (Reverse), the transmission will shift to R (Reverse) unless the
transmission is compromised by overspeeding or a direction change; then it will lock in N (Neutral).
• DTC P0732 is stored in the TCM history.
• The CHECK TRANS light illuminates.
• The TCM freezes shift adapts (DNA).
• The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• Incorrect ratio codes typically indicate mechanical problems with specific clutches, i.e. C1 and C4 for 2nd
range.
• An incorrect ratio code could indicate a hydraulically failed solenoid. Check the DTC information for the specific
solenoid.
• You may have to drive the vehicle to experience the fault. Clutch test mode can be used to check stall speed.
• Incorrect TCM calibrations will cause this DTC to set. Verify that the proper TCM calibration is being used with
the correct transmission series (there are different gear ratios for the 1000 Series™ and 2000 Series™/
2400 Series™ transmissions).

5–88 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Test Description
The numbers below refer to the step numbers on the diagnostic table.
3. This step tests ignition voltage.
4. This step tests speed sensor readings.
5. This step tests for turbine speed not remaining at zero in second range.
6. This step checks for evidence of clutch failure.

DTC P0732 Incorrect 2nd Gear Ratio


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Perform the A/T Fluid Checking Procedure — Go to Step 3 Go to A/T Fluid
(Appendix P) and correct the fluid level if Checking
necessary. Procedure
Did you perform the procedure? (Appendix P)
3 1. Start the engine. 9–18V Go to Step 4 Resolve
2. Record the DTC Failure Record data. (12V TCM); voltage problem
3. Using the Scan Tool, measure ignition 18–32V (Refer to
voltage. (24V TCM) DTC P0562
Is voltage within the specified value? and P0563)
4 1. Turn the ignition ON and drive the vehicle — Go to appropriate Go to Step 5
under normal operating conditions. speed sensor
2. Using the Scan Tool, monitor engine, turbine, DTC
and output speed readings.
Is speed sensor data erratic or are signal
dropouts detected?

Copyright© 2003 General Motors Corp. 5–89


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0732 Incorrect 2nd Gear Ratio (cont’d)
Step Action Value(s) Yes No
5 — Go to Go to Step 6
WARNING: To help avoid injury or property Diagnostic Aids
damage caused by sudden and
unexpected vehicle movement, do not
start a stationary stall test until you:
• Put the transmission in N (Neutral)...and
• Apply the parking brake and service
brake...and
• Chock the vehicle wheels and take any
other steps necessary to prevent the
vehicle from moving...and
Warn personnel to keep clear of the vehicle
and its path.

CAUTION: Do not perform a clutch test In


fourth or fifth range under stall conditions
(above 1400 rpm with brakes held), or
possible clutch damage could occur.

1. Using the Scan Tool, select clutch test mode.


2. With brakes applied, move the selector lever
to D (Drive).
3. With engine at idle, select and attain the
range indicated by the DTC. Turbine speed
should go to zero.
4. Monitor turbine speed while increasing
engine speed to 1400 rpm.
Did turbine speed remain at zero?
6 Remove the dipstick and inspect the — Go to Step 7 Go to Step 8
transmission fluid for clutch debris or burnt
odor. If necessary, drain a small amount of fluid
for this inspection.
Are there signs of a clutch failure?
7 Remove the transmission for overhaul or — Go to Step 10 —
replacement (refer to Mechanic’s Tips).
Is replacement complete?
8 Inspect the control valve body for stuck or — Go to Step 10 Go to Step 9
sticking trimmer valves (refer to
Mechanic’s Tips).
Was a valve problem found and repaired?
9 Replace B solenoid (refer to Mechanic’s Tips). — Go to Step 10 —
Is replacement complete?
10 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle in all ranges under Go to Step 1
normal driving conditions.
Did the DTC return?

5–90 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0733 Incorrect 3rd Gear Ratio

REFER TO
3rd RANGE HYDRAULIC SCHEMATIC
(APPENDIX H)
Circuit Description

The Transmission Control Module (TCM) uses input from the turbine speed sensor and output speed sensor to
determine gear ratios. The TCM then compares the known gear ratio to the calculated gear ratio for the current
range.

Conditions for Running the DTC

• Output speed exceeds 200 rpm.


• Third range is selected and attained.
• DTC P0716, P0717, P0721, or P0722 is not active.

Conditions for Setting the DTC

DTC P0733 sets when the calculated third range ratio (steady state) differs from the known third range ratio.

Action Taken When the DTC Sets

• When DTC P0733 is active, the following conditions will occur:

— The transmission will fail to 4th range.

— If the shift selector is moved to N (Neutral), the transmission will shift to N (Neutral).

— If the shift selector is moved to R (Reverse), the transmission will shift to N (Neutral).

— If the shift selector is returned to a forward range and the transmission is compromised by overspeeding or
a direction change, the transmission will lock in N (Neutral).
• DTC P0733 is stored in the TCM history.
• The CHECK TRANS light illuminates.
• The TCM freezes shift adapts (DNA).
• The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light

A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Copyright© 2003 General Motors Corp. 5–91


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Diagnostic Aids
• Incorrect ratio codes typically indicate mechanical problems with specific clutches, i.e. C1 and C3 for 3rd
range.
• An incorrect ratio code could indicate a hydraulically failed solenoid. Check the DTC information for the specific
solenoid.
• You may have to drive the vehicle to experience the fault. Clutch test mode can be used to check stall speed.
• Incorrect TCM calibrations will cause this DTC to set. Verify that the proper TCM calibration is being used with
the correct transmission series (there are different gear ratios for the 1000 Series™ and 2000 Series™/
2400 Series™ transmissions).

Test Description
The numbers below refer to the step numbers on the diagnostic table.
3. This step tests ignition voltage.
4. This step tests speed sensor readings.
5. This step tests for turbine speed not remaining at zero in third range.
6. This step checks for evidence of clutch failure.

DTC P0733 Incorrect 3rd Gear Ratio


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Perform the A/T Fluid Checking Procedure — Go to Step 3 Go to A/T Fluid
(Appendix P) and correct the fluid level if Checking
necessary. Procedure
Did you perform the procedure? (Appendix P)
3 1. Start the engine. 9–18V Go to Step 4 Resolve
2. Record the DTC Failure Record data. (12V TCM); voltage problem
3. Using the Scan Tool, measure ignition 18–32V (Refer to
voltage. (24V TCM) DTC P0562
Is voltage within the specified value? and P0563)
4 1. Turn the ignition ON and drive the vehicle — Go to appropriate Go to Step 5
under normal operating conditions. speed sensor
2. Using the Scan Tool, monitor engine, turbine, DTC
and output speed readings.
Is speed sensor data erratic or are signal
dropouts detected?

5–92 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0733 Incorrect 3rd Gear Ratio (cont’d)
Step Action Value(s) Yes No
5 — Go to Go to Step 6
WARNING: To help avoid injury or property Diagnostic Aids
damage caused by sudden and
unexpected vehicle movement, do not
start a stationary stall test until you:
• Put the transmission in N (Neutral)...and
• Apply the parking brake and service
brake...and
• Chock the vehicle wheels and take any
other steps necessary to prevent the
vehicle from moving...and
Warn personnel to keep clear of the vehicle
and its path.

CAUTION: Do not perform a clutch test In


fourth or fifth range under stall conditions
(above 1400 rpm with brakes held), or
possible clutch damage could occur.

1. Using the Scan Tool, select clutch test mode.


2. With brakes applied, move the selector lever
to D (Drive).
3. With engine at idle, select and attain the
range indicated by the DTC. Turbine speed
should go to zero.
4. Monitor turbine speed while increasing
engine speed to 1400 rpm.
Did turbine speed remain at zero?
6 Remove the dipstick and inspect the — Go to Step 7 Go to Step 8
transmission fluid for clutch debris or burnt
odor. If necessary, drain a small amount of fluid
for this inspection.
Are there signs of a clutch failure?
7 Remove the transmission for overhaul or — Go to Step 10 —
replacement (refer to Mechanic’s Tips).
Is replacement complete?
8 Inspect the control valve body for stuck or — Go to Step 10 Go to Step 9
sticking trimmer valves (refer to Mechanic’s
Tips).
Was a valve problem found and repaired?
9 Replace A solenoid (refer to Mechanic’s Tips). — Go to Step 10 —
Is replacement complete?
10 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle in all ranges under Go to Step 1
normal driving conditions.
Did the DTC return?

Copyright© 2003 General Motors Corp. 5–93


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0734 Incorrect 4th Gear Ratio

REFER TO
4th RANGE HYDRAULIC SCHEMATIC
(APPENDIX H)
Circuit Description
The Transmission Control Module (TCM) uses input from the turbine speed sensor and output speed sensor to
determine gear ratios. The TCM then compares the known gear ratio to the calculated gear ratio for the current
range.

Conditions for Running the DTC


• Output speed exceeds 200 rpm.
• Fourth range is selected and attained.
• DTC P0716, P0717, P0721, or P0722 is not active.

Conditions for Setting the DTC

DTC P0734 sets when the calculated fourth range ratio (steady state) differs from the known fourth range ratio.

Action Taken When the DTC Sets


• When DTC P0734 is active, the following conditions will occur:
— The transmission will fail to 5th range.
— If the shift selector is moved to N (Neutral), the transmission will shift to N (Neutral).
— If the shift selector is moved to R (Reverse), the transmission will shift to R (Reverse) unless the
transmission is compromised by a direction change; then the transmission will shift to N (Neutral).
— If the shift selector is returned to a forward range and the transmission is compromised by overspeeding or
a direction change, the transmission will lock in N (Neutral).
• DTC P0734 is stored in the TCM history.
• The CHECK TRANS light illuminates.
• The TCM freezes shift adapts (DNA).
• The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light

A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• Incorrect ratio codes typically indicate mechanical problems with specific clutches, i.e. C1 and C2 for 4th range.
• An incorrect ratio code could indicate a hydraulically failed solenoid. Check the DTC information for the specific
solenoid.
• You may have to drive the vehicle to experience the fault. Clutch test mode can be used to check stall speed.

5–94 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Test Description
The numbers below refer to the step numbers on the diagnostic table.
3. This step tests ignition voltage.
4. This step tests speed sensor readings.
5. This step tests for turbine speed not remaining at zero in fourth range.
6. This step checks for evidence of clutch failure.

DTC P0734 Incorrect 4th Gear Ratio


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Perform the A/T Fluid Checking Procedure — Go to Step 3 Go to A/T Fluid
(Appendix P) and correct the fluid level if Checking
necessary. Procedure
Did you perform the procedure? (Appendix P)
3 1. Start the engine. 9–18V Go to Step 4 Resolve
2. Record the DTC Failure Record data. (12V TCM); voltage problem
3. Using the Scan Tool, measure ignition 18–32V (Refer to
voltage. (24V TCM) DTC P0562
Is voltage within the specified value? and P0563)
4 1. Turn the ignition ON and drive the vehicle — Go to appropriate Go to Step 5
under normal operating conditions. speed sensor
2. Using the Scan Tool, monitor engine, turbine, DTC
and output speed readings.
Is speed sensor data erratic or are signal
dropouts detected?

Copyright© 2003 General Motors Corp. 5–95


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0734 Incorrect 4th Gear Ratio (cont’d)
Step Action Value(s) Yes No
5 — Go to Go to Step 6
WARNING: To help avoid injury or property Diagnostic Aids
damage caused by sudden and
unexpected vehicle movement, do not
start a stationary stall test until you:
• Put the transmission in N (Neutral)...and
• Apply the parking brake and service
brake...and
• Chock the vehicle wheels and take any
other steps necessary to prevent the
vehicle from moving...and
Warn personnel to keep clear of the vehicle
and its path.

CAUTION: Do not perform a clutch test In


fourth or fifth range under stall conditions
(above 1400 rpm with brakes held), or
possible clutch damage could occur.

1. Using the Scan Tool, select clutch test mode.


2. With brakes applied, move the selector lever
to D (Drive).
3. With engine at idle, select and attain the
range indicated by the DTC. Turbine speed
should go to zero.
4. Monitor turbine speed while increasing
engine speed to 1400 rpm.
Did turbine speed remain at zero?
6 Remove the dipstick and inspect the — Go to Step 7 Go to Step 8
transmission fluid for clutch debris or burnt
odor. If necessary, drain a small amount of fluid
for this inspection.
Are there signs of a clutch failure?
7 Remove the transmission for overhaul or — Go to Step 10 —
replacement (refer to Mechanic’s Tips).
Is replacement complete?
8 Inspect the control valve body for stuck or — Go to Step 10 Go to Step 9
sticking trimmer valves (refer to
Mechanic’s Tips).
Was a valve problem found and repaired?
9 Replace B solenoid (refer to Mechanic’s Tips). — Go to Step 10 —
Is replacement complete?
10 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle in all ranges under Go to Step 1
normal driving conditions.
Did the DTC return?

5–96 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0735 Incorrect 5th Gear Ratio

REFER TO
5th RANGE HYDRAULIC SCHEMATIC
(APPENDIX H)
Circuit Description

The Transmission Control Module (TCM) uses input from the turbine speed sensor and output speed sensor to
determine gear ratios. The TCM then compares the known gear ratio to the calculated gear ratio for the current
range.

Conditions for Running the DTC


• Output speed exceeds 200 rpm.
• Fifth range is selected and attained.
• DTC P0716, P0717, P0721, or P0722 is not active.

Conditions for Setting the DTC

DTC P0735 sets when the calculated fifth range ratio (steady state) differs from the known fifth range ratio.

Action Taken When the DTC Sets


• When DTC P0735 is active, the following conditions will occur:

— The transmission will fail to 4th range.

— If the shift selector is moved to N (Neutral), the transmission will shift to N (Neutral).

— If the shift selector is moved to R (Reverse), the transmission will shift to R (Reverse) unless the
transmission is compromised by a direction change; then the transmission will shift to N (Neutral).

— If the shift selector is returned to a forward range and the transmission is compromised by overspeeding or
a direction change, the transmission will lock in N (Neutral).
• DTC P0735 is stored in the TCM history.
• The CHECK TRANS light illuminates.
• The TCM freezes shift adapts (DNA).
• The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light

A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Copyright© 2003 General Motors Corp. 5–97


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Diagnostic Aids
• Incorrect ratio codes typically indicate mechanical problems with specific clutches, i.e. C2 and C3 for 5th range.
• An incorrect ratio code could indicate a hydraulically failed solenoid. Check the DTC information for the specific
solenoid.
• You may have to drive the vehicle to experience the fault. Clutch test mode can be used to check stall speed.
• Incorrect TCM calibrations will cause this DTC to set. Verify that the proper TCM calibration is being used with
The correct transmission series (there are different gear ratios for the 1000 Series™ and 2000 Series™/
2400 Series™ transmissions).

Test Description
The numbers below refer to the step numbers on the diagnostic table.
3. This step tests ignition voltage.
4. This step tests speed sensor readings.
5. This step tests for turbine speed not remaining at zero in fifth range.
6. This step checks for evidence of clutch failure.

DTC P0735 Incorrect 5th Gear Ratio


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Perform the A/T Fluid Checking Procedure — Go to Step 3 Go to A/T Fluid
(Appendix P) and correct the fluid level if Checking
necessary. Procedure
Did you perform the procedure? (Appendix P)
3 1. Start the engine. 9–18V Go to Step 4 Resolve
2. Record the DTC Failure Record data. (12V TCM); voltage problem
3. Using the Scan Tool, measure ignition 18–32V (Refer to
voltage. (24V TCM) DTC P0562
Is voltage within the specified value? and P0563)
4 1. Turn the ignition ON and drive the vehicle — Go to appropriate Go to Step 5
under normal operating conditions. speed sensor
2. Using the Scan Tool, monitor engine, turbine, DTC
and output speed readings.
Is speed sensor data erratic or are signal
dropouts detected?

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ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0735 Incorrect 5th Gear Ratio (cont’d)
Step Action Value(s) Yes No
5 — Go to Go to Step 6
WARNING: To help avoid injury or property Diagnostic Aids
damage caused by sudden and
unexpected vehicle movement, do not
start a stationary stall test until you:
• Put the transmission in N (Neutral)...and
• Apply the parking brake and service
brake...and
• Chock the vehicle wheels and take any
other steps necessary to prevent the
vehicle from moving...and
Warn personnel to keep clear of the vehicle
and its path.

CAUTION: Do not perform a clutch test In


fourth or fifth range under stall conditions
(above 1400 rpm with brakes held), or
possible clutch damage could occur.

1. Using the Scan Tool, select clutch test mode.


2. With brakes applied, move the selector lever
to D (Drive).
3. With engine at idle, select and attain the
range indicated by the DTC. Turbine speed
should go to zero.
4. Monitor turbine speed while increasing
engine speed to 1400 rpm.
Did turbine speed remain at zero?
6 Remove the dipstick and inspect the — Go to Step 7 Go to Step 8
transmission fluid for clutch debris or burnt
odor. If necessary, drain a small amount of fluid
for this inspection.
Are there signs of a clutch failure?
7 Remove the transmission for overhaul or — Go to Step 10 —
replacement (refer to Mechanic’s Tips).
Is replacement complete?
8 Inspect the control valve body for stuck or — Go to Step 10 Go to Step 9
sticking trimmer valves (refer to
Mechanic’s Tips).
Was a valve problem found and repaired?
9 Replace A solenoid (refer to Mechanic’s Tips). — Go to Step 10 —
Is replacement complete?
10 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle in all ranges under Go to Step 1
normal driving conditions.
Did the DTC return?

Copyright© 2003 General Motors Corp. 5–99


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0736 Incorrect Reverse Ratio

REFER TO
REVERSE RANGE
HYDRAULIC SCHEMATIC
(APPENDIX H)
Circuit Description
The Transmission Control Module (TCM) uses input from the turbine speed sensor and output speed sensor to
determine gear ratios. The TCM then compares the known gear ratio to the calculated gear ratio for the current
gear.

Conditions for Running the DTC


• Output speed exceeds 200 rpm.
• Reverse is selected and attained.
• DTC P0716, P0717, P0721, or P0722 is not active.

Conditions for Setting the DTC

DTC P0736 sets when the calculated reverse range ratio (steady state) differs from the known reverse range ratio.

Action Taken When the DTC Sets


• When DTC P0736 is active, the transmission will lock in N (Neutral).
• DTC P0736 is stored in the TCM history.
• The CHECK TRANS light illuminates.
• The TCM freezes shift adapts (DNA).
• The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• Incorrect ratio codes typically indicate mechanical problems with specific clutches, i.e. C3 and C5 for Reverse
range.
• An incorrect ratio code could indicate a hydraulically failed solenoid. Check the DTC information for the specific
solenoid.
• You may have to drive the vehicle to experience the fault. Clutch test mode can be used to check stall speed.

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DIAGNOSTIC TROUBLE CODES (DTC)


Test Description
The numbers below refer to the step numbers on the diagnostic table.
3. This step tests ignition voltage.
4. This step tests for current reverse range ratio.
5. This step tests for noise induced from the engine speed sensor.
6. This step tests for turbine speed not remaining at zero in reverse range.
7. This step checks for evidence of clutch failure.

DTC P0736 Incorrect Reverse Ratio


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Perform the A/T Fluid Checking Procedure — Go to Step 3 Go to A/T Fluid
(Appendix P) and correct the fluid level if Checking
necessary. Procedure
Did you perform the procedure? (Appendix P)
3 1. Start the engine. 9–18V Go to Step 4 Resolve
2. Record the DTC Failure Record data. (12V TCM); voltage problem
3. Using the Scan Tool, measure ignition 18–32V (Refer to
voltage. (24V TCM) DTC P0562
Is voltage within the specified value? and P0563)
4 Using the Scan Tool, monitor the reverse gear 4.49 for 1000; Go to Step 5 Go to
ratio. 5.09 for 2000/ Diagnostic Aids
Is the gear ratio correct for the transmission 2400
series that is installed in the vehicle?
5 1. Turn the ignition ON. — Go to Go to Step 6
2. Start the engine and run at idle. appropriate
3. Using the Scan Tool, monitor engine, turbine, speed sensor
and output speed readings in Reverse range DTC
with the vehicle brakes applied.
Is noise indicated on the output speed sensor
or turbine speed sensor
data?

Copyright© 2003 General Motors Corp. 5–101


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0736 Incorrect Reverse Ratio (cont’d)
Step Action Value(s) Yes No
6 — Go to Go to Step 7
WARNING: To help avoid injury or property Diagnostic Aids
damage caused by sudden and unexpected
vehicle movement, do not start a stationary
stall test until you:
• Put the transmission in N (Neutral)...and
• Apply the parking brake and service
brake...and
• Chock the vehicle wheels and take any
other steps necessary to prevent the
vehicle from moving...and
Warn personnel to keep clear of the vehicle
and its path.

CAUTION: NEVER perform a full throttle stall


test (brakes held) in reverse range, or damage
to the vehicle driveline or axle may occur.

1. Apply vehicle brakes and select Reverse.


2. With engine at idle and Reverse range
attained, turbine speed should go to zero.
3. Using the Scan Tool, monitor turbine speed
while increasing engine speed to 1000 rpm.
Did turbine speed remain at zero?
7 Remove the dipstick and inspect the — Go to Step 9 Go to Step 8
transmission fluid for clutch debris or burnt
odor. If necessary, drain a small amount of fluid
for this inspection.
Are there signs of a clutch failure?
8 Using the Scan Tool, monitor turbine speed — Go to Step 10 —
while selecting first range.
If turbine speed is ever greater than zero after
first range is attained, there may be a problem
with A solenoid or A trimmer valve.
If shift to first range is harsh and delayed, there
may be a problem with B solenoid or B trimmer
valve.
Remove the control valve body and inspect for
stuck or sticking trimmer valves. If valves are
moving freely, replace either solenoid A or B
(refer to Mechanic’s Tips) based on the shift
characteristics described.
Is replacement complete?
9 Remove the transmission for overhaul or — Go to Step 10 —
replacement (refer to Mechanic’s Tips).
Is replacement complete?

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DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0736 Incorrect Reverse Ratio (cont’d)
Step Action Value(s) Yes No
10 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle in all ranges under Go to Step 1
normal driving conditions.
The ratio must fall within the specified range.
Did the DTC return?

Copyright© 2003 General Motors Corp. 5–103


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0741 Torque Converter Clutch System Stuck Off

PRE-BLOCK 1
GAIN VALVE
AND A TRIM A Trim Accumulator
SOLENOID N/C
Solenoid
W/O SPRING
B
N/C Solenoid
F Trim Filter
Solenoid

N/C

CONTROL MAIN
EBF
CONV – IN
MAIN

A TRIM
PRESSURE

CONV – OUT

MAIN

TCC SIGNAL
MAIN

EXHAUST

Control
Main
Main Valve
Regulator
Valve

OVERDRIVE
KNOCKDOWN

OVERAGE TCC

Converter CONV – OUT TO COOLER


Relief
Valve OVERAGE
Charging
Pump
CONV – IN
TCC SIGNAL
SUMP Cooler

LUBE Converter
Flow
Valve
Lube
Regulator
Valve

Main Filter

V07737.00.00.eps

Circuit Description
The Transmission Control Module (TCM) uses data from the engine speed sensor and the turbine speed sensor to
calculate torque converter slip value. The TCM then compares this calculated slip value to a preset value in the
TCM calibration.

Conditions for Running the DTC


• DTC P0122, P0123, P0716, P0717, P0721, P0722, or P0743 (previously P1860) is not active.
• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• Engine speed is greater than 200 rpm for 5 seconds.
• Transmission is in a valid forward range.
• Throttle position is over 10 percent but less than 90 percent.
• 6 seconds or more have expired since TCC was applied in a range.

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DIAGNOSTIC TROUBLE CODES (DTC)


Conditions for Setting the DTC

DTC P0741 sets when the TCM detects a torque converter clutch slip value greater than 80 rpm for more than
15 seconds, indicating no TCC apply.

Action Taken When the DTC Sets

• DTC P0741 is stored in the TCM history.


• The CHECK TRANS light illuminates on the second occurrence.
• The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light

A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids

• Residue or contamination may cause shift valves to stick intermittently.

Test Description

The numbers below refer to the step numbers on the diagnostic table.

2. This step tests for a slip speed indicating the TCC is not applied when it should be.

4. This step verifies the repair performed.

DTC P0741 Torque Converter Clutch System Stuck Off


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. More than 80 rpm Go to Step 3 Go to
2. Turn ON the ignition, with the engine OFF. Diagnostic Aids
3. Record the failure records.
4. Clear the DTC.
5. Drive the vehicle.
6. With the Scan Tool, monitor converter slip
speed indicated when a range is attained
where the TCC should be applied.
NOTE: This DTC sets when converter slip
speed is detected above 80 rpm for
15 seconds or more. This indicates the TCC
has not applied.
Is the slip speed value at or above the specified
value when the TCC should be applied?

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ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0741 Torque Converter Clutch System Stuck Off (cont’d)
Step Action Value(s) Yes No
3 This condition indicates that the TCC is — Go to Step 4 —
mechanically stuck OFF. Check for the following
conditions:
• Worn TCC clutch
• Faulty solenoid F
• Debris in the TCC valve bore (stuck valve)
• Clogged or restricted converter relief pas-
sage
Did you find and repair a problem?
4 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under conditions noted in Go to Step 1
failure records.
3. Using the Scan Tool, monitor TCC slip
speed. The TCC must engage/disengage
when commanded.
4. Use the Scan Tool, in the test passed
section, to confirm the diagnostic test was
run.
Did the DTC return?

5–106 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0742 Torque Converter Clutch System Stuck On

PRE-BLOCK 1
GAIN VALVE
AND A TRIM A Trim Accumulator
SOLENOID N/C
Solenoid
W/O SPRING
B
N/C Solenoid
F Trim Filter
Solenoid

N/C

CONTROL MAIN
EBF
CONV – IN
MAIN

A TRIM
PRESSURE

CONV – OUT

MAIN

TCC SIGNAL
MAIN

EXHAUST

Control
Main
Main Valve
Regulator
Valve

OVERDRIVE
KNOCKDOWN

OVERAGE TCC

Converter CONV – OUT TO COOLER


Relief
Valve OVERAGE
Charging
Pump
CONV – IN
TCC SIGNAL
SUMP Cooler

LUBE Converter
Flow
Valve
Lube
Regulator
Valve

Main Filter

V07737.00.00.eps

Circuit Description
The Transmission Control Module (TCM) uses data from the engine speed sensor and the turbine speed sensor to
calculate the torque converter slip value. The TCM then compares this calculated slip value to a preset value in the
TCM calibration.

Conditions for Running the DTC


• DTC P0122, P0123, P0716, P0717, P0721, P0722, P0726, P0727, or P0743 (previously P1860) is not active.
• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• Engine speed is greater than 200 rpm for 5 seconds.
• Transmission is in a valid forward range.
• The torque converter clutch is OFF.

Copyright© 2003 General Motors Corp. 5–107


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Conditions for Setting the DTC

DTC P0742 sets when the conditions listed below are present and the TCM detects converter slip speed between
–5 and –40 rpm for over 2 seconds.
• Transmission output speed is 100 rpm or higher.
• Engine throttle percentage is 15 percent or higher.
• Engine torque is 130 N·m or higher.
• Engine and turbine speed are under 5500 rpm.

Action Taken When the DTC Sets


• Illuminate CHECK TRANS light on second occurrence.
• Response is calibration dependent.
• If response is disabled, no action is performed.
• If enabled, when DTC is set before or during a shift, response is a shift to neutral. If DTC is set after shifting is
complete, transmission shifts to neutral or 1st range. While response is active, if the selector is moved to a
forward range, transmission shifts to neutral or 1st range. If the selector is moved to reverse, the transmission
shifts to neutral or reverse.

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids

This DTC sets when converter slip speed indicates the TCC is staying applied when it should be released for a
period of time that is calibration dependent. This may indicate an internal failure of the TCC or a stuck or sticking
TCC valve.

Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests for a slip speed indicating the TCC is locked up when it should be off.
4. This step verifies the repair performed.

5–108 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0742 Torque Converter Clutch System Stuck On
Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. –5 to –40 rpm for Go to Step 3 Go to
2. Turn ON the ignition, with the engine OFF. more than Diagnostic Aids
3. Record the failure records. 2 seconds.
4. Clear the DTC. See Conditions for
5. Drive the vehicle. Setting the DTC
6. With the Scan Tool, observe converter slip
speed indicated when a range is attained
where TCC should not be applied.
NOTE: This DTC sets when converter slip
speed is detected between –5 and –40 rpm
for over 2 seconds. This indicates that TCC
did not release properly and remained in a
locked state for over a calibration
dependent time.
Is the slip speed value between the specified
values?
3 This condition indicates that the TCC is — Go to Step 6 —
mechanically stuck ON, check for the following
conditions:
• Worn TCC clutch
• Faulty solenoid F
• Stuck or sticking TCC valve
• Clogged converter relief passage
Did you find and repair a problem?
4 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under conditions in failure Go to Step 1
records.
3. Using the Scan Tool, monitor TCC slip speed.
The TCC must engage/disengage when
commanded.
4. Use the Scan Tool, in the test passed
section, to confirm the diagnostic test was
run.
Did the DTC return?

Copyright© 2003 General Motors Corp. 5–109


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0743 (Previously P1860) Torque Converter Clutch Pulse Width Modulation (PWM)
Solenoid Circuit — Electrical

TRANSMISSION J2 HARNESS CONNECTOR


HARNESS (RED)
CONNECTOR
S J
R

TCM
J2-32
J2-30
TRANSMISSION J2-29
BULKHEAD
CONNECTOR
S
J
R J2

J1

NOTE: Letters I, O, and Q are not used.

TCM
229
J J2-29
SOL F SOL G
(PWM) TRANSMISSION R
230
J2-30
LOCKUP
232 12V
S J2-32

NOTE: Wire 232 is a 12V DC ignition power source for TCC solenoids F and G.

V06222.01.00

Circuit Description
The torque converter clutch (TCC) solenoid, solenoid F, is a pulse width modulated solenoid. Pulse width
modulation (PWM) occurs when the signal from the transmission control module (TCM) to a solenoid is modulated
at an established frequency, causing the steel check ball in the solenoid to rapidly open and close the solenoid
passage. This serves to vary the output fluid pressure.

Conditions for Running the DTC


• DTC P0122, P0123, P0716, P0717, P0721, P0722, or P0743 (previously P1860) is not active.
• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
18V and less than 32V (24V TCM).
• TCC is commanded on.
• TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.

Conditions for Setting the DTC


DTC P0743 sets when the TCM detects an open circuit, a short to power, or a short to ground in the solenoid F
circuit for 6 seconds or longer.

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DIAGNOSTIC TROUBLE CODES (DTC)


Action Taken When the DTC Sets
• DTC P0743 is stored in the TCM history.
• The CHECK TRANS light illuminates on the second occurrence.
• Reverse operation is disabled.

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• If this DTC is cleared and does not return, but the TCC appears to be cycling, an intermittent circuit connection
may exist that is not detected by the TCM since the circuit error must be present for more than 6 seconds. If a
short to ground occurs at wire 229, the TCC will apply regardless of the range selected. A shudder in
reverse may be caused by the intermittent apply or release of C5 clutch through the F solenoid valve.
• Inspect the wiring for poor electrical connections at the TCM connector and the transmission main connector.
Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A broken wire inside the insulation.
• Inspect the OEM wiring harness routing looking for possible contact points where chafing could occur. Moving
parts on the vehicle could be contacting the harness. Items to check would include the parking brake drum,
suspension components, transmission shift linkage, etc.
• Inspect the internal transmission wiring harness for possible contact areas where chafing may occur.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change. It may be necessary to check for shorting to ground at individual wires within a
harness to isolate an intermittent condition. Refer to Section 4 wire check procedures.
• You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc.
This data can be useful in reproducing the failure mode where the DTC was set.
• If the DTC appears to be temperature related, suspect a defective F solenoid. It is possible for a shift solenoid
to be temperature sensitive causing resistance values to fluctuate. This may cause an intermittent DTC to be
set.

Test Description
The numbers below refer to the step numbers on the diagnostic table.

2. This step tests for proper ignition voltage.


3. This step tests for an active DTC.
4. This step tests the TCM for proper command status.
5. This step tests the OEM wiring harness for an open condition.
6. This step tests for proper resistance at the main transmission connector.
8. This step tests for the proper resistance value at the shift solenoid.

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DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0743 Torque Converter Clutch Pulse Width Modulation (PWM)


Solenoid Circuit—Electrical
Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. 9–18V Go to Step 3 Resolve
2. Start the engine. (12V TCM); voltage problem
3. Record the DTC Failure Record data. 18–32V (Refer to
4. Use the Scan Tool to measure ignition (24V TCM) DTC P0562
voltage. and P0563)
Is voltage within the specified value?
3 1. Turn ON the ignition, with the engine OFF. — Go to Step 4 Go to Diagnostic
2. Record the failure records. Aids
3. Clear the DTC.
4. Drive the vehicle under the same condition
noted in the failure records.
5. Using the Scan Tool, observe the TCC
solenoid F status.
NOTE: This DTC sets when an open, a short
to ground or a short to power is present in
the TCC circuit for over 6 seconds.
Did the DTC return?
4 With the Scan Tool in Solenoid Test Mode 85 percent duty Go to Step 5 Go to Step 11
command F solenoid ON. cycle or above
Does the Scan Tool indicate a duty cycle at or
above the indicated value?
5 NOTE: Review Section 4 — Wire Check Refer to Solenoid Go to Step 6 Go to Diagnostic
Procedures before performing the following Resistance Table Aids
steps. (Page 5–12)
1. Turn the ignition OFF.
2. Disconnect J2 connector from TCM. Using NOTE: To allow
J 39700 Breakout Box and J 43799 Breakout for resistance of
Box Adapter, connect only to the J2 harness harness wire, add
connector. See Beginning the 0.1 Ohms per foot
Troubleshooting Process, Page 5–4, Figure of length for
5–2 for diagram of J 43799 adapter harness 18-gauge wire.
hook-ups.
3. Using a DVOM, attach leads to J2 pins 29
and 32.
4. Measure the resistance of the circuit.
Is the resistance reading within the specified
value

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DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0743 Torque Converter Clutch Pulse Width Modulation (PWM)
Solenoid Circuit—Electrical (cont’d)
Step Action Value(s) Yes No
6 1. Turn the ignition OFF. Refer to Solenoid Go to Step 7 Go to Step 8
2. Disconnect the transmission main connector Resistance Table
from the back of the transmission. Using (Page 5–12)
J 39700 Breakout Box and J 44722 Adapter
Harness, connect only to the transmission
main connector at the rear of the
transmission. Do not attach the other end of
J 44722 to the vehicle transmission harness.
See Beginning the Troubleshooting Process,
Page 5–5, Figure 5–3 for diagram of J 44722
transmission harness hook-ups.
3. Using a DVOM, measure the resistance
between pins S and J at the magnetic
overlay.
Is the resistance within the specified value?
7 NOTE: The vehicle OEM has responsibility — Go to Step 12 —
for all external wiring harness repair. Harness
repairs performed by ATD distributors and
dealers are not covered by ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?
8 1. Remove the oil pan. Refer to Service Manual Refer to Solenoid Go to Step 9 Go to Step 10
or Mechanic’s Tips. Resistance Table
2. Remove the internal wiring harness from (Page 5–12)
Solenoid F (TCC) connector.
3. Using a DVOM, measure the resistance of
solenoid F.
Is resistance within the specified values?
9 Replace the internal wiring harness. Refer to — Go to Step 12 —
Service Manual or Mechanic’s Tips.
Is the replacement complete?
10 Replace F (TCC) Solenoid. Refer to Service — Go to Step 12 —
Manual or Mechanic’s Tips.
Is the replacement complete?
11 NOTE: In most cases, the TCM is not at fault. — Go to Step 12 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM.
Is the replacement complete?

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ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0743 Torque Converter Clutch Pulse Width Modulation (PWM)
Solenoid Circuit—Electrical (cont’d)
Step Action Value(s) Yes No
12 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under conditions noted in Go to Step 1
failure records.
3. Use the Scan Tool, in the test passed
section, to confirm the diagnostic test was
run.
Did the DTC return?

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DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0746 (Previously P1720) Solenoid A Controlled Clutch Stuck Off

REFER TO HYDRAULIC SCHEMATIC


(APPENDIX H)
Circuit Description
Trim solenoid A is used to control on-coming, off-going, and holding pressure in any one of five clutches. This
solenoid is referred to as a Pressure Proportional to Current (PPC) solenoid since the output hydraulic pressure
supplied by this solenoid is proportional to the controlled current command.

The Transmission Control Module (TCM) uses information from the turbine and output speed sensors to detect if a
clutch is slipping. The clutch being controlled by the solenoid A will vary depending on the shift that is being
completed.

Conditions for Running the DTC


• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• Turbine speed is greater than 60 rpm.
• Output speed is greater than 125 rpm.
• Transmission is at normal operating temperature.
• DTC P0708, P0716, P0717, P0721, P0722, P0875, or P0876 is not active.

Conditions for Setting the DTC


DTC P0746 sets when the TCM detects an incorrect oncoming ratio (range-to-range) for an accumulated number
of occurrences.

Action Taken When the DTC Sets


• When DTC P0746 is active, the following conditions will occur:
— If failure occurs while in a forward range, the transmission will shift to the previous range.
— If failure occurs while in N (Neutral) or R (Reverse), the transmission will lock in N (Neutral).
— If the shift selector is moved to N (Neutral), the transmission will shift to N (Neutral) (some cases may lock
in N (Neutral)).
— If the shift selector is moved to R (Reverse), the transmission will shift to R (Reverse) or N (Neutral).
— If the shift selector is returned to a forward range and the transmission is compromised by overspeeding or
a direction change, the transmission will shift to N (Neutral).
• DTC P0746 is stored in the TCM history.
• The CHECK TRANS light illuminates.
• The TCM freezes shift adapts (DNA).
• The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

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ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Diagnostic Aids
• This DTC indicates the on-coming clutch being controlled by solenoid A is not applied or applied too slowly.
This could indicate a leak or obstruction in a specific clutch apply circuit. Check the Scan Tool Failure Record
data for previous or current range information when the DTC was set to determine the specific shift when the
DTC was set. Refer to the Solenoid and Clutch Table (Appendix C) to determine which clutch circuit is suspect.
• If the condition is intermittent, connect the Scan Tool and select the speed sensor indicated by the code. If the
signal is erratic, investigate and eliminate the following:
— Intermittent wiring connection
— Excessive vibration (driveline or engine torsionals)
— Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel)
• Inspect and confirm that the OEM engine rating does not exceed the transmission model rating. Also inspect for the
presence of an add-on engine power package or module. Whenever the engine horsepower or torque is increased
over the transmission factory rating, a shift flare condition may occur leading to the diagnostic code indicated.
NOTE: Clutch failure due to an OEM engine rating exceeding the Allison transmission rating, or the
installation of a engine power package or module will not be covered under the Allison transmission
warranty.

Test Description
The numbers below refer to the step numbers on the diagnostic table.
3. This step tests the ignition voltage.
4. This step tests for erratic speed sensor readings or signal dropout.
5. This step tests for internal hydraulic leakage.
6. This step tests for clutch capacity.

DTC P0746 (Previously P1720) Solenoid A Controlled Clutch Stuck Off


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Perform the A/T Fluid Checking Procedure — Go to Step 3 Go to A/T Fluid
(Appendix P) and correct the fluid level if Checking
necessary. Procedure
Did you perform the procedure? (Appendix P)
3 1. Install the Scan Tool. 9–18V Go to Step 4 Resolve
2. Start the engine. (12V TCM); voltage problem
3. Record the DTC Failure Record data. 18–32V (Refer to
4. Use the Failure Record data to determine (24V TCM) DTC P0562
during which shift the code was set. and P0563)
5. Using the Scan Tool, measure ignition voltage.
Is voltage within the specified value?
4 1. Turn the ignition ON and drive the vehicle — Go to the Go to Step 5
under normal operating conditions. Make the appropriate
shift determined in Step 3. speed sensor
2. Using the Scan Tool, monitor turbine, engine, DTC
and output speed sensor readings.
Is speed sensor data erratic or are dropouts in
signal indicated?

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DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0746 (Previously P1720) Solenoid A Controlled Clutch Stuck Off (cont’d)
Step Action Value(s) Yes No
5 1. Connect a 2000 kPa (300 psi) pressure — Go to General Go to Step 6
gauge to the main-pressure tap (refer to Troubleshooting
Mechanic’s Tips). — Low Pressure
2. Use the Scan Tool, in clutch test mode, to (Section 7)
cycle through all transmission ranges with
the engine at idle and vehicle brakes applied.
3. Record main pressure in each range.
Was the main pressure low in a specific range
or in ranges where the same clutch was
applied?
6 Refer to Main Go to Diagnostic Go to Step 7
CAUTION: Do not perform a clutch test on Pressure Table Aids
fourth and fifth range under stall conditions
(above 1400 rpm with brakes held), or (Pages 5–8
possible clutch damage could occur. and 5–9)

1. Using the Scan Tool, select the clutch test


mode.
2. With engine at idle speed (600 rpm), vehicle
brakes applied, select D (Drive).
3. Using clutch test mode, select and attain first
range. Turbine speed should go to zero.
4. Increase engine speed to 1400 rpm. Did
turbine speed remain at zero?
5. Repeat the two previous steps for ranges two
through five.
Did turbine speed remain at zero in all ranges?
7 Remove the dipstick and inspect the — Go to Step 8 Go to Step 9
transmission fluid for clutch debris or burnt
odor. If necessary, drain a small amount of fluid
for this inspection.
Are there signs of a clutch failure?
8 Remove the transmission for overhaul or — Go to Step 11 —
replacement.
Is the overhaul or replacement complete?
9 Inspect the control valve body for stuck or — Go to Step 11 Go to Step 10
sticking trimmer valves (refer to
Mechanic’s Tips).
Was a valve problem found and repaired?
10 Replace A solenoid. — Go to Step 11 —
Is solenoid replacement complete?
11 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Use the Scan Tool to reset adaptive for all Go to Step 1
shifts.
3. Operate the vehicle in all ranges under
normal driving conditions.
Did the DTC return?

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ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0747 (Previously P1723) Solenoid A Controlled Clutch Stuck On

REFER TO HYDRAULIC SCHEMATIC


(APPENDIX H)
Circuit Description
Trim solenoid A is used to control on-coming, off-going, and holding pressure to any one of the five clutches. This
solenoid is referred to as a Pressure Proportional to Current (PPC) solenoid since the output hydraulic pressure
supplied by this solenoid is proportional to the controlled current command.

The Transmission Control Module (TCM) uses information from the turbine and output speed sensors to detect if a
clutch is in a tie-up condition or 3 clutches are applied. The clutch being controlled by solenoid A will vary
depending on the shift.
Conditions for Running the DTC
• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• One of the following conditions occurs:
— Output speed is greater than 200 rpm.
— Turbine speed is greater than 200 rpm.
• DTC P0708, P0716, P0717, P0721, P0722, P0875, or P0876 is not active.

Conditions for Setting the DTC


DTC P0747 sets when the TCM detects an incorrect offgoing ratio (range-to-range) for an accumulated number of
occurrences.

Action Taken When the DTC Sets


• When DTC P0747 is active, the following conditions will occur:
— If failure occurs while in a forward range, the transmission will shift to the previous range.
— If failure occurs while in N (Neutral) or R (Reverse), the transmission will lock in N (Neutral).
— If the shift selector is moved to N (Neutral), the transmission will shift to N (Neutral).
— If the shift selector is moved to R (Reverse), the transmission will shift to R (Reverse) or N (Neutral)
(some cases may lock in N (Neutral)).
— If the shift selector is returned to a forward range and the transmission is compromised by overspeeding or
a direction change, the transmission will shift to N (Neutral).
• DTC P0747 is stored in the TCM history.
• The CHECK TRANS light illuminates.
• The TCM freezes shift adapts (DNA).
• The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

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DIAGNOSTIC TROUBLE CODES (DTC)


Diagnostic Aids
• This DTC indicates the off-going clutch being controlled by solenoid A is not releasing or is slow to release.
This could indicate a leak or obstruction in a specific clutch apply circuit. Check the Scan Tool Failure Record
data for previous or current range information when the DTC was set to determine the specific shift when the
DTC was set. Refer to the Solenoid and Clutch Table (Appendix C) to determine which clutch circuit is suspect.
• If the condition is intermittent, connect the Scan Tool and select the speed sensor indicated by the code. If the
signal is erratic, investigate and eliminate the following:
— Intermittent wiring connection
— Excessive vibration (driveline or engine torsionals)
— Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel)
• Inspect and confirm that the OEM engine rating does not exceed the transmission model rating. Also inspect for the
presence of an add-on engine power package or module. Whenever the engine horsepower or torque is increased
over the transmission factory rating, a shift flare condition may occur leading to the diagnostic code indicated.
NOTE: Clutch failure due to an OEM engine rating exceeding the Allison transmission rating, or the
installation of a engine power package or module will not be covered under the Allison transmission
warranty.

Test Description
The numbers below refer to the step numbers on the diagnostic table.
3. This step tests the ignition voltage.
4. This step tests for erratic speed sensor readings or signal dropout.
5. This step tests for internal hydraulic leakage.
6. This step tests for clutch capacity.

DTC P0747 (Previously P1723) Solenoid A Controlled Clutch Stuck On


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Perform the A/T Fluid Checking Procedure — Go to Step 3 Go to A/T Fluid
(Appendix P) and correct the fluid level if Checking
necessary. Procedure
Did you perform the procedure? (Appendix P)
3 1. Install the Scan Tool. 9–18V Go to Step 4 Resolve
2. Start the engine. (12V TCM); voltage problem
3. Record the DTC Failure Record data. 18–32V (Refer to
4. Use the Failure Record data to determine (24V TCM) DTC P0562
during which shift the code was set. and P0563)
5. Using the Scan Tool, measure ignition voltage.
Is voltage within the specified value?
4 1. Turn the ignition ON and drive the vehicle — Go to the Go to Step 5
under normal operating conditions. Make the appropriate
shift determined in Step 3. speed sensor
2. Using the Scan Tool, monitor turbine, engine, DTC
and output speed sensor readings.
Is speed sensor data erratic or are dropouts in
signal indicated?

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ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0747 (Previously P1723) Solenoid A Controlled Clutch Stuck On (cont’d)
Step Action Value(s) Yes No
5 1. Connect a 2000 kPa (300 psi) pressure — Go to General Go to Step 6
gauge to the main-pressure tap. Refer to Troubleshooting
Mechanic’s Tips. — Low Pressure
2. Use the Scan Tool, in clutch test mode, to (Section 7)
cycle through all transmission ranges with
the engine at idle and vehicle brakes applied.
3. Record main pressure in each range.
Was the main pressure low in a specific range
or in ranges where the same clutch was
applied?
6 Refer to Main Go to Diagnostic Go to Step 7
CAUTION: Do not perform a clutch test on Pressure Table Aids
fourth and fifth range under stall conditions
(above 1400 rpm with brakes held), or (Pages 5–8
possible clutch damage could occur. and 5–9)

1. Using the Scan Tool, select the clutch test


mode.
2. With engine at idle speed (600 rpm), vehicle
brakes applied, select D (Drive).
3. Using clutch test mode, select and attain first
range. Turbine speed should go to zero.
4. Increase engine speed to 1400 rpm. Did
turbine speed remain at zero?
5. Repeat the two previous steps for ranges two
through five.
Did turbine speed remain at zero in all ranges?
7 Remove the dipstick and inspect the — Go to Step 8 Go to Step 9
transmission fluid for clutch debris or burnt
odor. If necessary, drain a small amount of fluid
for this inspection.
Are there signs of a clutch failure?
8 Remove the transmission for overhaul or — Go to Step 11 —
replacement.
Is the overhaul or replacement complete?
9 Inspect the control valve body for stuck or — Go to Step 11 Go to Step 10
sticking trimmer valves. Refer to
Mechanic’s Tips.
Was a valve problem found and repaired?
10 Replace A solenoid. — Go to Step 11 —
Is solenoid replacement complete?
11 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Use the Scan Tool to reset adaptive for all Go to Step 1
shifts.
3. Operate the vehicle in all ranges under
normal driving conditions.
Did the DTC return?

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ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0748 Pressure Control Solenoid A Electrical

TRANSMISSION
HARNESS J2 HARNESS CONNECTOR
CONNECTOR (RED)

L J2-22 TCM
J2-23
TRANSMISSION
BULKHEAD
CONNECTOR

M
J2

J1
L
NOTE: Letters I, O, and Q are not used.

TCM
223
M J2-23
SOL A
(PCS) TRANSMISSION
222
L J2-22
BATTERY

NOTE: Wire 222 is a battery direct power source for trim solenoid A. V06223.01.00

Circuit Description
Trim solenoid A is used to control on-coming, off-going, and holding pressure to any one of the five clutches. This
solenoid is referred to as a Pressure Proportional to Current (PPC) solenoid since the pressure output is
proportional to the amount of controlled current commanded by the TCM.

The solenoid operates at a very high 1000 Hz frequency. Unlike the pulse width modulated Torque Converter Clutch
(TCC) solenoid, where the ball follows the pulse width square wave, the PPC ball remains stationary due to the high
frequency at which the solenoid operates. This allows the ball to move in a linear up and down motion proportional to
the current commanded from the TCM. This supplies the desired signal pressure to control the trim valve.

Conditions for Running the DTC


• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• Engine crank time is under 4 seconds.

Conditions for Setting the DTC

DTC P0748 is set when one of the following conditions is detected for 125 milliseconds.
• Open circuit — TCM commanded duty cycle between 31 percent and 87 percent with no current present at trim
solenoid A.

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DIAGNOSTIC TROUBLE CODES (DTC)


• Short to ground — TCM commanded duty cycle is over 87 percent with a current of less than 1.0 ampere at
trim solenoid A.
• Short to power — TCM commanded duty cycle is under 15 percent with electrical current present.
• Whenever a P0748, P0778 combination is set in failure records, this is generally caused by having the
transmission harness disconnected at the main transmission connector while the vehicle ignition is ON. Check
the connection at the transmission and clear codes.
Action Taken When the DTC Sets
• When DTC P0748 is active, the following conditions will occur:
— If failure occurs while in a forward range, the transmission shifts to 1st, 3rd, or 5th range.
— If the shift selector is moved to N (Neutral), the transmission will shift to N (Neutral).
— If the shift selector is moved to R (Reverse), the transmission will shift to R (Reverse) unless the
transmission is compromised by a direction change; then the transmission will shift to or lock in N (Neutral).
— If the shift selector is returned to a forward range and the transmission is compromised by overspeeding or
a direction change, the transmission will lock in N (Neutral).
• DTC P0748 is stored in the TCM history.
• The CHECK TRANS light illuminates.
• The TCM freezes shift adapts (DNA).
Conditions for Clearing the DTC/CHECK TRANS Light
A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.
Diagnostic Aids
The diagnostic test performed to detect this DTC is very sensitive. Therefore, there is a high probability that an
intermittent circuit condition may be causing this DTC to set. Check for the following conditions at the OEM harness
first, then at the transmission internal harness.
• Inspect the wiring for poor electrical connections at the TCM connector and the transmission main connector.
Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
— Inspect OEM wiring harness routing, looking for possible contact points where chafing could occur. Moving
parts on the vehicle could be contacting the harness. Check for contact at the parking brake drum, suspen-
sion components, transmission shift linkage, etc.
— Inspect the internal transmission wiring harness for possible contact areas where chafing may occur.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change. It may be necessary to check for shorting to ground at individual wires within a
harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures.
• You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc.
This data can be useful in reproducing the failure mode where the DTC was set.
• If this DTC appears to be temperature-related, suspect a defective solenoid. A failing solenoid may be
temperature sensitive causing resistance values to fluctuate. This may cause an intermittent DTC to be set.

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DIAGNOSTIC TROUBLE CODES (DTC)


Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests for the proper ignition voltage.
3. This step tests the TCM for proper operation.
4. This step tests for the proper resistance at the OEM vehicle harness.
5. This step tests the resistance value at the transmission main connector.
7. This step tests the resistance value at the trim solenoid.

DTC P0748 Pressure Control Solenoid A Electrical


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. 9–18V Go to Step 3 Resolve
2. Start the engine. (12V TCM); voltage problem
3. Record the DTC Failure Record data. 18–32V (Refer to
4. Using the Scan Tool, measure ignition (24V TCM) DTC P0562
voltage. and P0563)
Is voltage within the specified value?
3 1. Install the Scan Tool. Duty cycle value of Go to Step 4 Go to Step 10
2. Turn the ignition ON, with the engine OFF. 75 percent is an
3. In solenoid test mode, command A trim indication that
solenoid ON. the TCM is com-
Did the Scan Tool indicate A solenoid as being manding the
commanded ON? solenoid ON.
4 NOTE: Review Section 4 — Wire Check Refer to Solenoid Go to Diagnostic Go to Step 5
Procedures before performing the following Resistance Table Aids
steps. (Page 5–12)
1. Turn the ignition OFF.
2. Disconnect J2 connector from TCM. Using NOTE: To allow
J 39700 Breakout Box and J 43799 Breakout for resistance of
Box Adapter, connect only to the J2 harness harness wire, add
connector. See Beginning the 0.1 Ohms per foot
Troubleshooting Process, Page 5–4, Figure of length for
5–2 for diagram of J 43799 adapter harness 18-gauge wire.
hook-ups.
3. Using a DVOM, attach leads to J2 pins 22
and 23.
4. Measure the resistance of the circuit.
Is the resistance reading within the specified
value?

Copyright© 2003 General Motors Corp. 5–123


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0748 Pressure Control Solenoid A Electrical (cont’d)
Step Action Value(s) Yes No
5 1. Turn the ignition OFF. Refer to Solenoid Go to Step 6 Go to Step 7
2. Disconnect the wiring harness from the main Resistance Table
transmission connector at the back of the (Page 5–12)
transmission. Using J 39700 Breakout Box
and J 44722 Adapter Harness, connect only
to the transmission main connector at the
rear of the transmission. Do not attach the
other end of J 44722 to the vehicle
transmission harness. See Beginning the
Troubleshooting Process, Page 5–5, Figure
5–3 for diagram of J 44722 transmission
harness hook-ups.
3. Using a DVOM, measure the resistance
between pins L and M at the magnetic overlay.
Is the resistance within the specified value?
6 NOTE: The vehicle OEM has responsibility — Go to Step 11 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?
7 1. Remove the oil pan. Refer to Service Manual Refer to Solenoid Go to Step 8 Go to Step 9
or Mechanic’s Tips. Resistance Table
2. Remove the internal wiring harness at (Page 5–12)
solenoid A connector.
3. Using a DVOM, measure the resistance of
solenoid A.
Is the solenoid resistance within the specified
value?
8 Replace the internal wiring harness. Refer to — Go to Step 11 —
Service Manual or Mechanic’s Tips.
Is the replacement complete?
9 Replace solenoid A. Refer to Service Manual or — Go to Step 11 —
Mechanic’s Tips.
Is the replacement complete?
10 NOTE: In most cases, the TCM is not at fault. — Go to Step 11 —
Investigate thoroughly before replacing
the TCM. Refer to TCM Replacement
Procedure (Section 3–6).
Replace the TCM.
Is the replacement complete?

5–124 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0748 Pressure Control Solenoid A Electrical (cont’d)
Step Action Value(s) Yes No
11 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under conditions noted in Go to Step 1
failure records.
3. Use the Scan Tool, in the test passed section,
to confirm the diagnostic test was run.
Did the DTC return?

Copyright© 2003 General Motors Corp. 5–125


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0763 Shift Solenoid C Electrical

TRANSMISSION
HARNESS
CONNECTOR J2 CONNECTOR
(RED)
W
C

A
J2-31 J2-26 TCM
J2-28 J2-27
TRANSMISSION
BULKHEAD
CONNECTOR
W
C

B J2

A J1

NOTE: Letters I, O, and Q are not used.

231
C J2-31 12V (A)
SOL C (ON/OFF) TCM
226
A J2-26
SOL D (ON/OFF)
TRANSMISSION 227
B J2-27
SOL E (ON/OFF)
228
W J2-28
BATTERY

NOTE: Wire 231 is a 12V DC ignition power source for shift solenoids C, D, and E. V06230.01.00

Circuit Description

Shift solenoid C is a normally closed (N/C) solenoid that provides control main pressure to stroke the C shift valve.
The TCM determines the proper solenoid command logic to move the C shift valve to attain a particular range
requested. A pressure switch, located at the end of the shift valve, sends shift valve position feedback to the TCM.

Conditions for Running the DTC


• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.

Conditions for Setting the DTC

DTC P0763 is set when the TCM detects one of the following conditions for more than 100 milliseconds:

• Open circuit or short to ground detected when C solenoid is commanded OFF.


• Short to power is detected when C solenoid is commanded ON.

5–126 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Action Taken When the DTC Sets
• When DTC P0763 is active, the following conditions will occur:
— If the failure occurs while in a forward range, the transmission shifts to 1st, 3rd, or 5th range.
— If the shift selector is moved to N (Neutral), the transmission will shift to neutral.
— if the shift selector is moved to R (Reverse), the transmission shifts to neutral or reverse.
— If the shift selector is moved to a forward range or reverse and transmission is compromised by
overspeeding or direction change, transmission shifts to neutral.
— If this failure is present at the solenoid electrical feed wire 231, the response is hydraulic default.
• DTC P0763 is stored in TCM history.
• The CHECK TRANS light illuminates on first occurrence.
• The TCM freezes shift adapts (DNA).
• The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light


A scan tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• The diagnostic test performed to detect this DTC is very sensitive. Therefore, there is a high probability that an
intermittent circuit condition may be causing this DTC to set. Make sure you check for the following conditions
at the OEM harness first and then at the transmission internal harness.
• Inspect the wiring for poor electrical connections at the TCM connector and the transmission main connector.
Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
— Inspect OEM wiring harness routing, looking for possible contact points where chafing could occur. Moving
parts on the vehicle could be contacting the harness. Check for contact at the parking brake drum, suspen-
sion components, transmission shift linkage etc.
— Inspect the internal transmission wiring harness for possible contact areas where chafing may occur.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change. It may be necessary to check for shorting to ground at individual wires within a
harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures.
• You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc.
This data can be useful in reproducing the failure mode where DTC was set.
• If the DTC appears to be temperature related, suspect a defective shift solenoid. It is possible for a shift
solenoid to be temperature sensitive causing resistance values to fluctuate. This may cause an intermittent
DTC to be set.
• If the circuit problem (open or short) is present at the 231 solenoid feed wire, other shift solenoid electrical
DTCs may be present (C, D, E electrical codes).

Copyright© 2003 General Motors Corp. 5–127


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests for the proper ignition voltage.
3. This step tests the TCM for proper command status.
4. This step tests the OEM harness for an open condition.
5. This step tests for the proper resistance at the main transmission connector.
7. This step tests for the proper resistance value at the shift solenoid.

DTC P0763 Shift Solenoid C Electrical


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. 9–18V Go to Step 3 Resolve
2. Start the engine. (12V TCM); voltage problem
3. Record the DTC Failure Record data. 18–32V (Refer to
4. Using the Scan Tool, measure ignition (24V TCM) DTC P0562
voltage. and P0563)
Is voltage within the specified value?
3 1. Turn the ignition OFF. Battery Voltage Go to Step 4 Go to Step 10
2. Disconnect the J2 connector (RED) at the
TCM.
3. Install J 39700 breakout box and J 43799
breakout box adapter
4. Turn ON the ignition, with the engine OFF.
5. Using the Scan Tool in solenoid test mode,
command C solenoid to ON.
6. Using a DVOM measure the voltage between
J2 terminal 26 and terminal 31.
Is the voltage within the range specified when C
solenoid is commanded ON?
4 NOTE: Review Section 4 — Wire Check 22 Ohms at 68°F Go to Diagnostic Go to Step 5
Procedures before performing the following Aids
steps. Refer to Solenoid
1. Turn the ignition OFF. Resistance Table
2. Disconnect J2 connector from TCM. (Page 5–12)
3. Using J 39700 Breakout Box and J 43799
Breakout Box Adapter Harness, connect only NOTE: To allow
to the J2 harness connector. See Beginning for resistance of
the Troubleshooting Process, Page 5–4, harness wire, add
Figure 5–2 for diagram of J 43799 adapter 0.1 Ohms per foot
harness hook-ups. of length for
4. Using a DMM, attach leads to J2 pins 31 and 18-gauge wire.
26
5. Measure the resistance of the circuit.
Is the resistance within the specified value?

5–128 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0763 Shift Solenoid C Electrical (cont’d)
Step Action Value(s) Yes No
5 1. Turn the ignition OFF. 22 Ohms at 68°F Go to Step 6 Go to Step 7
2. Disconnect the wiring harness from the main
transmission connector at the back of the
transmission. Refer to Solenoid
3. Using J 39700 Breakout Box and J 44722 Resistance Table
Adapter Harness, connect only to the (Page 5–12)
transmission main connector at the rear of
the transmission. Do not attach the other end
of J 44722 to the vehicle transmission
harness. See Beginning the Troubleshooting
Process, Page 5–5, Figure 5–3 for diagram
of J 44722 transmission harness hook-ups.
4. Using a DMM, measure resistance between
bulkhead connector pins A and C at the
magnetic overlay.
Is the resistance within the specified values?
6 NOTE: The vehicle OEM has responsibility — Go to Step 11 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair or replace the vehicle wiring harness.
Is the repair complete?
7 1. Remove the oil pan. Refer to Service Manual 22 Ohms at 68°F Go to Step 8 Go to Step 9
or Mechanic’s Tips.
2. Remove the connector from C solenoid. Refer to Solenoid
3. Using a DMM, measure the resistance at the Resistance Table
solenoid. (Page 5–12)
Is the solenoid resistance within the specified
value?
8 Replace the internal wiring harness. Refer to — Go to Step 11 —
Service Manual or Mechanic’s Tips.
Is the replacement complete?
9 Replace solenoid C. Refer to Service Manual or — Go to Step 11 —
Mechanic’s Tips.
Is the replacement complete?
10 NOTE: In most cases, the TCM is not at fault. — Go to Step 11 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM.
Is the replacement complete?

Copyright© 2003 General Motors Corp. 5–129


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0763 Shift Solenoid C Electrical (cont’d)
Step Action Value(s) Yes No
11 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under conditions noted in Go to Step 1
failure records.
3. Use the Scan Tool, in the test passed section,
to confirm the diagnostic test was run.
Did the DTC return?

5–130 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0768 Shift Solenoid D Electrical

TRANSMISSION
HARNESS
CONNECTOR J2 CONNECTOR
(RED)
W
C

A
J2-31 J2-26 TCM
J2-28 J2-27
TRANSMISSION
BULKHEAD
CONNECTOR
W
C

B J2

A J1

NOTE: Letters I, O, and Q are not used.

231
C J2-31 12V (A)
SOL C (ON/OFF) TCM
226
A J2-26
SOL D (ON/OFF)
TRANSMISSION 227
B J2-27
SOL E (ON/OFF)
228
W J2-28
BATTERY

NOTE: Wire 231 is a 12V DC ignition power source for shift solenoids C, D, and E. V06230.01.00

Circuit Description

Shift solenoid D is a normally closed (N/C) solenoid that provides control main pressure to stroke the D shift valve.
The TCM determines the proper solenoid command logic to move the D shift valve to attain a particular range
requested. A pressure switch, located at the end of the shift valve, sends shift valve position feedback to the TCM.

Conditions for Running the DTC


• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.

Conditions for Setting the DTC

DTC P0768 is set when the TCM detects one of the following conditions for more than 100 milliseconds:

• Open circuit or short to ground detected when D solenoid is commanded OFF.


• Short to power is detected when D solenoid is commanded ON.

Copyright© 2003 General Motors Corp. 5–131


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Action Taken When the DTC Sets
• When DTC P0768 is active, the following conditions will occur:
— If the failure occurs while in a forward range, the transmission shifts to 1st, 3rd, or 5th range.
— If the shift selector is moved to N (Neutral), the transmission will shift to neutral.
— if the shift selector is moved to R (Reverse), the transmission shifts to neutral or reverse.
— If the shift selector is moved to a forward range or reverse and transmission is compromised by
overspeeding or direction change, transmission shifts to neutral.
— If this failure is present at the solenoid electrical feed wire 231, the response is hydraulic default.
• DTC P0768 is stored in TCM history.
• The CHECK TRANS light illuminates on first occurrence.
• The TCM freezes shift adapts (DNA).
• The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light


A scan tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• The diagnostic test performed to detect this DTC is very sensitive. Therefore, there is a high probability that an
intermittent circuit condition may be causing this DTC to set. Make sure you check for the following conditions
at the OEM harness first and then at the transmission internal harness.
• Inspect the wiring for poor electrical connections at the TCM connector and the transmission main connector.
Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
— Inspect OEM wiring harness routing, looking for possible contact points where chafing could occur. Moving
parts on the vehicle could be contacting the harness. Check for contact at the parking brake drum, suspen-
sion components, transmission shift linkage etc.
— Inspect the internal transmission wiring harness for possible contact areas where chafing may occur.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change. It may be necessary to check for shorting to ground at individual wires within a
harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures.
• You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc.
This data can be useful in reproducing the failure mode where DTC was set.
• If the DTC appears to be temperature related, suspect a defective shift solenoid. It is possible for a shift
solenoid to be temperature sensitive causing resistance values to fluctuate. This may cause an intermittent
DTC to be set.
• If the circuit problem (open or short) is present at the 231 solenoid feed wire, other shift solenoid electrical
DTCs may be present (C, D, E electrical codes).

5–132 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Test Description
The numbers below refer to the step numbers on the diagnostic table.

2. This step tests for the proper ignition voltage.


3. This step tests the TCM for proper command status.
4. This step tests the OEM harness for an open condition.
5. This step tests for the proper resistance at the main transmission connector.
7. This step tests for the proper resistance value at the shift solenoid.

DTC P0768 Shift Solenoid D Electrical


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. 9–18V Go to Step 3 Resolve
2. Start the engine. (12V TCM); voltage problem
3. Record the DTC Failure Record data. 18–32V (Refer to
4. Using the Scan Tool, measure ignition (24V TCM) DTC P0562
voltage. and P0563)
Is voltage within the specified value?
3 1. Turn the ignition OFF. Battery Voltage Go to Step 4 Go to Step 10
2. Disconnect the J2 connector (RED) at the
TCM.
3. Install J 39700 breakout box and J 43799
breakout box adapter
4. Turn ON the ignition, with the engine OFF.
5. Using the Scan Tool in solenoid test mode,
command D solenoid to ON.
6. Using a DVOM measure the voltage between
J2 terminal 27 and terminal 31.
Is the voltage within the range specified when D
solenoid is commanded ON?
4 NOTE: Review Section 4 — Wire Check 22 Ohms at 68°F Go to Diagnostic Go to Step 5
Procedures before performing the following Aids
steps. Refer to Solenoid
1. Turn the ignition OFF. Resistance Table
2. Disconnect J2 connector from TCM. (Page 5–12)
3. Using J 39700 Breakout Box and J 43799
Breakout Box Adapter Harness, connect only NOTE: To allow
to the J2 harness connector. See Beginning for resistance of
the Troubleshooting Process, Page 5–4, harness wire, add
Figure 5–2 for diagram of J 43799 adapter 0.1 Ohms per foot
harness hook-ups. of length for
4. Using a DMM, attach leads to J2 pins 27 and 18-gauge wire.
31
5. Measure the resistance of the circuit.
Is the resistance within the specified value?

Copyright© 2003 General Motors Corp. 5–133


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0768 Shift Solenoid D Electrical (cont’d)
Step Action Value(s) Yes No
5 1. Turn the ignition OFF. 22 Ohms at 68°F Go to Step 6 Go to Step 7
2. Disconnect the wiring harness from the main
transmission connector at the back of the
transmission. Refer to Solenoid
3. Using J 39700 Breakout Box and J 44722 Resistance Table
Adapter Harness, connect only to the (Page 5–12)
transmission main connector at the rear of
the transmission. Do not attach the other end
of J 44722 to the vehicle transmission
harness. See Beginning the Troubleshooting
Process, Page 5–5, Figure 5–3 for diagram
of J 44722 transmission harness hook-ups.
4. Using a DMM, measure resistance between
pins B and C at the magnetic overlay.
Is the resistance within the specified values?
6 NOTE: The vehicle OEM has responsibility — Go to Step 11 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair or replace the vehicle wiring harness.
Is the repair complete?
7 1. Remove the oil pan. Refer to Service Manual 22 Ohms at 68°F Go to Step 8 Go to Step 9
or Mechanic’s Tips.
2. Remove the connector from D solenoid. Refer to Solenoid
3. Using a DMM, measure the resistance at the Resistance Table
solenoid. (Page 5–12)
Is the resistance within the specified value?
8 Replace the internal wiring harness. Refer to — Go to Step 11 —
Service Manual or Mechanic’s Tips.
Is the replacement complete?
9 Replace solenoid D. Refer to Service Manual or — Go to Step 11 —
Mechanic’s Tips.
Is the replacement complete?
10 NOTE: In most cases, the TCM is not at fault. — Go to Step 11 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM.
Is the replacement complete?
11 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under conditions noted in Go to Step 1
failure records.
3. Use the Scan Tool, in the test passed section,
to confirm the diagnostic test was run.
Did the DTC return?

5–134 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0773 Shift Solenoid E Electrical

TRANSMISSION
HARNESS
CONNECTOR J2 CONNECTOR
(RED)
W
C

A
J2-31 J2-26 TCM
J2-28 J2-27
TRANSMISSION
BULKHEAD
CONNECTOR
W
C

B J2

A J1

NOTE: Letters I, O, and Q are not used.

231
C J2-31 12V (A)
SOL C (ON/OFF) TCM
226
A J2-26
SOL D (ON/OFF)
TRANSMISSION 227
B J2-27
SOL E (ON/OFF)
228
W J2-28
BATTERY

NOTE: Wire 231 is a 12V DC ignition power source for shift solenoids C, D, and E. V06230.01.00

Circuit Description

Shift solenoid E is a normally closed (N/C) solenoid that provides control main pressure to stroke the E shift valve.
The TCM determines the proper solenoid command logic to move the E shift valve to attain a particular range
requested. A pressure switch, located at the end of the shift valve, sends shift valve position feedback to the TCM.

Conditions for Running the DTC


• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.

Conditions for Setting the DTC

DTC P0773 is set when the TCM detects one of the following conditions for more than 100 milliseconds:

• Open circuit or short to ground detected when E solenoid is commanded OFF.


• Short to power is detected when E solenoid is commanded ON.

Copyright© 2003 General Motors Corp. 5–135


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Action Taken When the DTC Sets
• When DTC P0773 is active, the following conditions will occur:
— If the failure occurs while in a forward range, the transmission shifts to 1st, 3rd, or 5th range.
— If the shift selector is moved to N (Neutral), the transmission will shift to neutral.
— if the shift selector is moved to R (Reverse), the transmission shifts to neutral or reverse.
— If the shift selector is moved to a forward range or reverse and transmission is compromised by
overspeeding or direction change, transmission shifts to neutral.
— If this failure is present at the solenoid electrical feed wire 231, the response is hydraulic default.
• DTC P0773 is stored in TCM history.
• The CHECK TRANS light illuminates on first occurrence.
• The TCM freezes shift adapts (DNA).
• The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light


A scan tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• The diagnostic test performed to detect this DTC is very sensitive. Therefore, there is a high probability that an
intermittent circuit condition may be causing this DTC to set. Make sure you check for the following conditions
at the OEM harness first and then at the transmission internal harness.
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
— Inspect OEM wiring harness routing, looking for possible contact points where chafing could occur. Moving
parts on the vehicle could be contacting the harness. Check for contact at the parking brake drum, suspen-
sion components, transmission shift linkage etc.
— Inspect the internal transmission wiring harness for possible contact areas where chafing may occur.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change. It may be necessary to check for shorting to ground at individual wires within a
harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures.
• You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc.
This data can be useful in reproducing the failure mode where DTC was set.
• If the DTC appears to be temperature related, suspect a defective shift solenoid. It is possible for a shift
solenoid to be temperature sensitive causing resistance values to fluctuate. This may cause an intermittent
DTC to be set.
• If the circuit problem (open or short) is present at the 231 solenoid feed wire, other shift solenoid electrical
DTCs may be present (C, D, E electrical codes).

5–136 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests for the proper ignition voltage.
3. This step tests the TCM for proper command status.
4. This step tests the OEM harness for an open condition.
5. This step tests for the proper resistance at the main transmission connector.
7. This step tests for the proper resistance value at the shift solenoid.

DTC P0773 Shift Solenoid E Electrical


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. 9–18V Go to Step 3 Resolve
2. Start the engine. (12V TCM); voltage problem
3. Record the DTC Failure Record data. 18–32V (Refer to
4. Using the Scan Tool, measure ignition (24V TCM) DTC P0562
voltage. and P0563)
Is voltage within the specified value?
3 1. Turn the ignition OFF. Battery Voltage Go to Step 4 Go to Step 10
2. Disconnect the J2 connector (RED) at the
TCM.
3. Install J 39700 breakout box and J 43799
breakout box adapter
4. Turn ON the ignition, with the engine OFF.
5. Using the Scan Tool in solenoid test mode,
command E solenoid to ON.
6. Using a DVOM measure the voltage between
J2 terminal 28 and terminal 31.
Is the voltage within the range specified when E
solenoid is commanded ON?
4 NOTE: Review Section 4 — Wire Check 22 Ohms at 68°F Go to Diagnostic Go to Step 5
Procedures before performing the following Aids
steps. Refer to Solenoid
1. Turn the ignition OFF. Resistance Table
2. Disconnect J2 connector from TCM. (Page 5–12)
3. Using J 39700 Breakout Box and J 43799
Breakout Box Adapter Harness, connect only NOTE: To allow
to the J2 harness connector. See Beginning for resistance of
the Troubleshooting Process, Page 5–4, harness wire, add
Figure 5–2 for diagram of J 43799 adapter 0.1 Ohms per foot
harness hook-ups. of length for
4. Using a DMM, attach leads to J2 pins 31 and 18-gauge wire.
28
5. Measure the resistance of the circuit.
Is the resistance within the specified value?

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ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0773 Shift Solenoid E Electrical (cont’d)
Step Action Value(s) Yes No
5 1. Turn the ignition OFF. 22 Ohms at 68°F Go to Step 6 Go to Step 7
2. Disconnect the wiring harness from the main
transmission connector at the back of the
transmission. Refer to Solenoid
3. Using J 39700 Breakout Box and J 44722 Resistance Table
Adapter Harness, connect only to the (Page 5–12)
transmission main connector at the rear of
the transmission. Do not attach the other end
of J 44722 to the vehicle transmission
harness. See Beginning the Troubleshooting
Process, Page 5–5, Figure 5–3 for diagram
of J 44722 transmission harness hook-ups.
4. Using a DMM, measure resistance between
pins W and C at the magnetic overlay.
Is the resistance within the specified values?
6 NOTE: The vehicle OEM has responsibility — Go to Step 11 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair or replace the vehicle wiring harness.
Is the repair complete?
7 1. Remove the oil pan. Refer to Service Manual 22 Ohms at 68°F Go to Step 8 Go to Step 9
or Mechanic’s Tips.
2. Remove the connector from E solenoid. Refer to Solenoid
3. Using a DMM, measure the resistance at the Resistance Table
solenoid. (Page 5–12)
Is the resistance within the specified value?
8 Replace the internal wiring harness. Refer to — Go to Step 11 —
Service Manual or Mechanic’s Tips.
Is the replacement complete?
9 Replace solenoid E. Refer to Service Manual or — Go to Step 11 —
Mechanic’s Tips.
Is the replacement complete?
10 NOTE: In most cases, the TCM is not at fault. — Go to Step 11 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM.
Is the replacement complete?
11 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under conditions noted in Go to Step 1
failure records.
3. Use the Scan Tool, in the test passed section,
to confirm the diagnostic test was run.
Did the DTC return?

5–138 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0776 (Previously P1721) Solenoid B Controlled Clutch Stuck Off

REFER TO HYDRAULIC SCHEMATIC


(APPENDIX H)
Circuit Description
Trim solenoid B is used to control on-coming, off-going, and holding pressure to any one of the five clutches. This
solenoid is referred to as a Pressure Proportional to Current (PPC) solenoid since the output hydraulic pressure
supplied by this solenoid is proportional to the controlled current command.
The Transmission Control Module (TCM) uses information from the turbine and output speed sensors to detect if a
clutch is slipping. The clutch being controlled by the solenoid B will vary depending on the shift that was being
completed.

Conditions for Running the DTC


• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• Turbine speed is greater than 60 rpm.
• Output speed is greater than 125 rpm.
• Transmission is at normal operating temperature.
• DTC P0708, P0716, P0717, P0721, P0722, P0875, or P0876 is not active.

Conditions for Setting the DTC


DTC P0776 sets when the TCM detects an incorrect oncoming ratio (range-to-range) for an accumulated number
of occurrences.

Action Taken When the DTC Sets


• When DTC P0776 is active, the following conditions will occur:
— If failure occurs while in a forward range, the transmission will shift to the previous range.
— If failure occurs while in N (Neutral) or R (Reverse), the transmission will lock in N (Neutral).
— If the shift selector is moved to N (Neutral), the transmission will shift to N (Neutral) (some cases may lock
in N (Neutral)).
— If the shift selector is moved to R (Reverse), the transmission will shift to R (Reverse) or N (Neutral).
— If the shift selector is returned to a forward range and the transmission is compromised by overspeeding or
a direction change, the transmission will shift to N (Neutral).
• DTC P0776 is stored in the TCM history.
• The CHECK TRANS light illuminates.
• The TCM freezes shift adapts (DNA).
• The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Copyright© 2003 General Motors Corp. 5–139


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Diagnostic Aids
• This DTC indicates the on-coming clutch being controlled by solenoid B is not applied or applied too slowly.
This could indicate a leak or obstruction in a specific clutch apply circuit. Check the Scan Tool Failure Record
data for previous or current range information when the DTC was set to determine the specific shift when the
DTC was set. Refer to the Solenoid and Clutch Table (Appendix C) to determine which clutch circuit is suspect.
• If the condition is intermittent, connect the Scan Tool and select the speed sensor indicated by the code. If the
signal is erratic, investigate and eliminate the following:
— Intermittent wiring connection
— Excessive vibration (driveline or engine torsionals)
— Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel)
• Inspect and confirm that the OEM engine rating does not exceed the transmission model rating. Also inspect for the
presence of an add-on engine power package or module. Whenever the engine horsepower or torque is increased
over the transmission factory rating, a shift flare condition may occur leading to the diagnostic code indicated.
NOTE: Clutch failure due to an OEM engine rating exceeding the Allison transmission rating, or the
installation of a engine power package or module will not be covered under the Allison transmission
warranty.

Test Description
The numbers below refer to the step numbers on the diagnostic table.
3. This step tests the ignition voltage.
4. This step tests speed sensor readings.
5. This step tests for internal hydraulic leakage.
6. This step tests for clutch capacity.

DTC P0776 (Previously P1721) Solenoid B Controlled Clutch Stuck Off


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Perform the A/T Fluid Checking Procedure — Go to Step 3 Go to A/T Fluid
(Appendix P) and correct the fluid level if Checking
necessary. Procedure
Did you perform the procedure? (Appendix P)
3 1. Install the Scan Tool. 9–18V Go to Step 4 Resolve
2. Start the engine. (12V TCM); voltage problem
3. Record DTC Failure Record data. 18–32V (Refer to
4. Use the Failure Record data to determine (24V TCM) DTC P0562
during which shift the code was set. and P0563)
5. Using the Scan Tool, measure ignition voltage.
Is voltage within the specified value?
4 1. Turn the ignition ON and drive the vehicle — Go to the Go to Step 5
under normal operating conditions. Make the appropriate
shift determined in Step 3. speed sensor
2. Using the Scan Tool, monitor turbine, engine, DTC
and output speed sensor readings.
Is speed sensor data erratic or are dropouts in
signal indicated?

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ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0776 (Previously P1721) Solenoid B Controlled Clutch Stuck Off (cont’d)
Step Action Value(s) Yes No
5 1. Connect a 2000 kPa (300 psi) pressure — Go to General Go to Step 6
gauge to the main-pressure tap (refer to Troubleshooting
Mechanic’s Tips). — Low Pressure
2. Use the Scan Tool, in clutch test mode, to (Section 7)
cycle through all transmission ranges with
the engine at idle and vehicle brakes applied.
3. Record main pressure in each range.
Was the main pressure low in a specific range
or in ranges where the same clutch was
applied?
6 CAUTION: Do not perform a clutch test on Refer to Main Go to Diagnostic Go to Step 7
fourth and fifth range under stall conditions Pressure Table Aids
(above 1400 rpm with brakes held), or (Pages 5–8
possible clutch damage could occur. and 5–9)
1. Using the Scan Tool, select the clutch test
mode.
2. With engine at idle speed (600 rpm), vehicle
brakes applied, select D (Drive).
3. Using clutch test mode, select and attain first
range. Turbine speed should go to zero.
4. Increase engine speed to 1400 rpm. Did
turbine speed remain at zero?
5. Repeat the two previous steps for ranges two
through five.
Did turbine speed remain at zero in all ranges?
7 Remove the dipstick and inspect the — Go to Step 8 Go to Step 9
transmission fluid for clutch debris or burnt
odor. If necessary, drain a small amount of fluid
for this inspection.
Are there signs of a clutch failure?
8 Remove the transmission for overhaul or — Go to Step 11 —
replacement.
Is the overhaul or replacement complete?
9 Inspect the control valve body for stuck or — Go to Step 11 Go to Step 10
sticking trimmer valves (refer to Mechanic’s
Tips).
Was a valve problem found and repaired?
10 Replace B solenoid. — Go to Step 11 —
Is solenoid replacement complete?
11 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Use the Scan Tool to reset adaptive for all Go to Step 1
shifts.
3. Operate the vehicle in all ranges under
normal driving conditions.
Did the DTC return?

Copyright© 2003 General Motors Corp. 5–141


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0777 (Previously P1724) Solenoid B Controlled Clutch Stuck On

REFER TO HYDRAULIC SCHEMATIC


(APPENDIX H)
Circuit Description
Trim solenoid B is used to control on-coming, off-going, and holding pressure to any one of five clutches. This
solenoid is referred to as a Pressure Proportional to Current (PPC) solenoid since the output hydraulic pressure
supplied by this solenoid is proportional to the controlled current command.

The Transmission Control Module (TCM) uses information from the turbine and output speed sensors to detect if a
clutch is in a tie-up condition or if three clutches are applied. The clutch being controlled by solenoid B will vary
depending on the shift.

Conditions for Running the DTC


• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• One of the following conditions occurs:
— Output speed is greater than 200 rpm.
— Turbine speed is greater than 200 rpm.
• DTC P0708, P0716, P0717, P0721, P0722, P0875, or P0876 is not active.

Conditions for Setting the DTC

DTC P0777 sets when the TCM detects an incorrect off-going ratio, range-to-range, for an accumulated number of
occurrences.

Action Taken When the DTC Sets


• When DTC P0777 is active, the following conditions will occur:
— If failure occurs while in a forward range, the transmission will shift to the previous range.
— If failure occurs while in N (Neutral) or R (Reverse), the transmission will lock in N (Neutral).
— If the shift selector is moved to N (Neutral), the transmission will shift to N (Neutral).
— If the shift selector is moved to R (Reverse), the transmission will shift to R (Reverse) or N (Neutral)
(some cases may lock in N (Neutral)).
— If the shift selector is returned to a forward range and the transmission is compromised by overspeeding or
a direction change, the transmission will shift to N (Neutral).
• DTC P0777 is stored in the TCM history.
• The CHECK TRANS light illuminates.
• The TCM freezes shift adapts (DNA).
• The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

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ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Diagnostic Aids
• This DTC indicates the off-going clutch being controlled by solenoid B is not released or is released too slowly.
This could indicate a leak or obstruction in a specific clutch apply circuit. Check the Scan Tool Failure Record
data for previous or current range information when the DTC was set to determine the specific shift when the
DTC was set. Refer to the Solenoid and Clutch Table (Appendix C) to determine which clutch circuit is suspect.
• If the condition is intermittent, connect the Scan Tool and select the speed sensor indicated by the code. If the
signal is erratic, investigate and eliminate the following:
— Intermittent wiring connection
— Excessive vibration (driveline or engine torsionals)
— Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel)
• Inspect and confirm that the OEM engine rating does not exceed the transmission model rating. Also inspect for the
presence of an add-on engine power package or module. Whenever the engine horsepower or torque is increased
over the transmission factory rating, a shift flare condition may occur leading to the diagnostic code indicated.
NOTE: Clutch failure due to an OEM engine rating exceeding the Allison transmission rating, or the
installation of a engine power package or module will not be covered under the Allison transmission
warranty.
Test Description
The numbers below refer to the step numbers on the diagnostic table.
3. This step tests the ignition voltage.
4. This step tests for correct speed sensor operation.
5. This step tests for internal hydraulic leakage.
6. This step tests for clutch capacity.

DTC P0777 (Previously P1724) Solenoid B Controlled Clutch Stuck On


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Perform the A/T Fluid Checking Procedure — Go to Step 3 Go to A/T Fluid
(Appendix P) and correct the fluid level if Checking
necessary. Procedure
Did you perform the procedure? (Appendix P)
3 1. Install the Scan Tool. 9–18V Go to Step 4 Resolve
2. Start the engine. (12V TCM); voltage problem
3. Record the DTC Failure Record data. 18–32V (Refer to
4. Use the Failure Record Data to determine (24V TCM) DTC P0562
during which shift the code was set. and P0563)
5. Using the Scan Tool, measure ignition voltage.
Is voltage within the specified value?
4 1. Turn the ignition ON and drive the vehicle — Go to the Go to Step 5
under normal operating conditions. Make the appropriate
shift determined in Step 3. speed sensor
2. Using the Scan Tool, monitor turbine, engine, DTC
and output speed sensor readings.
Is speed sensor data erratic or are dropouts in
signal indicated?

Copyright© 2003 General Motors Corp. 5–143


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0777 (Previously P1724) Solenoid B Controlled Clutch Stuck On (cont’d)
Step Action Value(s) Yes No
5 1. Connect a 2000 kPa (300 psi) pressure — Go to General Go to Step 6
gauge to the main-pressure tap. Refer to Troubleshooting
Mechanic’s Tips. — Low Pressure
2. Use the Scan Tool, in clutch test mode, to (Section 7)
cycle through all transmission ranges with
the engine at idle and vehicle brakes applied.
3. Record main pressure in each range.
Was the main pressure low in a specific range
or in ranges where the same clutch was
applied?
6 Refer to Main Go to Diagnostic Go to Step 7
CAUTION: Do not perform a clutch test on Pressure Table Aids
fourth and fifth range under stall conditions
(above 1400 rpm with brakes held), or (Pages 5–8
possible clutch damage could occur. and 5–9)

1. Using the Scan Tool, select the clutch test


mode.
2. With engine at idle speed (600 rpm), vehicle
brakes applied, select D (Drive).
3. Using clutch test mode, select and attain first
range. Turbine speed should go to zero.
4. Increase engine speed to 1400 rpm. Did
turbine speed remain at zero?
5. Repeat the two previous steps for ranges two
through five.
Did turbine speed remain at zero in all ranges?
7 Remove the dipstick and inspect the — Go to Step 8 Go to Step 9
transmission fluid for clutch debris or burnt
odor. If necessary, drain a small amount of fluid
for this inspection.
Are there signs of a clutch failure?
8 Remove the transmission for overhaul or — Go to Step 11 —
replacement.
Is the overhaul or replacement complete?
9 Inspect the control valve body for stuck or — Go to Step 11 Go to Step 10
sticking trimmer valves. Refer to Mechanic’s
Tips.
Was a valve problem found and repaired?
10 Replace B solenoid. — Go to Step 11 —
Is solenoid replacement complete?
11 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Use the Scan Tool to reset adaptive for all Go to Step 1
shifts.
3. Operate the vehicle in all ranges under
normal driving conditions.
Did the DTC return?

5–144 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0778 Pressure Control Solenoid B Electrical

TRANSMISSION
HARNESS J2 HARNESS CONNECTOR
CONNECTOR (RED)
P

N
J2-25 J2-24 TCM
TRANSMISSION
BULKHEAD
CONNECTOR
P

J2
N J1

NOTE: Letters I, O, and Q are not used.

TCM
224
N J2-24
SOL B BATTERY
(PCS) TRANSMISSION
225
P J2-25

NOTE: Wire 225 is a battery direct power source for trim solenoid B. V06224.01.00

Circuit Description

Trim solenoid B is used to control on-coming, off-going, and holding pressure to any of the five clutches. This
solenoid is referred to as a Pressure Proportional to Current (PPC) solenoid since the output hydraulic pressure
supplied by this solenoid is proportional to the controlled current command.

The solenoid operates at a very high 1000 Hz frequency. Unlike the pulse width modulated Torque Converter
Clutch (TCC) solenoid, where the ball follows the pulse width square wave, the PPC ball remains stationary due to
the high frequency at which the solenoid operates. This allows the ball to move in a linear up and down motion
proportional to the current commanded from the TCM. This supplies the desired signal pressure to control the trim
valve.

Conditions for Running the DTC

• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• Engine crank time is under 4 seconds.

Copyright© 2003 General Motors Corp. 5–145


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Conditions for Setting the DTC

DTC P0748 is set when one of the following conditions is detected for 125 milliseconds.
• Open circuit — TCM commanded duty cycle between 31 percent and 87 percent with no current present at trim
solenoid A.
• Short to ground — TCM commanded duty cycle is over 87 percent with a current of less than 1.0 ampere at
trim solenoid A.
• Short to power — TCM commanded duty cycle is under 15 percent with electrical current present.
• Whenever a P0748, P0778 combination is set in failure records, this is generally caused by having the
transmission harness disconnected at the main transmission connector while the vehicle ignition is ON. Check
the connection at the transmission and clear codes.

Action Taken When the DTC Sets


• When DTC P0778 is active, the following conditions will occur:
— If the failure occurs while in a forward range, the transmission will shift to 1st, 3rd, or 5th range.
— If the shift selector is moved to N (Neutral), the transmission will shift to neutral.
— If the shift selector is moved to R (Reverse), the transmission will shift to reverse.
— If the shift selector is moved to a forward range or reverse and the transmission is compromised by over-
speeding or a direction change, the transmission shifts to neutral.
• DTC P0778 is stored in the TCM history.
• The CHECK TRANS light illuminates.
• The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
The diagnostic test performed to detect this DTC is very sensitive. Therefore, there is a high probability that an
intermittent circuit condition may be causing this DTC to set. Check for the following conditions at the OEM harness
first, then at the transmission internal harness.
• Inspect the wiring for poor electrical connections at the TCM connector and the main transmission connector.
Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
— Inspect OEM wiring harness routing, looking for possible contact points where chafing could occur. Moving
parts on the vehicle could be contacting the harness. Check for contact at the parking brake drum, suspen-
sion components, transmission shift linkage, etc.
— Inspect the internal transmission wiring harness for possible contact areas where chafing may occur.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change. It may be necessary to check for shorting to ground at individual wires within a
harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures.

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DIAGNOSTIC TROUBLE CODES (DTC)


• You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc.
This data can be useful in reproducing the failure mode where the DTC was set.
• If this DTC appears to be temperature-related, suspect a defective trim solenoid. It is possible for a trim
solenoid to be temperature sensitive causing resistance values to fluctuate. This may cause an intermittent
DTC to be set.

Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests for proper ignition voltage.
3. This step tests the command signal from the TCM and tests the external wiring harness for shorts or
opens.
4. This step tests for the proper resistance at the OEM vehicle harness.
5. This step tests for the proper resistance value at the main transmission connector.
8. This step tests for the proper resistance value at the trim solenoid.

DTC P0778 Pressure Control Solenoid B Electrical


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. 9–18V Go to Step 3 Resolve
2. Start the engine. (12V TCM); voltage problem
3. Record the DTC Failure Record data. 18–32V (Refer to
4. Using the Scan Tool, measure ignition (24V TCM) DTC P0562
voltage. and P0563)
Is voltage within the specified value?
3 1. Install the Scan Tool. Duty cycle value of Go to Step 4 Go to Step 10
2. Turn the ignition ON, with the engine OFF. 75 percent is an
3. In solenoid test mode, command B trim indication that the
solenoid ON. solenoid is in the
Did the Scan Tool indicate B solenoid as being ON state.
commanded ON?

Copyright© 2003 General Motors Corp. 5–147


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0778 Pressure Control Solenoid B Electrical (cont’d)
Step Action Value(s) Yes No
4 NOTE: Review Section 4 — Wire Check Refer to Solenoid Go to Diagnostic Go to Step 5
Procedures before performing the following Resistance Table Aids
steps. (Page 5–12)
1. Turn the ignition OFF.
2. Disconnect J2 connector from TCM. Using NOTE: To allow
J 39700 Breakout Box and J 43799 Breakout for resistance of
Box Adapter, connect only to the J2 harness harness wire, add
connector. See Beginning the 0.1 Ohms per foot
Troubleshooting Process, Page 5–4, Figure of length for
5–2 for diagram of J 43799 adapter harness 18-gauge wire.
hook-ups.
3. Using a DVOM, attach leads to J2 pins 24
and 25.
4. Measure the resistance of the circuit.
Is the resistance reading within the specified
value?
5 1. Turn the ignition OFF. Refer to Solenoid Go to Step 6 Go to Step 7
2. Disconnect the wiring harness from the main Resistance Table
transmission connector at the back of the (Page 5–12)
transmission. Using J 39700 Breakout Box
and J 44722 Adapter Harness, connect only
to the transmission main connector at the
rear of the transmission. Do not attach the
other end of J 44722 to the vehicle
transmission harness. See Beginning the
Troubleshooting Process, Page 5–5, Figure
5–3 for diagram of J 44722 transmission
harness hook-ups.
3. Using a DVOM, measure resistance between
transmission bulkhead connector pins N
and P at the magnetic overlay.
Is resistance within the specified values?
6 NOTE: The vehicle OEM has responsibility — Go to Step 11 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?
7 1. Remove the oil pan. Refer to Service Manual Refer to Solenoid Go to Step 8 Go to Step 9
or Mechanic’s Tips. Resistance Table
2. Remove the internal wiring harness at (Page 5–12)
solenoid B connector.
3. Using a DVOM, measure the resistance of
solenoid B.
Is the solenoid resistance within the specified
value?

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DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0778 Pressure Control Solenoid B Electrical (cont’d)
Step Action Value(s) Yes No
8 Replace the internal wiring harness. Refer to — Go to Step 11 —
Service Manual or Mechanic’s Tips.
Is the replacement complete?
9 Replace solenoid B. Refer to Service Manual or — Go to Step 11 —
Mechanic’s Tips.
Is the replacement complete?
10 NOTE: In most cases, the TCM is not at fault. — Go to Step 11 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM.
Is the replacement complete?
11 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under conditions noted in Go to Step 1
failure records.
3. Use the Scan Tool, in the test passed
section, to confirm the diagnostic test was
run.
Did the DTC return?

Copyright© 2003 General Motors Corp. 5–149


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0840 Transmission Pressure Switch Solenoid C Circuit

TRANSMISSION
HARNESS J2 HARNESS CONNECTOR
CONNECTOR (RED)
K J2-3 J2-2
D J2-4 J2-1

TCM
F
E

TRANSMISSION
BULKHEAD
CONNECTOR
K
D
J2

J1

F
E
NOTE: Letters I, O, and Q are not used.

TCM
201
C A D J2-1
202
D B F J2-2 DIGITAL
TRANSMISSION
203 INTERFACE
E C E J2-3
204
R D K J2-4

E
F
NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH
MANIFOLD
R E D
C
F E D C B A

V06213.01.00

Circuit Description

The Pressure Switch Manifold (PSM) is a multiple-switch assembly made up of three normally open (N/O) and one
normally closed (N/C) pressure switches. The C pressure switch monitors C shift valve positioning and relays it to
the TCM. When C pressure switch is in the open state, C shift valve should be in the destroked position.

Conditions for Running the DTC


• Components are powered and the ignition voltage is greater than 5V.
• DTC P0561, P0562, or P0563 is not active.
• C shift valve is destroked.
• Transmission temperature is above –25°C (–13°F).
• Vehicle shutdown is not in process.

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DIAGNOSTIC TROUBLE CODES (DTC)


Conditions for Setting the DTC
DTC P0840 sets during steady state operation when C shift valve is in the destroked state (commanded OFF) and
C pressure switch status is detected as stroked (commanded ON). Steady state is defined as attaining a valid
range. The intent of this code is to detect shorts to ground in the pressure switch wiring circuit or the pressure
switch.
Later software levels incorporate retry logic that allows the TCM to command C solenoid ON and OFF. If the
pressure switch state does not change, and remains in the ON state, DTCs P0840 and P0842 will set.

Action Taken When the DTC Sets


• When DTC P0840 is active, the following conditions will occur:
— If the failure occurs while in a forward range, the transmission shifts to 1st, 3rd, or 5th range.
— If the shift selector is moved to N (Neutral), the transmission will shift to neutral.
— if the shift selector is moved to R (Reverse), the transmission shifts to reverse.
— If the shift selector is moved to a forward range or reverse and the transmission is compromised by over-
speeding or direction change, the transmission shifts to neutral.
• DTC P0840 is stored in TCM history.
• The CHECK TRANS light illuminates.
• The TCM inhibits TCC engagement.
• The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• When only a P0840 is set, look for an intermittent short to ground at the pressure switch circuit or intermittent
hydraulic failure (sticking valve). This code is set when the condition occurs more than 3 times during the
current drive cycle. See Appendix A, Section B — Finding an Intermittent Fault.
• When a P0840 and P0842 are set in combination, this may indicate a short to ground at the pressure switch
circuit or the shift valve is stuck in the stroked state. See Section 4 — Beginning the Troubleshooting Process.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change. Check for shorting to ground at individual wires within a harness to isolate an
intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A, Section B.
• You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc.
This data can be useful in reproducing the failure mode where the DTC was set.
• Multiple inactive pressure switch DTCs may be due to a plugged Control Main Filter. Ensure that the initial
8000 km (5,000 mile) filter change was performed.

Copyright© 2003 General Motors Corp. 5–151


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests for proper fluid level.
3. This step tests for proper main pressure.
4. This step tests for an active DTC.
5. This step tests the TCM for proper switch status.
6. This step tests for shorts in the OEM wiring harness.
7. This step tests for shorts in the internal wiring harness.
8. This step tests the PSM switch function.

DTC P0840 Transmission Pressure Switch Solenoid C Circuit


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Perform the A/T Fluid Checking Procedure — Go to Step 3 Go to A/T Fluid
(Appendix P). Checking
Did you perform the procedure and correct fluid Procedure
level if necessary? (Appendix P)
3 Perform the Main Pressure Check Procedure Refer to Main Go to Step 4 Go to General
(Appendix B). Pressure Table Troubleshooting
Is main pressure within the specified values? (Pages 5–8 (Section 7)
and 5–9)
4 1. Install the Scan Tool. — Go to Step 5 Go to Diagnostic
2. Turn ON the ignition, with the engine OFF. Aids
3. Record the failure records.
4. Clear the DTC.
5. Start the vehicle and perform a test drive.
Attempt to duplicate the same operating
conditions observed in failure records (range
attained, transmission temperature, etc.).
NOTE: This DTC indicates that a short
circuit condition may exist in the OEM
harness, the internal transmission wiring
harness, or the PSM.
Did DTC P0840 return?

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DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0840 Transmission Pressure Switch Solenoid C Circuit (cont’d)
Step Action Value(s) Yes No
5 1. Turn the ignition OFF. — Go to Step 6 Go to Step 12
2. Disconnect J2 connector from the TCM and
install J 39700 Breakout Box and J 43799
Breakout Box Adapter.
3. Connect J2 connector pin 1 to a known good
ground.
4. Turn the ignition ON.
Does the Scan Tool indicate pressure switch C
status as ON when grounded and OFF when
circuit is open?
6 1. Turn the ignition OFF and reconnect the J2 — Go to Step 7 Go to Step 11
connector to the TCM.
2. Disconnect the transmission wiring harness
from the main transmission connector at the
back of the transmission.
3. Turn the ignition ON.
4. Connect wire 201 (pin D) at the main
transmission connector to a known good
ground.*
Does the Scan Tool indicate pressure switch C
status as ON when grounded and OFF when
circuit is open?
7 1. Remove the oil pan. Refer to Service Manual — Go to Step 8 Go to Step 10
or Mechanic’s Tips.
2. Disconnect the internal wiring harness from
the PSM and ground pin A.
Does the Scan Tool indicate pressure switch C
status as ON when grounded and OFF when
circuit is open?
8 1. Remove the PSM from the control valve body — Go To Diagnostic Go to Step 9
and leave the internal harness connected. Aids
Refer to Service Manual or Mechanic’s Tips.
2. Provide a ground connection for the PSM to
the control valve body or the transmission
main case.
3. Use your finger or the eraser end of a pencil
to push gently on the pressure switch C
membrane.
Does the Scan Tool indicate pressure switch C
status as ON when grounded and OFF when
circuit is open?
9 Replace the PSM. Refer to Service Manual or — Go to Step 13 —
Mechanic’s Tips.
Is the replacement complete?
10 Replace the internal wiring harness. Refer to — Go to Step 13 —
Service Manual or Mechanic’s Tips.
Is the replacement complete?

Copyright© 2003 General Motors Corp. 5–153


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DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0840 Transmission Pressure Switch Solenoid C Circuit (cont’d)
Step Action Value(s) Yes No
11 NOTE: The vehicle OEM has responsibility — Go to Step 13 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?
12 NOTE: In most cases, the TCM is not at fault. — Go to Step 13 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM.
Is the replacement complete?
13 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under conditions noted Go to Step 1
in failure records.
3. Use the Scan Tool, in the test passed
section, to confirm the diagnostic test was
run.
Did the DTC return?
* If J 39700 and J 44722 are available, they may be used to perform this operation.

5–154 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0841 Transmission Pressure Switch Solenoid C Circuit Stuck Open

TRANSMISSION
HARNESS J2 HARNESS CONNECTOR
CONNECTOR (RED)
K J2-3 J2-2
D J2-4 J2-1

TCM
F
E

TRANSMISSION
BULKHEAD
CONNECTOR
K
D
J2

J1

F
E
NOTE: Letters I, O, and Q are not used.

TCM
201
C A D J2-1
202
D B F J2-2 DIGITAL
TRANSMISSION
203 INTERFACE
E C E J2-3
204
R D K J2-4

E
F
NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH
MANIFOLD
R E D
C
F E D C B A

V06213.01.00

Circuit Description
The Pressure Switch Manifold (PSM) is a multiple-switch assembly made up of three normally open (N/O) and one
normally closed (N/C) pressure switches. The C pressure switch monitors C shift valve positioning and relays it to
the TCM. When C pressure switch is in the open state, C shift valve should be in the destroked position.

Conditions for Running the DTC


• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• DTC P0561, P0562, or P0563 is not active.
• C shift valve is commanded to the ON (stroked) position.

Copyright© 2003 General Motors Corp. 5–155


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Conditions for Setting the DTC
DTC P0841 is set when C solenoid is commanded ON and C pressure switch status remains OFF for a period of
time. The time period is 5 seconds at 0°C (32°F) to -40°C (-40°F). The intent of this DTC is to detect a stuck shift
valve, in the destroked state, a mechanical solenoid failure, or an open circuit.

Action Taken When the DTC Sets


• When DTC P0841 is active, the following conditions will occur:
— If the failure occurs while in a forward range, the transmission shifts to 1st, 3rd or 5th range.
— If the shift selector is moved to N (Neutral), the transmission will shift to neutral.
— if the shift selector is moved to R (Reverse), the transmission shifts to reverse.
— If the shift selector is moved to a forward range or reverse and the transmission is compromised by
overspeeding or direction change, the transmission shifts to neutral.
• DTC P0841 is stored in TCM history.
• The CHECK TRANS light illuminates.
• The TCM inhibits TCC engagement.
• The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light

A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• When a P0841 and P0843 are set in combination, this may indicate an open circuit condition is present at the
pressure switch circuit or the shift valve is stuck in the destroked state. See Section 4 — Beginning the
Troubleshooting Process.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change. It may be necessary to check for shorting to ground or opens at individual wires within
a harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A,
Section B.
• You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc.
This data can be useful in reproducing the failure mode where the DTC was set.
• Multiple inactive pressure switch DTCs may be due to a plugged Control Main Filter. Ensure that the initial
8000 km (5,000 mile) filter change was performed.

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DIAGNOSTIC TROUBLE CODES (DTC)


Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests for proper fluid level.
3. This step tests for proper main pressure.
4. This step tests for an active DTC.
5. This step tests the TCM for proper switch status.
6. This step tests for opens in the OEM wiring harness.
7. This step tests for opens in the internal wiring harness.
8. This step tests the PSM switch function.

DTC P0841 Transmission Pressure Switch Solenoid C Circuit Stuck Open


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Perform the A/T Fluid Checking Procedure — Go to Step 3 Go to A/T Fluid
(Appendix P). Checking
Did you perform the procedure and correct fluid Procedure
level if necessary? (Appendix P)
3 Perform the Main Pressure Check Procedure Refer to Main Go to Step 4 Go to General
(Appendix B). Pressure Table Troubleshooting
Is main pressure within the specified values? (Pages 5–8 (Section 7)
and 5–9)
4 1. Install the Scan Tool. — Go to Step 5 Go to Diagnostic
2. Turn ON the ignition, with the engine OFF. Aids
3. Record the failure records.
4. Clear the DTC.
5. Start the vehicle and perform a test drive.
Attempt to duplicate the same operating
conditions observed in failure records (range
attained, transmission temperature, etc.).
NOTE: This DTC may indicate a stuck shift
valve, mechanically failed solenoid, open in
switch circuit, or defective PSM.
Did DTC P0841 return?
5 1. Turn the ignition OFF. — Go to Step 6 Go to Step 15
2. Disconnect J2 connector from the TCM and
install J 39700 Breakout Box and J 43799
Breakout Box Adapter.
3. Connect J2 connector pin 1 to a known good
ground.
4. Turn the ignition ON.
Does the Scan Tool indicate pressure switch C
status as ON when grounded and OFF when
circuit is open?

Copyright© 2003 General Motors Corp. 5–157


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0841 Transmission Pressure Switch Solenoid C Circuit Stuck Open (cont’d)
Step Action Value(s) Yes No
6 1. Turn the ignition OFF and reconnect the J2 — Go to Step 7 Go to Step 14
connector to the TCM.
2. Disconnect the transmission wiring harness
from the main transmission connector at the
back of the transmission.
3. Turn the ignition ON.
4. Connect wire 201 (pin D) on the harness
connector to a known good ground.*
Does the Scan Tool indicate pressure switch C
status as ON when grounded and OFF when
circuit is open?
7 1. Remove the oil pan. Refer to Service Manual — Go to Step 8 Go to Step 13
or Mechanic’s Tips.
2. Disconnect the internal wiring harness from
the PSM and ground pin A.
Does the Scan Tool indicate pressure switch C
status as ON when grounded and OFF when
circuit is open?
8 1. Remove the PSM from the control valve body Go to Step 9 Go to Step 12
and leave the internal harness connected.
Refer to Service Manual or Mechanic’s Tips.
2. Provide a ground connection for the PSM to
either the control valve body or the
transmission main case.
3. Use your finger or the eraser end of a pencil
to push gently on the pressure switch C
membrane.
Does the Scan Tool indicate pressure switch C
status as ON when grounded and OFF when
circuit is open?
9 Remove the control valve body and check for a Go to Step 11 Go to Step 10
stuck or sticking C shift valve. Refer to Service
Manual or Mechanic’s Tips.
Was the C shift valve stuck or sticking?
10 Replace the C shift solenoid and reinstall the Go to Step 16
control valve body. Refer to Service Manual or
Mechanic’s Tips.
Is replacement of solenoid and reinstalling of
control valve body complete?
11 Clean and/or polish the sticking valve to restore Go to Step 16
free movement or replace the control valve
body assembly. Refer to Service Manual or
Mechanic’s Tips.
Was free movement restored or valve body
replaced?
12 Replace the PSM. Refer to Service Manual or — Go to Step 16 —
Mechanic’s Tips.
Is the replacement complete?

5–158 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0841 Transmission Pressure Switch Solenoid C Circuit Stuck Open (cont’d)
Step Action Value(s) Yes No
13 Replace the internal wiring harness. Refer to — Go to Step 16 —
Service Manual or Mechanic’s Tips.
Is the replacement complete?
14 NOTE: The vehicle OEM has responsibility — Go to Step 16 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?
15 NOTE: In most cases, the TCM is not at fault. — Go to Step 16 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM.
Is the replacement complete?
16 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under conditions noted Go to Step 1
in failure records.
3. Use the Scan Tool, in the test passed
section, to confirm the diagnostic test was
run.
Did the DTC return?
* If J 39700 and J 44722 are available, they may be used to perform this operation.

Copyright© 2003 General Motors Corp. 5–159


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0842 Transmission Pressure Switch Solenoid C Circuit Stuck Closed

TRANSMISSION
HARNESS J2 HARNESS CONNECTOR
CONNECTOR (RED)
K J2-3 J2-2
D J2-4 J2-1

TCM
F
E

TRANSMISSION
BULKHEAD
CONNECTOR
K
D
J2

J1

F
E
NOTE: Letters I, O, and Q are not used.

TCM
201
C A D J2-1
202
D B F J2-2 DIGITAL
TRANSMISSION
203 INTERFACE
E C E J2-3
204
R D K J2-4

E
F
NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH
MANIFOLD
R E D
C
F E D C B A

V06213.01.00

Circuit Description

The Pressure Switch Manifold (PSM) is a multiple-switch assembly made up of three normally open (N/O) and one
normally closed (N/C) pressure switches. The C pressure switch monitors C shift valve positioning and relays it to
the TCM. When C pressure switch is in the open state, C shift valve should be in the destroked position.

Conditions for Running the DTC

• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• DTC P0561, P0562, or P0563 is not active.
• C shift valve is commanded to the OFF (destroked) position.

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ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Conditions for Setting the DTC
DTC P0842 is set when C solenoid is commanded OFF and C pressure switch status remains ON for a period of time
that is temperature dependent. The time period is 2 seconds at 0°C (32°F) or up to 6 seconds at –40°C (–40°F). The
intent of this DTC is to detect a stuck shift valve, in the stroked state, a mechanical solenoid failure, or a circuit short
to ground.

Action Taken When the DTC Sets


• When DTC P0842 is active, the following conditions will occur:
— If the failure occurs while in a forward range, the transmission shifts to another forward range.
— If the shift selector is moved to N (Neutral), the transmission will shift to neutral.
— if the shift selector is moved to R (Reverse), the transmission shifts to reverse.
— If the shift selector is moved to a forward range or reverse and the transmission is compromised by
overspeeding or direction change, the transmission shifts to neutral.
• DTC P0842 is stored in TCM history.
• The CHECK TRANS light illuminates.
• The TCM inhibits TCC engagement.
• The TCM freezes shift adapts (DNA).
Conditions for Clearing the DTC/CHECK TRANS Light
A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• When a P0842 and P0840 are set in combination, this may indicate a short to ground at the pressure switch
circuit or the shift valve is stuck in the stroked state. See Section 4 — Beginning the Troubleshooting Process.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change. It may be necessary to check for shorting to ground at individual wires within a harness
to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A, Section B.
• You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc.
This data can be useful in reproducing the failure mode where the DTC was set.
• Multiple inactive pressure switch DTCs may be due to a plugged Control Main Filter. Ensure that the initial
8000 km (5,000 mile) filter change was performed.
Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests for proper fluid level.
3. This step tests for proper main pressure.
4. This step tests for an active DTC.
5. This step tests the TCM for proper switch status.
6. This step tests for shorts in the OEM wiring harness.
7. This step tests for shorts in the internal wiring harness.
8. This step tests the PSM switch function.

Copyright© 2003 General Motors Corp. 5–161


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0842 Transmission Pressure Switch Solenoid C Circuit Stuck Closed


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Perform the A/T Fluid Checking Procedure — Go to Step 3 Go to A/T Fluid
(Appendix P). Checking
Did you perform the procedure and correct Procedure
fluid level if necessary? (Appendix P)
3 Perform the Main Pressure Check Procedure Refer to Main Go to Step 4 Go to General
(Appendix B). Pressure Table Troubleshooting
Is main pressure within the specified values? (Pages 5–8 (Section 7)
and 5–9)
4 1. Install the Scan Tool. — Go to Step 5 Go to Diagnostic
2. Turn ON the ignition, with the engine OFF. Aids
3. Record the failure records.
4. Clear the DTC.
5. Start the vehicle and perform a test drive.
Attempt to duplicate the same operating
conditions observed in failure records (range
attained, transmission temperature, etc.).
NOTE: This DTC may indicate a stuck shift
valve, mechanically failed solenoid, short to
ground in the switch circuit, or a defective
PSM.
Did DTC P0842 return?
5 1. Turn the ignition OFF. — Go to Step 6 Go to Step 15
2. Disconnect J2 connector from the TCM and
install J 39700 Breakout Box and J 43799
Breakout Box Adapter.
3. Connect J2 connector pin 1 to a known good
ground.
4. Turn the ignition ON.
Does the Scan Tool indicate pressure switch C
status as ON when grounded and OFF when
circuit is open?
6 1. Turn the ignition OFF and reconnect the J2 — Go to Step 7 Go to Step 14
connector to the TCM.
2 Disconnect the transmission wiring harness
from the main transmission connector at the
back of the transmission.
3. Turn the ignition ON.
4. Connect wire 201 (pin D) at the main
transmission connector to a known good
ground.*
Does the Scan Tool indicate pressure switch C
status as ON when grounded and OFF when
circuit is open?

5–162 Copyright© 2003 General Motors Corp.


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DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0842 Transmission Pressure Switch Solenoid C Circuit Stuck Closed (cont’d)
Step Action Value(s) Yes No
7 1. Remove the oil pan. Refer to Service Manual — Go to Step 8 Go to Step 13
or Mechanic’s Tips.
2. Disconnect the internal wiring harness from
the PSM and ground pin A.
Does the Scan Tool indicate reverse pressure
switch C status as ON when grounded and OFF
when circuit is open?
8 1. Remove the PSM from the control valve body Go to Step 9 Go to Step 12
and leave the internal harness connected.
Refer to Service Manual or Mechanic’s Tips.
2. Provide a ground connection for the PSM to
either the control valve body or the
transmission main case.
3. Use your finger or the eraser end of a pencil
to push gently on the pressure switch C
membrane.
Does the Scan Tool indicate pressure switch C
status as ON when grounded and OFF when
circuit is open?
9 Remove the control valve body and inspect for Go to Step 11 Go to Step 10
a stuck or sticking C shift valve. Refer to
Service Manual or Mechanic’s Tips.
Was the C shift valve stuck or sticking?
10 Replace the C shift solenoid and reinstall the Go to Step 16
control valve body. Refer to Service Manual or
Mechanic’s Tips.
Is replacement of solenoid and reinstalling of
valve body complete?
11 Clean and/or polish the sticking valve to restore Go to Step 16
free movement or replace the control valve
body assembly. Refer to Service Manual or
Mechanic’s Tips.
Was free movement restored or valve body
replaced?
12 Replace the PSM. Refer to Service Manual or — Go to Step 16 —
Mechanic’s Tips.
Is the replacement complete?
13 Replace the internal wiring harness. Refer to — Go to Step 16 —
Service Manual or Mechanic’s Tips.
Is the replacement complete?
14 NOTE: The vehicle OEM has responsibility — Go to Step 16 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?

Copyright© 2003 General Motors Corp. 5–163


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0842 Transmission Pressure Switch Solenoid C Circuit Stuck Closed (cont’d)
Step Action Value(s) Yes No
15 NOTE: In most cases, the TCM is not at fault. — Go to Step 16 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM.
Is the replacement complete?
16 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under conditions noted Go to Step 1
in failure records.
3. Use the Scan Tool, in the test passed
section, to confirm the diagnostic test was
run.
Did the DTC return?
* If J 39700 and J 44722 are available, they may be used to perform this operation.

5–164 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0843 Transmission Pressure Switch Solenoid C Circuit High

TRANSMISSION
HARNESS J2 HARNESS CONNECTOR
CONNECTOR (RED)
K J2-3 J2-2
D J2-4 J2-1

TCM
F
E

TRANSMISSION
BULKHEAD
CONNECTOR
K
D
J2

J1

F
E
NOTE: Letters I, O, and Q are not used.

TCM
201
C A D J2-1
202
D B F J2-2 DIGITAL
TRANSMISSION
203 INTERFACE
E C E J2-3
204
R D K J2-4

E
F
NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH
MANIFOLD
R E D
C
F E D C B A

V06213.01.00

Circuit Description

The Pressure Switch Manifold (PSM) is a multiple-switch assembly made up of three normally open (N/O) and one
normally closed (N/C) pressure switches. The C pressure switch monitors C shift valve positioning and relays it to
the TCM. When C pressure switch is in the open state, C shift valve should be in the destroked position.
Conditions for Running the DTC
• Components are powered and the ignition voltage is greater than 5V.
• DTC P0561, P0562, or P0563 is not active.
• C shift valve is commanded to the ON (stroked) position.
• Transmission temperature is above –25°C (–13°F).
• Vehicle shutdown is not in process.

Copyright© 2003 General Motors Corp. 5–165


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DIAGNOSTIC TROUBLE CODES (DTC)


Conditions for Setting the DTC
DTC P0843 sets during steady state operation when C shift valve is in the stroked state (commanded ON) and C
pressure switch status is detected as destroked (commanded OFF). Steady state is defined as attaining a valid
range. The intent of this code is to detect an open condition in the pressure switch wiring circuit or the pressure
switch.
Later software levels incorporate retry logic that allows the TCM to command C solenoid OFF and ON. If the
pressure switch state does not change, and remains in the OFF state, DTCs P0841 and P0843 will set.

Action Taken When the DTC Sets


• When DTC P0843 is active, the following conditions will occur:
— If the failure occurs while in a forward range, the transmission shifts to another forward range.
— If the shift selector is moved to N (Neutral), the transmission will shift to neutral.
— if the shift selector is moved to R (Reverse), the transmission shifts to reverse.
— If the shift selector is moved to a forward range or reverse and the transmission is compromised by
overspeeding or direction change, the transmission shifts to neutral.
• DTC P0843 is stored in TCM history.
• The CHECK TRANS light illuminates.
• The TCM inhibits TCC engagement.
• The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• When only a DTC P0843 is set, look for an intermittent open condition at the pressure switch circuit or an
intermittent hydraulic failure (sticking valve). This code is set when the condition is present more than 3 times
during a current drive cycle. See Appendix A, Section B — Finding an Intermittent Fault.
• When a P0843 and P0841 are set in combination, this may indicate an open circuit condition is present at the
pressure switch circuit or the shift valve is stuck in the destroked state. See Section 4 — Beginning the
Troubleshooting Process.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change. It may be necessary to check for an open condition at individual wires within a
harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A,
Section B.
• You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc.
This data can be useful in reproducing the failure mode where the DTC was set.
• Multiple inactive pressure switch DTCs may be due to a plugged Control Main Filter. Ensure that the initial
8000 km (5,000 mile) filter change was performed.

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DIAGNOSTIC TROUBLE CODES (DTC)


Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests for proper fluid level.
3. This step tests for proper main pressure.
4. This step tests for an active DTC.
5. This step tests the TCM for proper switch status.
6. This step tests for opens in the OEM wiring harness.
7. This step tests for opens in the internal wiring harness.
8. This step tests for PSM switch function.

DTC P0843 Transmission Pressure Switch Solenoid C Circuit High


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Perform the A/T Fluid Checking Procedure — Go to Step 3 Go to A/T Fluid
(Appendix P). Checking
Did you perform the procedure and correct fluid Procedure
level if necessary? (Appendix P)
3 Perform the Main Pressure Check Procedure Refer to Main Go to Step 4 Go to General
(Appendix B). Pressure Table Troubleshooting
Is main pressure within the specified values? (Pages 5–8 (Section 7)
and 5–9)
4 1. Install the Scan Tool. — Go to Step 5 Go to Diagnostic
2. Turn ON the ignition, with the engine OFF. Aids
3. Record the failure records.
4. Clear the DTC.
5. Start the vehicle and perform a test drive.
Attempt to duplicate the same operating
conditions observed in failure records (range
attained, transmission temperature, etc.).
NOTE: This DTC indicates an open circuit
condition may exist in the OEM wiring
harness, the internal transmission wiring
harness, or the PSM.
Did DTC P0843 return?

Copyright© 2003 General Motors Corp. 5–167


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0843 Transmission Pressure Switch Solenoid C Circuit High (cont’d)
Step Action Value(s) Yes No
5 1. Turn the ignition OFF. — Go to Step 6 Go to Step 12
2. Disconnect J2 connector from the TCM and
install J 39700 Breakout Box and J 43799
Breakout Box Adapter.
3. Connect J2 connector pin 1 to a known good
ground.
4. Turn the ignition ON.
Does the Scan Tool indicate pressure switch C
status as ON when grounded and OFF when
circuit is open?
6 1. Turn the ignition OFF and reconnect the J2 — Go to Step 7 Go to Step 11
connector to the TCM.
2. Disconnect the transmission wiring harness
from the main transmission connector at the
back of the transmission.
3. Turn the ignition ON.
4. Connect wire 201 (pin D) at the main
transmission connector to a known good
ground.*
Does the Scan Tool indicate pressure switch C
status as ON when grounded and OFF when
circuit is open?
7 1. Remove the oil pan. Refer to Service Manual — Go to Step 8 Go to Step10
or Mechanic’s Tips.
2. Disconnect the internal wiring harness from
the PSM and ground pin A.
Does the Scan Tool indicate pressure switch C
status as ON when grounded and OFF when
circuit is open?
8 1. Remove the PSM from the control valve body Go to Diagnostic Go to Step 9
and leave the internal harness connected. Aids
Refer to Service Manual or Mechanic’s Tips.
2. Provide a ground connection for the PSM to
either the control valve body or the
transmission main case.
3. Use your finger or the eraser end of a pencil
to push gently on the pressure switch C
membrane.
Does the Scan Tool indicate pressure switch C
status as ON when grounded and OFF when
circuit is open?
9 Replace the PSM. Refer to Service Manual or — Go to Step 13 —
Mechanic’s Tips.
Is the replacement complete?
10 Replace the internal wiring harness. Refer to — Go to Step 13 —
Service Manual or Mechanic’s Tips.
Is the replacement complete?

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DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0843 Transmission Pressure Switch Solenoid C Circuit High (cont’d)
Step Action Value(s) Yes No
11 NOTE: The vehicle OEM has responsibility — Go to Step 13 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?
12 NOTE: In most cases, the TCM is not at fault. — Go to Step 13 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM.
Is the replacement complete?
13 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under conditions noted in Go to Step 1
failure records.
3. Use the Scan Tool, in the test passed
section, to confirm the diagnostic test was
run.
Did the DTC return?
* If J 39700 and J 44722 are available, they may be used to perform this operation.

Copyright© 2003 General Motors Corp. 5–169


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0845 Transmission Pressure Switch Solenoid D Circuit

TRANSMISSION
HARNESS J2 HARNESS CONNECTOR
CONNECTOR (RED)
K J2-3 J2-2
D J2-4 J2-1

TCM
F
E

TRANSMISSION
BULKHEAD
CONNECTOR
K
D
J2

J1

F
E
NOTE: Letters I, O, and Q are not used.

TCM
201
C A D J2-1
202
D B F J2-2 DIGITAL
TRANSMISSION
203 INTERFACE
E C E J2-3
204
R D K J2-4

E
F
NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH
MANIFOLD
R E D
C
F E D C B A

V06213.01.00

Circuit Description

The Pressure Switch Manifold (PSM) is a multiple-switch assembly made up of three normally open (N/O) and one
normally closed (N/C) pressure switches. The D pressure switch monitors D shift valve positioning and relays it to
the TCM. When D pressure switch is in the open state, D shift valve should be in the destroked position.
Conditions for Running the DTC
• Components are powered and the ignition voltage is greater than 5V.
• DTC P0561, P0562, or P0563 is not active.
• D shift valve is commanded to the OFF (destroked) position.
• Transmission temperature is above –25°C (–13°F).
• Vehicle shutdown is not in process.

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DIAGNOSTIC TROUBLE CODES (DTC)


Conditions for Setting the DTC
DTC P0845 sets during steady state operation when D shift valve is in the destroked state (commanded OFF) and
D pressure switch status is detected as stroked (commanded ON). Steady state is defined as attaining a valid
range. The intent of this code is to detect shorts to ground in the pressure switch wiring circuit or the pressure
switch.
Later software levels incorporate retry logic that allows the TCM to command D solenoid ON and OFF. If the
pressure switch state does not change, and remains in the ON state, DTCs P0845 and P0847 will set.

Action Taken When the DTC Sets


• When DTC P0845 is active, the following conditions will occur:
— If the failure occurs while in a forward range, the transmission shifts to another forward range.
— If the shift selector is moved to N (Neutral), the transmission will shift to neutral.
— if the shift selector is moved to R (Reverse), the transmission shifts to reverse.
— If the shift selector is moved to a forward range or reverse and the transmission is compromised by
overspeeding or direction change, the transmission shifts to neutral.
• DTC P0845 is stored in TCM history.
• The CHECK TRANS light illuminates.
• The TCM inhibits TCC engagement.
• The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• When only a DTC P0845 is set, look for an intermittent short to ground at the pressure switch circuit or an
intermittent hydraulic failure (sticking valve). This code is set when the condition is present more than 3 times
during a current drive cycle. See Appendix A, Section B — Finding an Intermittent Fault.
• When a P0845 and P0847 are set in combination, this may indicate a short to ground is present at the
pressure switch circuit or the shift valve is stuck in the stroked state. See Section 4 — Beginning the
Troubleshooting Process.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change. It may be necessary to check for shorting to ground at individual wires within a
harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A,
Section B.
• You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc.
This data can be useful in reproducing the failure mode when the DTC was set.
• Multiple inactive pressure switch DTCs may be due to a plugged Control Main Filter. Ensure that the initial
8000 km (5,000 mile) filter change was performed.

Copyright© 2003 General Motors Corp. 5–171


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests for proper fluid level.
3. This step tests for proper main pressure.
4. This step tests for an active DTC.
5. This step tests the TCM for proper switch status.
6. This step tests for shorts in the OEM wiring harness.
7. This step tests for shorts in the internal wiring harness.
8. This step tests the PSM switch function.

DTC P0845 Transmission Pressure Switch Solenoid D Circuit


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Perform the A/T Fluid Checking Procedure — Go to Step 3 Go to A/T Fluid
(Appendix P). Checking
Did you perform the procedure and correct fluid Procedure
level if necessary? (Appendix P)
3 Perform the Main Pressure Check Procedure Refer to Main Go to Step 4 Go to General
(Appendix B). Pressure Table Troubleshooting
Is main pressure within the specified values? (Pages 5–8 (Section 7)
and 5–9)
4 1. Install the Scan Tool. — Go to Step 5 Go to Diagnostic
2. Turn ON the ignition, with the engine OFF. Aids
3. Record the failure records.
4. Clear the DTC.
5. Start the vehicle and perform a test drive.
Attempt to duplicate the same operating
conditions observed in failure records (range
attained, transmission temperature, etc.).
NOTE: This DTC indicates a short circuit
condition may exist in the OEM wiring
harness, the internal transmission wiring
harness, or the PSM.
Did DTC P0845 return?

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DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0845 Transmission Pressure Switch Solenoid D Circuit (cont’d)
Step Action Value(s) Yes No
5 1. Turn the ignition OFF. — Go to Step 6 Go to Step 12
2. Disconnect J2 connector from the TCM and
install J 39700 Breakout Box and J 43799
Breakout Box Adapter.
3. Connect J2 connector pin 2 to a known good
ground.
4. Turn the ignition ON.
Does the Scan Tool indicate pressure switch D
status as ON when grounded and OFF when
circuit is open?
6 1. Turn the ignition OFF and reconnect J2 — Go to Step 7 Go to Step 11
connector to the TCM.
2. Disconnect the transmission wiring harness
from the main transmission connector at the
back of the transmission.
3. Turn the ignition ON.
4. Connect wire 202 (pin F) at the main
transmission connector to a known good
ground.*
Does the Scan Tool indicate pressure switch D
status as ON when grounded and OFF when
circuit is open?
7 1. Remove the oil pan. Refer to Service Manual — Go to Step 8 Go to Step 10
or Mechanic’s Tips.
2. Disconnect the internal wiring harness from
the PSM and ground pin B.
Does the Scan Tool indicate pressure switch D
status as ON when grounded and OFF when
circuit is open?
8 1. Remove the PSM from the control valve body — Go to Diagnostic Go to Step 9
and leave the internal harness connected. Aids
Refer to Service Manual or Mechanic’s Tips.
2. Provide a ground connection for the PSM to
either the control valve body or the
transmission main case.
3. Use your finger or the eraser end of a pencil
to push gently on the pressure switch D
membrane.
Does the Scan Tool indicate pressure switch D
status as ON when grounded and OFF when
circuit is open?
9 Replace the PSM. Refer to Service Manual or — Go to Step 13 —
Mechanic’s Tips.
Is the replacement complete?
10 Replace the internal wiring harness. Refer to — Go to Step 13 —
Service Manual or Mechanic’s Tips.
Is the replacement complete?

Copyright© 2003 General Motors Corp. 5–173


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0845 Transmission Pressure Switch Solenoid D Circuit (cont’d)
Step Action Value(s) Yes No
11 NOTE: The vehicle OEM has responsibility — Go to Step 13 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?
12 NOTE: In most cases, the TCM is not at fault. — Go to Step 13 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM.
Is the replacement complete?
13 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under conditions noted in Go to Step 1
failure report.
3. Use the Scan Tool, in the test passed
section, to confirm the diagnostic test was
run.
Did the DTC return?
* If J 39700 and J 44722 are available, they may be used to perform this operation.

5–174 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0846 Transmission Pressure Switch Solenoid D Circuit Stuck Open

TRANSMISSION
HARNESS J2 HARNESS CONNECTOR
CONNECTOR (RED)
K J2-3 J2-2
D J2-4 J2-1

TCM
F
E

TRANSMISSION
BULKHEAD
CONNECTOR
K
D
J2

J1

F
E
NOTE: Letters I, O, and Q are not used.

TCM
201
C A D J2-1
202
D B F J2-2 DIGITAL
TRANSMISSION
203 INTERFACE
E C E J2-3
204
R D K J2-4

E
F
NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH
MANIFOLD
R E D
C
F E D C B A

V06213.01.00

Circuit Description

The Pressure Switch Manifold (PSM) is a multiple-switch assembly made up of three normally open (N/O) and one
normally closed (N/C) pressure switches. The D pressure switch monitors D shift valve positioning and relays it to
the TCM. When D pressure switch is in the open state, D shift valve should be in the destroked position.

Conditions for Running the DTC

• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• D shift valve is commanded to the ON (stroked) position.

Copyright© 2003 General Motors Corp. 5–175


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Conditions for Setting the DTC
DTC P0846 sets when D solenoid is commanded ON and D pressure switch status remains OFF for a period of
time. The time period is 5 seconds at 0°C (32°F) to –40°C (–40°F). The intent of this DTC is to detect a stuck shift
valve, in the destroked state, a mechanical solenoid failure, or an open circuit.

Action Taken When the DTC Sets


• When DTC P0846 is active, the following conditions will occur:
— If the failure occurs while in a forward range, the transmission shifts to another forward range.
— If the shift selector is moved to N (Neutral), the transmission will shift to neutral.
— if the shift selector is moved to R (Reverse), the transmission shifts to reverse.
— If the shift selector is moved to a forward range or reverse and the transmission is compromised by
overspeeding or direction change, the transmission shifts to neutral.
• DTC P0846 is stored in TCM history.
• The CHECK TRANS light illuminates.
• The TCM inhibits TCC engagement.
• The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light

A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• When a P0846 and P0848 are set in combination, this may indicate an open circuit condition is present at the
pressure switch circuit or the shift valve is stuck in the destroked state. See Section 4 — Beginning the
Troubleshooting Process.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change. It may be necessary to check for an open condition at individual wires within a
harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A,
Section B.
• You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc.
This data can be useful in reproducing the failure mode when the DTC was set.
• Multiple inactive pressure switch DTCs may be due to a plugged Control Main Filter. Ensure that the initial
8000 km (5,000 mile) filter change was performed.

5–176 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests for proper fluid level.
3. This step tests for proper main pressure.
4. This step tests for an active DTC.
5. This step tests the TCM for proper switch status.
6. This step tests for opens in the OEM wiring harness.
7. This step tests for opens in the internal wiring harness.
8. This step tests the PSM switch function.

DTC P0846 Transmission Pressure Switch Solenoid D Circuit Stuck Open


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Perform the A/T Fluid Checking Procedure — Go to Step 3 Go to A/T Fluid
(Appendix P). Checking
Did you perform the procedure and correct fluid Procedure
level if necessary? (Appendix P)
3 Perform the Main Pressure Check Procedure Refer to Main Go to Step 4 Go to General
(Appendix B). Pressure Table Troubleshooting
Is main pressure within the specified values? (Pages 5–8 (Section 7)
and 5–9)
4 1. Install the Scan Tool. — Go to Step 5 Go to Diagnostic
2. Turn ON the ignition, with the engine OFF. Aids
3. Record the failure records.
4. Clear the DTC.
5. Start the vehicle and perform a test drive.
Attempt to duplicate the same operating
conditions observed in failure records (range
attained, transmission temperature, etc.).
NOTE: This DTC may indicate a stuck shift
valve, solenoid mechanically failed, an open
condition in the switch circuit, or a defective
PSM.
Did DTC P0846 return?
5 1. Turn the ignition OFF. — Go to Step 6 Go to Step 15
2. Disconnect J2 connector from the TCM and
install J 39700 Breakout Box and J 43799
Breakout Box Adapter.
3. Connect J2 connector pin 2 to a known good
ground.
4. Turn the ignition ON.
Does the Scan Tool indicate pressure switch D
status as ON when grounded and OFF when
circuit is open?

Copyright© 2003 General Motors Corp. 5–177


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0846 Transmission Pressure Switch Solenoid D Circuit Stuck Open (cont’d)
Step Action Value(s) Yes No
6 1. Turn the ignition OFF and reconnect J2 — Go to Step 7 Go to Step 14
connector to the TCM.
2. Disconnect the transmission wiring harness
from the main transmission connector at the
back of the transmission.
3. Turn the ignition ON.
4. Connect wire 202 (pin F) on the harness
connector to a known good ground.*
Does the Scan Tool indicate pressure switch D
status as ON when grounded and OFF when
circuit is open?
7 1. Remove the oil pan. Refer to Service Manual — Go to Step 8 Go to Step 13
or Mechanic’s Tips.
2. Disconnect the internal wiring harness from
the PSM and ground pin B.
Does the Scan Tool indicate pressure switch D
status as ON when grounded and OFF when
circuit is open?
8 1. Remove the PSM from the control valve body — Go to Step 9 Go to Step 12
and leave the internal harness connected.
Refer to Service Manual or Mechanic’s Tips.
2. Provide a ground connection for the PSM to
either the control valve body or the
transmission main case.
3. Use your finger or the eraser end of a pencil
to push gently on the pressure switch D
membrane.
Does the Scan Tool indicate pressure switch D
status as ON when grounded and OFF when
circuit is open?
9 Remove the control valve body and check for a — Go to Step 11 Go to Step 10
stuck or sticking D shift valve. Refer to Service
Manual or Mechanic’s Tips.
Was the D shift valve stuck or sticking?
10 Replace the D shift solenoid and reinstall the — Go to Step 16 —
control valve body. Refer to Service Manual or
Mechanic’s Tips.
Is replacement of the solenoid and reinstalling
of the control valve body complete?
11 Clean and/or polish the sticking valve to restore — Go to Step 16 —
free movement or replace the control valve
body assembly. Refer to Service Manual or
Mechanic’s Tips.
Was free movement restored or valve body
replaced?
12 Replace the PSM. Refer to Service Manual or — Go to Step 16 —
Mechanic’s Tips.
Is the replacement complete?

5–178 Copyright© 2003 General Motors Corp.


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DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0846 Transmission Pressure Switch Solenoid D Circuit Stuck Open (cont’d)
Step Action Value(s) Yes No
13 Replace the internal wiring harness. Refer to — Go to Step 16 —
Service Manual or Mechanic’s Tips.
Is the replacement complete?
14 NOTE: The vehicle OEM has responsibility — Go to Step 16 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?
15 NOTE: In most cases, the TCM is not at fault. — Go to Step 16 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM.
Is the replacement complete?
16 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under conditions noted in Go to Step 1
failure records.
3. Use the Scan Tool, in the test passed
section, to confirm the diagnostic test was
run.
Did the DTC return?
* If J 39700 and J 44722 are available, they may be used to perform this operation.

Copyright© 2003 General Motors Corp. 5–179


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0847 Transmission Pressure Switch Solenoid D Circuit Stuck Closed

TRANSMISSION
HARNESS J2 HARNESS CONNECTOR
CONNECTOR (RED)
K J2-3 J2-2
D J2-4 J2-1

TCM
F
E

TRANSMISSION
BULKHEAD
CONNECTOR
K
D
J2

J1

F
E
NOTE: Letters I, O, and Q are not used.

TCM
201
C A D J2-1
202
D B F J2-2 DIGITAL
TRANSMISSION
203 INTERFACE
E C E J2-3
204
R D K J2-4

E
F
NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH
MANIFOLD
R E D
C
F E D C B A

V06213.01.00

Circuit Description
The Pressure Switch Manifold (PSM) is a multiple-switch assembly made up of three normally open (N/O) and one
normally closed (N/C) pressure switches. The D pressure switch monitors D shift valve positioning and relays it to
the TCM. When D pressure switch is in the open state, D shift valve should be in the destroked position.
Conditions for Running the DTC
• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• D shift valve is commanded to the OFF (destroked) position.

Conditions for Setting the DTC


DTC P0847 sets when D solenoid is commanded OFF and D pressure switch status remains ON for a period of time
that is temperature dependent. The time period is 2 seconds at 0°C (32°F) or up to 16 seconds at –40°C (–40°F).
The intent of this DTC is to detect a stuck shift valve, in the stroked state, a mechanical solenoid failure, or a circuit
short to ground.

5–180 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Action Taken When the DTC Sets
• When DTC P0847 is active, the following conditions will occur:
— If the failure occurs while in a forward range, the transmission shifts to another forward range.
— If the shift selector is moved to N (Neutral), the transmission will shift to neutral.
— if the shift selector is moved to R (Reverse), the transmission shifts to reverse.
— If the shift selector is moved to a forward range or reverse and the transmission is compromised by
overspeeding or direction change, the transmission shifts to neutral.
• DTC P0847 is stored in TCM history.
• The CHECK TRANS light illuminates.
• The TCM inhibits TCC engagement.
• The TCM freezes shift adapts (DNA).
Conditions for Clearing the DTC/CHECK TRANS Light
A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.
Diagnostic Aids
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• When a P0847 and P0845 are set in combination, this may indicate a short to ground is present at the
pressure switch circuit or the shift valve is stuck in the stroked state. See Section 4 — Beginning the
Troubleshooting Process.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change. It may be necessary to check for shorting to ground at individual wires within a
harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A,
Section B.
• You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc.
This data can be useful in reproducing the failure mode when the DTC was set.
• Multiple inactive pressure switch DTCs may be due to a plugged Control Main Filter. Ensure that the initial
8000 km (5,000 mile) filter change was performed.
Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests for proper fluid level.
3. This step tests for proper main pressure.
4. This step tests for an active DTC.
5. This step tests for the TCM proper switch status.
6. This step tests for shorts in the OEM wiring harness.
7. This step tests for shorts in the internal wiring harness.
8. This step tests the PSM switch function.

Copyright© 2003 General Motors Corp. 5–181


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0847 Transmission Pressure Switch Solenoid D Circuit Stuck Closed


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Perform the A/T Fluid Checking Procedure — Go to Step 3 Go to A/T Fluid
(Appendix P). Checking
Did you perform the procedure and correct fluid Procedure
level if necessary? (Appendix P)
3 Perform the Main Pressure Check Procedure Refer to Main Go to Step 4 Go to General
(Appendix B). Pressure Table Troubleshooting
Is main pressure within the specified values? (Pages 5–8 (Section 7)
and 5–9)
4 1. Install the Scan Tool. — Go to Step 5 Go to Diagnostic
2. Turn ON the ignition, with the engine OFF. Aids
3. Record the failure records.
4. Clear the DTC.
5. Start the vehicle and perform a test drive.
Attempt to duplicate the same operating
conditions observed in failure records (range
attained, transmission temperature, etc.).
NOTE: This DTC may indicate a stuck shift
valve, solenoid mechanically failed, a short
to ground in the switch circuit, or a defective
PSM.
Did DTC P0847 return?
5 1. Turn the ignition OFF. — Go to Step 6 Go to Step 15
2. Disconnect J2 connector from the TCM and
install J 39700 Breakout Box and J 43799
Breakout Box Adapter.
3. Connect J2 connector pin 2 to a known good
ground.
4. Turn the ignition ON.
Does the Scan Tool indicate pressure switch D
status as ON when grounded and OFF when
circuit is open?
6 1. Turn the ignition OFF and reconnect J2 — Go to Step 7 Go to Step 14
connector to the TCM.
2. Disconnect the transmission wiring harness
from the main transmission connector at the
back of the transmission.
3. Turn the ignition ON.
4. Connect wire 202 (pin F) on the harness
connector to a known good ground.*
Does the Scan Tool indicate pressure switch D
status as ON when grounded and OFF when
circuit is open?

5–182 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0847 Transmission Pressure Switch Solenoid D Circuit Stuck Closed (cont’d)
Step Action Value(s) Yes No
7 1. Remove the oil pan. Refer to Service Manual — Go to Step 8 Go to Step 13
or Mechanic’s Tips.
2. Disconnect the internal wiring harness from
the PSM and ground pin B.
Does the Scan Tool indicate pressure switch D
status as ON when grounded and OFF when
circuit is open?
8 1. Remove the PSM from the control valve body Go to Step 9 Go to Step 12
and leave the internal harness connected.
Refer to Service Manual or Mechanic’s Tips.
2. Provide a ground connection for the PSM to
either the control valve body or the
transmission main case.
3. Use your finger or the eraser end of a pencil
to push gently on the pressure switch D
membrane.
Does the Scan Tool indicate pressure switch D
status as ON when grounded and OFF when
circuit is open?
9 Remove the control valve body and check for a Go to Step 11 Go to Step 10
stuck or sticking D shift valve. Refer to Service
Manual or Mechanic’s Tips.
Was the D shift valve stuck or sticking?
10 Replace the D shift solenoid and reinstall the Go to Step 16
control valve body. Refer to Service Manual or
Mechanic’s Tips.
Is the replacement of the solenoid and
reinstalling of the control valve body complete?
11 Clean and/or polish the sticking valve to restore Go to Step 16
free movement or replace the control valve
body assembly. Refer to Service Manual or
Mechanic’s Tips.
Was free movement restored or valve body
replaced?
12 Replace the PSM (refer to Service Manual or — Go to Step 16 —
Mechanic’s Tips).
Is the replacement complete?
13 Replace the internal wiring harness. Refer to — Go to Step 16 —
Service Manual or Mechanic’s Tips.
Is the replacement complete?
14 NOTE: The vehicle OEM has responsibility — Go to Step 16 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?

Copyright© 2003 General Motors Corp. 5–183


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0847 Transmission Pressure Switch Solenoid D Circuit Stuck Closed (cont’d)
Step Action Value(s) Yes No
15 NOTE: In most cases, the TCM is not at fault. — Go to Step 16 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM.
Is the replacement complete?
16 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under conditions noted in Go to Step 1
failure records.
3. Use the Scan Tool, in the test passed
section, to confirm the diagnostic test was
run.
Did the DTC return?
* If J 39700 and J 44722 are available, they may be used to perform this operation.

5–184 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0848 Transmission Pressure Switch Solenoid D Circuit High

TRANSMISSION
HARNESS J2 HARNESS CONNECTOR
CONNECTOR (RED)
K J2-3 J2-2
D J2-4 J2-1

TCM
F
E

TRANSMISSION
BULKHEAD
CONNECTOR
K
D
J2

J1

F
E
NOTE: Letters I, O, and Q are not used.

TCM
201
C A D J2-1
202
D B F J2-2 DIGITAL
TRANSMISSION
203 INTERFACE
E C E J2-3
204
R D K J2-4

E
F
NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH
MANIFOLD
R E D
C
F E D C B A

V06213.01.00

Circuit Description
The Pressure Switch Manifold (PSM) is a multiple-switch assembly made up of three normally open (N/O) and one
normally closed (N/C) pressure switches. The D pressure switch monitors D shift valve positioning and relays it to
the TCM. When D pressure switch is in the open state, D shift valve should be in the destroked position.
Conditions for Running the DTC
• Components are powered and the ignition voltage is greater than 5V.
• DTC P0561, P0562, or P0563 is not active.
• D shift valve is commanded to the ON (stroked) position.
• Transmission temperature is above –25°C (–13°F).
• Vehicle shutdown is not in process.

Copyright© 2003 General Motors Corp. 5–185


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Conditions for Setting the DTC
DTC P0848 sets during steady state operation when D shift valve is in the stroked state (commanded ON) and D
pressure switch status is detected as destroked (commanded OFF). Steady state is defined as attaining a valid
range. The intent of this code is to detect an open condition in the pressure switch wiring circuit or the pressure switch.
Later software levels incorporate retry logic that allows the TCM to command D solenoid OFF and ON. If the
pressure switch state does not change, and remains in the OFF state, DTCs P0848 and P0846 will set.

Action Taken When the DTC Sets


• When DTC P0848 is active, the following conditions will occur:
— If the failure occurs while in a forward range, the transmission shifts to another forward range.
— If the shift selector is moved to N (Neutral), the transmission will shift to neutral.
— if the shift selector is moved to R (Reverse), the transmission shifts to reverse.
— If the shift selector is moved to a forward range or reverse and the transmission is compromised by
overspeeding or direction change, the transmission shifts to neutral.
• DTC P0848 is stored in TCM history.
• The CHECK TRANS light illuminates.
• The TCM inhibits TCC engagement.
• The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• When only a DTC P0848 is set, look for an intermittent open condition at the pressure switch circuit or an
intermittent hydraulic failure (sticking valve). This code is set when the condition is present more than 3 times
during a current drive cycle. See Appendix A, Section B — Finding an Intermittent Fault.
• When a P0848 and P0846 are set in combination, this may indicate an open circuit condition is present at the
pressure switch circuit or the shift valve is stuck in the destroked state. See Section 4 — Beginning the
Troubleshooting Process.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change. It may be necessary to check for an open condition at individual wires within a
harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A,
Section B.
• You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc.
This data can be useful in reproducing the failure mode when the DTC was set.
• Multiple inactive pressure switch DTCs may be due to a plugged Control Main Filter. Ensure that the initial
8000 km (5,000 mile) filter change was performed.

5–186 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests for proper fluid level.
3. This step tests for proper main pressure.
4. This step tests for an active DTC.
5. This step tests the TCM for proper switch status.
6. This step tests for opens in the OEM wiring harness.
7. This step tests for opens in the internal wiring harness.
8. This step tests the PSM switch function.

DTC P0848 Transmission Pressure Switch Solenoid D Circuit High


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Perform the A/T Fluid Checking Procedure — Go to Step 3 Go to A/T Fluid
(Appendix P). Checking
Did you perform the procedure and correct fluid Procedure
level if necessary? (Appendix P)
3 Perform the Main Pressure Check Procedure Refer to Main Go to Step 4 Go to General
(Appendix B). Pressure Table Troubleshooting
Is main pressure within the specified values? (Pages 5–8 (Section 7)
and 5–9)
4 1. Install the Scan Tool. — Go to Step 5 Go to Diagnostic
2. Turn ON the ignition, with the engine OFF. Aids
3. Record the failure records.
4. Clear the DTC.
5. Start the vehicle and perform a test drive.
Attempt to duplicate the same operating
conditions observed in failure records (range
attained, transmission temperature, etc.).
NOTE: This DTC indicates an open circuit
condition may exist in the OEM wiring
harness, the internal transmission wiring
harness, or the PSM.
Did DTC P0848 return?

Copyright© 2003 General Motors Corp. 5–187


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0848 Transmission Pressure Switch Solenoid D Circuit High (cont’d)
Step Action Value(s) Yes No
5 1. Turn the ignition OFF. — Go to Step 6 Go to Step 12
2. Disconnect J2 connector from the TCM and
install J 39700 Breakout Box and J 43799
Breakout Box Adapter.
3. Connect J2 connector pin 2 to a known good
ground.
4. Turn the ignition ON.
Does the Scan Tool indicate pressure switch D
status as ON when grounded and OFF when
circuit is open?
6 1. Turn the ignition OFF and reconnect J2 — Go to Step 7 Go to Step 11
connector to the TCM.
2. Disconnect the transmission wiring harness
from the main transmission connector at the
back of the transmission.
3. Turn the ignition ON.
4. Connect wire 202 (pin F) at the main
transmission connector to a known good
ground.*
Does the Scan Tool indicate pressure switch D
status as ON when grounded and OFF when
circuit is open?
7 1. Remove the oil pan. Refer to Service Manual — Go to Step 8 Go to Step 10
or Mechanic’s Tips.
2. Disconnect the internal wiring harness from
the PSM and ground pin B.
Does the Scan Tool indicate pressure switch D
status as ON when grounded and OFF when
circuit is open?
8 1. Remove the PSM from the control valve body — Go to Diagnostic Go to Step 9
and leave the internal harness connected. Aids
Refer to Service Manual or Mechanic’s Tips.
2. Provide a ground connection for the PSM to
either the control valve body or the
transmission main case.
3. Use your finger or the eraser end of a pencil
to push gently on the pressure switch D
membrane.
Does the Scan Tool indicate pressure switch D
status as ON when grounded and OFF when
circuit is open?
9 Replace the PSM. Refer to Service Manual or — Go to Step 13 —
Mechanic’s Tips.
Is the replacement complete?
10 Replace the internal wiring harness. Refer to — Go to Step 13 —
Service Manual or Mechanic’s Tips.
Is the replacement complete?

5–188 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0848 Transmission Pressure Switch Solenoid D Circuit High (cont’d)
Step Action Value(s) Yes No
11 NOTE: The vehicle OEM has responsibility — Go to Step 13 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?
12 NOTE: In most cases, the TCM is not at fault. — Go to Step 13 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM.
Is the replacement complete?
13 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under conditions noted in Go to Step 1
failure records.
3. Use the Scan Tool, in the test passed
section, to confirm the diagnostic test was
run.
Did the DTC return?
* If J 39700 and J 44722 are available, they may be used to perform this operation.

Copyright© 2003 General Motors Corp. 5–189


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0870 (Previously P1709) Transmission Pressure Switch Solenoid E Circuit

TRANSMISSION
HARNESS J2 HARNESS CONNECTOR
CONNECTOR (RED)
K J2-3 J2-2
D J2-4 J2-1

TCM
F
E

TRANSMISSION
BULKHEAD
CONNECTOR
K
D
J2

J1

F
E
NOTE: Letters I, O, and Q are not used.

TCM
201
C A D J2-1
202
D B F J2-2 DIGITAL
TRANSMISSION
203 INTERFACE
E C E J2-3
204
R D K J2-4

E
F
NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH
MANIFOLD
R E D
C
F E D C B A

V06213.01.00

Circuit Description
The Pressure Switch Manifold (PSM) is a multiple-switch assembly made up of three normally open (N/O) and one
normally closed (N/C) pressure switches. The E pressure switch monitors E shift valve positioning and relays it to
the TCM. When E pressure switch is in the open state, E shift valve should be in the destroked position.
Conditions for Running the DTC
• Components are powered and the ignition voltage is greater than 5V.
• DTC P0561, P0562, or P0563 is not active.
• E shift valve is commanded to the OFF (destroked) position.
• Transmission temperature is above –25°C (–13°F).
• Vehicle shutdown is not in process.

5–190 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Conditions for Setting the DTC
DTC P0870 sets during steady state operation when E shift valve is in the destroked state (commanded OFF) and
E pressure switch status is detected as stroked (commanded ON). Steady state is defined as attaining a valid
range. The intent of this code is to detect shorts to ground in the pressure switch wiring circuit or the pressure
switch.
Later software levels incorporate retry logic that allows the TCM to command E solenoid ON and OFF. If the
pressure switch state does not change, and remains in the ON state, DTCs P0870 and P0872 will set.

Action Taken When the DTC Sets


• When DTC P0870 is active, the following conditions will occur:
— If the failure occurs while in a forward range, the transmission shifts to another forward range.
— If the shift selector is moved to N (Neutral), the transmission will shift to neutral.
— if the shift selector is moved to R (Reverse), the transmission shifts to reverse.
— If the shift selector is moved to a forward range or reverse and the transmission is compromised by
overspeeding or direction change, the transmission shifts to neutral.
• DTC P0870 is stored in TCM history.
• The CHECK TRANS light illuminates.
• The TCM inhibits TCC engagement.
• The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• When only a DTC P0870 is set, look for an intermittent short to ground at the pressure switch circuit or an
intermittent hydraulic failure (sticking valve). This code is set when the condition is present more than 3 times
during a current drive cycle. See Appendix A, Section B — Finding an Intermittent Fault.
• When a P0870 and P0872 are set in combination, this may indicate a short to ground is present at the
pressure switch circuit or the shift valve is stuck in the stroked state. See Section 4 — Beginning the
Troubleshooting Process.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change. It may be necessary to check for shorting to ground at individual wires within a
harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A,
Section B.
• You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc.
This data can be useful in reproducing the failure mode when the DTC was set.
• Multiple inactive pressure switch DTCs may be due to a plugged Control Main Filter. Ensure that the initial
8000 km (5,000 mile) filter change was performed.

Copyright© 2003 General Motors Corp. 5–191


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests for proper fluid level.
3. This step tests for proper main pressure.
4. This step tests for an active DTC.
5. This step tests the TCM for proper switch status.
6. This step tests for shorts in the OEM wiring harness.
7. This step tests for shorts in the internal wiring harness.
8. This step tests the PSM switch function.

DTC P0870 (Previously P1709) Transmission Pressure Switch Solenoid E Circuit


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Perform the A/T Fluid Checking Procedure — Go to Step 3 Go to A/T Fluid
(Appendix P). Checking
Did you perform the procedure and correct fluid Procedure
level if necessary? (Appendix P)
3 Perform the Main Pressure Check Procedure Refer to Main Go to Step 4 Go to General
(Appendix B). Pressure Table Troubleshooting
Is main pressure within the specified values? (Pages 5–8 (Section 7)
and 5–9)
4 1. Install the Scan Tool. — Go to Step 5 Go to Diagnostic
2. Turn ON the ignition, with the engine OFF. Aids
3. Record the failure records.
4. Clear the DTC.
5. Start the vehicle and perform a test drive.
Attempt to duplicate the same operating
conditions observed in failure records (range
attained, transmission temperature, etc.).
NOTE: This DTC indicates a short circuit
condition may exist in the OEM wiring
harness, the internal transmission wiring
harness, or the PSM.
Did DTC P0870 return?

5–192 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0870 (Previously P1709) Transmission Pressure Switch Solenoid E Circuit (cont’d)
Step Action Value(s) Yes No
5 1. Turn the ignition OFF. — Go to Step 6 Go to Step 12
2. Disconnect J2 connector from the TCM and
install J 39700 Breakout Box and J 43799
Breakout Box Adapter.
3. Connect J2 connector pin 3 to known good
ground.
4. Turn the ignition ON.
Does the Scan Tool indicate pressure switch E
status as ON when grounded and OFF when
circuit is open?
6 1. Turn the ignition OFF and reconnect J2 — Go to Step 7 Go to Step 11
connector to the TCM.
2. Disconnect the transmission wiring harness
from the main transmission connector at the
back of the transmission.
3. Turn the ignition ON.
4. Connect wire 203 (pin E) at the main
transmission connector to a known good
ground.*
Does the Scan Tool indicate pressure switch E
status as ON when grounded and OFF when
circuit is open?
7 1. Remove the oil pan. Refer to Service Manual — Go to Step 8 Go to Step 10
or Mechanic’s Tips.
2. Disconnect the internal wiring harness from
the PSM and ground pin C.
Does the Scan Tool indicate pressure switch E
status as ON when grounded and OFF when
circuit is open?
8 1. Remove the PSM from the control valve body — Go to Diagnostic Go to Step 9
and leave the internal harness connected. Aids
Refer to Service Manual or Mechanic’s Tips.
2. Provide a ground connection for the PSM to
either the control valve body or the
transmission main case.
3. Use your finger at the eraser end of a pencil
to push gently on the pressure switch E
membrane.
Does the Scan Tool indicate pressure switch E
status as ON when grounded and OFF when
circuit is open?
9 Replace the PSM. Refer to Service Manual or — Go to Step 13 —
Mechanic’s Tips.
Is the replacement complete?
10 Replace the internal wiring harness. Refer to — Go to Step 13 —
Service Manual or Mechanic’s Tips.
Is the replacement complete?

Copyright© 2003 General Motors Corp. 5–193


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0870 (Previously P1709) Transmission Pressure Switch Solenoid E Circuit (cont’d)
Step Action Value(s) Yes No
11 NOTE: The vehicle OEM has responsibility — Go to Step 13 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?
12 NOTE: In most cases, the TCM is not at fault. — Go to Step 13 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM.
Is the replacement complete?
13 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under conditions noted in Go to Step 1
failure records.
3. Use the Scan Tool, in the test passed
section, to confirm the diagnostic test was
run.
Did the DTC return?
* If J 39700 and J 44722 are available, they may be used to perform this operation.

5–194 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0871 (Previously P1710) Transmission Pressure Switch
Solenoid E Circuit Stuck Open

TRANSMISSION
HARNESS J2 HARNESS CONNECTOR
CONNECTOR (RED)
K J2-3 J2-2
D J2-4 J2-1

TCM
F
E

TRANSMISSION
BULKHEAD
CONNECTOR
K
D
J2

J1

F
E
NOTE: Letters I, O, and Q are not used.

TCM
201
C A D J2-1
202
D B F J2-2 DIGITAL
TRANSMISSION
203 INTERFACE
E C E J2-3
204
R D K J2-4

E
F
NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH
MANIFOLD
R E D
C
F E D C B A

V06213.01.00

Circuit Description

The Pressure Switch Manifold (PSM) is a multiple-switch assembly made up of three normally open (N/O) and one
normally closed (N/C) pressure switches. The E pressure switch monitors E shift valve positioning and relays it to
the TCM. When E pressure switch is in the open state, E shift valve should be in the destroked position.

Conditions for Running the DTC


• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• E shift valve is commanded to the ON (stroked) position.

Copyright© 2003 General Motors Corp. 5–195


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Conditions for Setting the DTC
DTC P0871 sets when E solenoid is commanded ON and E pressure switch status remains OFF for a period of
time. The time period is 5 seconds at 0°C (32°F) to –40°C (–40°F). The intent of this DTC is to detect a stuck shift
valve, in the destroked state, a mechanical solenoid failure, or an open circuit.

Action Taken When the DTC Sets


• When DTC P0871 is active, the following conditions will occur:
— If the failure occurs while in a forward range, the transmission shifts to another forward range.
— If the shift selector is moved to N (Neutral), the transmission will shift to neutral.
— if the shift selector is moved to R (Reverse), the transmission shifts to reverse.
— If the shift selector is moved to a forward range or reverse and the transmission is compromised by
overspeeding or direction change, the transmission shifts to neutral.
• DTC P0871 is stored in TCM history.
• The CHECK TRANS light illuminates.
• The TCM inhibits TCC engagement.
• The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• When a P0871 and P0873 are set in combination, this may indicate an open circuit condition is present at the
pressure switch circuit or the shift valve is stuck in the destroked state. See Section 4 — Beginning the
Troubleshooting Process.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change. It may be necessary to check for an open condition at individual wires within a
harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A,
Section B.
• You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc.
This data can be useful in reproducing the failure mode when the DTC was set.
• Multiple inactive pressure switch DTCs may be due to a plugged Control Main Filter. Ensure that the initial
8000 km (5,000 mile) filter change was performed.

Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests for proper fluid level.
3. This step tests for proper main pressure.

5–196 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


4. This step tests for an active DTC.
5. This step tests the TCM for proper switch status.
6. This step tests for opens in the OEM wiring harness.
7. This step tests for opens in the internal wiring harness.
8. This step tests the PSM switch function.

DTC P0871 (Previously P1710) Trans Pressure Switch


Solenoid E Circuit Stuck Open
Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Perform the A/T Fluid Checking Procedure — Go to Step 3 Go to A/T Fluid
(Appendix P). Checking
Did you perform the procedure and correct fluid Procedure
level if necessary? (Appendix P)
3 Perform the Main Pressure Check Procedure Refer to Main Go to Step 4 Go to General
(Appendix B). Pressure Table Troubleshooting
Is main pressure within the specified values? (Pages 5–8 (Section 7)
and 5–9)
4 1. Install the Scan Tool. — Go to Step 5 Go to Diagnostic
2. Turn ON the ignition, with the engine OFF. Aids
3. Record the failure records.
4. Clear the DTC.
5. Start the vehicle and perform a test drive.
Attempt to duplicate the same operating
conditions observed in failure records (range
attained, transmission temperature, etc.).
NOTE: This DTC may indicate a stuck shift
valve, solenoid mechanically failed, an open
condition in the switch circuit, or a defective
PSM.
Did DTC P0871 return?
5 1. Turn the ignition OFF. — Go to Step 6 Go to Step 15
2. Disconnect J2 connector from the TCM and
install J 39700 Breakout Box and J 43799
Breakout Box Adapter.
3. Connect J2 connector pin 3 to a known good
ground.
4. Turn the ignition ON.
Does the Scan Tool indicate pressure switch E
status as ON when grounded and OFF when
circuit is open?

Copyright© 2003 General Motors Corp. 5–197


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0871 (Previously P1710) Trans Pressure Switch
Solenoid E Circuit Stuck Open (cont’d)
Step Action Value(s) Yes No
6 1. Turn the ignition OFF and reconnect J2 — Go to Step 7 Go to Step 14
connector to the TCM.
2. Disconnect the transmission wiring harness
from the main transmission connector.
3. Turn the ignition ON.
4. Connect wire 203 (pin E) at the main
transmission connector to a known good
ground.*
Does the Scan Tool indicate pressure switch E
status as ON when grounded and OFF when
circuit is open?
7 1. Remove the oil pan. Refer to Service Manual — Go to Step 8 Go to Step 13
or Mechanic’s Tips.
2. Disconnect the internal wiring harness from
the PSM and ground pin C.
Does the Scan Tool indicate pressure switch E
status as ON when grounded and OFF when
circuit is open?
8 1. Remove the PSM from the control valve body — Go to Step 9 Go to Step 12
and leave the internal harness connected.
Refer to Service Manual or Mechanic’s Tips.
2. Provide a ground connection for the PSM to
either the control valve body or the
transmission main case.
3. Use your finger or the eraser end of a pencil
to push gently on the pressure switch E
membrane.
Does the Scan Tool indicate pressure switch E
status as ON when grounded and OFF when
circuit is open?
9 Remove the control valve body and inspect for — Go to Step 11 Go to Step 10
a stuck or sticking E shift valve. Refer to Service
Manual or Mechanic’s Tips.
Was the E shift valve stuck or sticking?
10 Replace the E shift solenoid and reinstall the — Go to Step 16 —
control valve body. Refer to Service Manual or
Mechanic’s Tips.
Is replacement of the solenoid and reinstalling
of the control valve body complete?
11 Clean and/or polish the sticking valve to restore — Go to Step 16 —
free movement or replace the control valve
body assembly. Refer to Service Manual or
Mechanic’s Tips.
Was free movement restored or valve body
replaced?

5–198 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0871 (Previously P1710) Trans Pressure Switch
Solenoid E Circuit Stuck Open (cont’d)
Step Action Value(s) Yes No
12 Replace the PSM. Refer to Service Manual or — Go to Step 16 —
Mechanic’s Tips.
Is the replacement complete?
13 Replace the internal wiring harness. Refer to — Go to Step 16 —
Service Manual or Mechanic’s Tips.
Is the replacement complete?
14 NOTE: The vehicle OEM has responsibility — Go to Step 16 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?
15 NOTE: In most cases, the TCM is not at fault. — Go to Step 16 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM.
Is the replacement complete?
16 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under conditions noted in Go to Step 1
failure records.
3. Use the Scan Tool, in the test passed
section, to confirm the diagnostic test was
run.
Did the DTC return?
* If J 39700 and J 44722 are available, they may be used to perform this operation.

Copyright© 2003 General Motors Corp. 5–199


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0872 (Previously P1711) Transmission Pressure Switch Solenoid E Circuit
Stuck Closed

TRANSMISSION
HARNESS J2 HARNESS CONNECTOR
CONNECTOR (RED)
K J2-3 J2-2
D J2-4 J2-1

TCM
F
E

TRANSMISSION
BULKHEAD
CONNECTOR
K
D
J2

J1

F
E
NOTE: Letters I, O, and Q are not used.

TCM
201
C A D J2-1
202
D B F J2-2 DIGITAL
TRANSMISSION
203 INTERFACE
E C E J2-3
204
R D K J2-4

E
F
NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH
MANIFOLD
R E D
C
F E D C B A

V06213.01.00

Circuit Description

The Pressure Switch Manifold (PSM) is a multiple-switch assembly made up of three normally open (N/O) and one
normally closed (N/C) pressure switches. The E pressure switch monitors E shift valve positioning and relays it to
the TCM. When E pressure switch is in the open state, E shift valve should be in the destroked position.

Conditions for Running the DTC


• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• E shift valve is commanded to the OFF (destroked) position.

5–200 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Conditions for Setting the DTC
DTC P0872 sets when E solenoid is commanded OFF and E pressure switch status remains ON for a period of time
that is temperature dependent. The time period is 2 seconds at 0°C (32°F) or up to 20 seconds at –40°C (–40°F).
The intent of this DTC is to detect a stuck shift valve, in the stroked state, a mechanical solenoid failure, or a circuit
short to ground.

Action Taken When the DTC Sets


• When DTC P0872 is active, the following conditions will occur:
— If the failure occurs while in a forward range, the transmission shifts to another forward range.
— If the shift selector is moved to N (Neutral), the transmission will shift to neutral.
— if the shift selector is moved to R (Reverse), the transmission shifts to reverse.
— If the shift selector is moved to a forward range or reverse and the transmission is compromised by
overspeeding or direction change, the transmission shifts to neutral.
• DTC P0872 is stored in TCM history.
• The CHECK TRANS light illuminates.
• The TCM inhibits TCC engagement.
• The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• When a P0872 and P0870 are set in combination, this may indicate a short to ground is present at the
pressure switch circuit or the shift valve is stuck in the stroked state. See Section 4 — Beginning the
Troubleshooting Process.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change. It may be necessary to check for shorting to ground at individual wires within a
harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A,
Section B.
• You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc.
This data can be useful in reproducing the failure mode when the DTC was set.
• Multiple inactive pressure switch DTCs may be due to a plugged Control Main Filter. Ensure that the initial
8000 km (5,000 mile) filter change was performed.

Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests for proper fluid level.
3. This step tests for proper main pressure.

Copyright© 2003 General Motors Corp. 5–201


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


4. This step tests for an active DTC.
5. This step tests the TCM for proper switch status.
6. This step tests for shorts in the OEM wiring harness.
7. This step tests for shorts in the internal wiring harness.
8. This step tests the PSM switch function.

DTC P0872 (Previously P1711) Trans Pressure Switch Solenoid E


Circuit Stuck Closed
Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Perform the A/T Fluid Checking Procedure — Go to Step 3 Go to A/T Fluid
(Appendix P). Checking
Did you perform the procedure and correct fluid Procedure
level if necessary? (Appendix P)
3 Perform the Main Pressure Check Procedure Refer to Main Go to Step 4 Go to General
(Appendix B). Pressure Table Troubleshooting
Is main pressure within the specified values? (Pages 5–8 (Section 7)
and 5–9)
4 1. Install the Scan Tool. — Go to Step 5 Go to Diagnostic
2. Turn ON the ignition, with the engine OFF. Aids
3. Record the failure records.
4. Clear the DTC.
5. Start the vehicle and perform a test drive.
Attempt to duplicate the same operating
conditions observed in failure records (range
attained, transmission temperature, etc.).
NOTE: This DTC may indicate a stuck shift
valve, solenoid mechanically failed, a short
to ground in the switch circuit, or a defective
PSM.
Did DTC P0872 return?
5 1. Turn the ignition OFF. — Go to Step 6 Go to Step 15
2. Disconnect J2 connector from the TCM and
install J 39700 Breakout Box and J 43799
Breakout Box Adapter.
3. Connect J2 connector pin 3 to a known good
ground.
4. Turn the ignition ON.
Does the Scan Tool indicate pressure switch E
status as ON when grounded and OFF when
circuit is open?

5–202 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0872 (Previously P1711) Trans Pressure Switch Solenoid E
Circuit Stuck Closed (cont’d)
Step Action Value(s) Yes No
6 1. Turn the ignition OFF and reconnect J2 — Go to Step 7 Go to Step 14
connector to the TCM.
2. Disconnect the transmission wiring harness
from the main transmission connector at the
back of the transmission.
3. Turn the ignition ON.
4. Connect wire 203 (pin E) at the main
transmission connector to a known good
ground.*
Does the Scan Tool indicate pressure switch E
status as ON when grounded and OFF when
circuit is open?
7 1. Remove the oil pan. Refer to Service Manual — Go to Step 8 Go to Step 13
or Mechanic’s Tips.
2. Disconnect the internal wiring harness from
the PSM and ground pin C.
Does the Scan Tool indicate pressure switch E
status as ON when grounded and OFF when
circuit is open?
8 1. Remove the PSM from the control valve body — Go to Step 9 Go to Step 12
and leave the internal harness connected.
Refer to Service Manual or Mechanic’s Tips.
2. Provide a ground connection for the PSM to
either the control valve body or the
transmission main case.
3. Use your finger or the eraser end of a pencil
to push gently on the pressure switch E
membrane.
Does the Scan Tool indicate pressure switch E
status as ON when grounded and OFF when
circuit is open?
9 Remove the control valve body and check for a — Go to Step 11 Go to Step 10
stuck or sticking E shift valve. Refer to Service
Manual or Mechanic’s Tips.
Was the E shift valve stuck or sticking?
10 Replace the E shift solenoid and reinstall the — Go to Step 16 —
control valve body. Refer to Service Manual or
Mechanic’s Tips.
Is replacement of the solenoid and reinstalling
of the control valve body complete?
11 Clean and/or polish the sticking valve to restore — Go to Step 16 —
free movement or replace the control valve
body assembly. Refer to Service Manual or
Mechanic’s Tips.
Was free movement restored or valve body
replaced?

Copyright© 2003 General Motors Corp. 5–203


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0872 (Previously P1711) Trans Pressure Switch Solenoid E
Circuit Stuck Closed (cont’d)
Step Action Value(s) Yes No
12 Replace the PSM. Refer to Service Manual or — Go to Step 16 —
Mechanic’s Tips.
Is the replacement complete?
13 Replace the internal wiring harness. Refer to — Go to Step 16 —
Service Manual or Mechanic’s Tips.
Is the replacement complete?
14 NOTE: The vehicle OEM has responsibility — Go to Step 16 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?
15 NOTE: In most cases, the TCM is not at fault. — Go to Step 16 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM.
Is the replacement complete?
16 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under conditions as Go to Step 1
noted in failure records.
3. Use the Scan Tool, in the test passed
section, to confirm the diagnostic test was
run.
Did the DTC return?
* If J 39700 and J 44722 are available, they may be used to perform this operation.

5–204 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0873 (Previously P1712) Transmission Pressure Switch Solenoid E Circuit High

TRANSMISSION
HARNESS J2 HARNESS CONNECTOR
CONNECTOR (RED)
K J2-3 J2-2
D J2-4 J2-1

TCM
F
E

TRANSMISSION
BULKHEAD
CONNECTOR
K
D
J2

J1

F
E
NOTE: Letters I, O, and Q are not used.

TCM
201
C A D J2-1
202
D B F J2-2 DIGITAL
TRANSMISSION
203 INTERFACE
E C E J2-3
204
R D K J2-4

E
F
NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH
MANIFOLD
R E D
C
F E D C B A

V06213.01.00

Circuit Description
The Pressure Switch Manifold (PSM) is a multiple-switch assembly made up of three normally open (N/O) and one
normally closed (N/C) pressure switches. The E pressure switch monitors E shift valve positioning and relays it to
the TCM. When E pressure switch is in the open state, E shift valve should be in the destroked position.
Conditions for Running the DTC
• Components are powered and the ignition voltage is greater than 5V.
• DTC P0561, P0562, or P0563 is not active.
• E shift valve is commanded to the ON (stroked) position.
• Transmission temperature is above –25°C (–13°F).
• Vehicle shutdown is not in process.

Copyright© 2003 General Motors Corp. 5–205


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Conditions for Setting the DTC
DTC P0873 sets during steady state operation when E shift valve is in the stroked state (commanded ON) and E
pressure switch status is detected as destroked (commanded OFF). Steady state is defined as attaining a valid
range. The intent of this code is to detect an open condition in the pressure switch wiring circuit or the pressure
switch.
Later software levels incorporate retry logic that allows the TCM to command E solenoid OFF and ON. If the
pressure switch state does not change, and remains in the OFF state, DTCs P0873 and P0871 will set.

Action Taken When the DTC Sets


• When DTC P0873 is active, the following conditions will occur:
— If the failure occurs while in a forward range, the transmission shifts to another forward range.
— If the shift selector is moved to N (Neutral), the transmission will shift to neutral.
— if the shift selector is moved to R (Reverse), the transmission shifts to reverse.
— If the shift selector is moved to a forward range or reverse and the transmission is compromised by
overspeeding or direction change, the transmission shifts to neutral.
• DTC P0873 is stored in TCM history.
• The CHECK TRANS light illuminates.
• The TCM inhibits TCC engagement.
• The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light

A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• When only a DTC P0873 is set, look for an intermittent open condition at the pressure switch circuit or an
intermittent hydraulic failure (sticking valve). This code is set when the condition is present more than 3 times
during a current drive cycle. See Appendix A, Section B — Finding an Intermittent Fault.
• When a P0873 and P0871 are set in combination, this may indicate an open circuit condition is present at the
pressure switch circuit or the shift valve is stuck in the destroked state. See Section 4 — Beginning the
Troubleshooting Process.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change. It may be necessary to check for an open condition at individual wires within a
harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A,
Section B.
• You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc.
This data can be useful in reproducing the failure mode when the DTC was set.
• Multiple inactive pressure switch DTCs may be due to a plugged Control Main Filter. Ensure that the initial
8000 km (5,000 mile) filter change was performed.

5–206 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests for proper fluid level.
3. This step tests for proper main pressure.
4. This step tests for an active DTC.
5. This step tests the TCM for proper switch status.
6. This step tests for opens in the OEM wiring harness.
7. This step tests for opens in the internal wiring harness.
8. This step tests the PSM switch function.

DTC P0873 (Previously P1712) Transmission Pressure Switch


Solenoid E Circuit High
Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Perform the A/T Fluid Checking Procedure — Go to Step 3 Go to A/T Fluid
(Appendix P). Checking
Did you perform the procedure and correct fluid Procedure
level if necessary? (Appendix P)
3 Perform the Main Pressure Check Procedure Refer to Main Go to Step 4 Go to General
(Appendix B). Pressure Table Troubleshooting
Is main pressure within the specified values? (Pages 5–8 (Section 7)
and 5–9)
4 1. Install the Scan Tool. — Go to Step 5 Go to Diagnostic
2. Turn ON the ignition, with the engine OFF. Aids
3. Record the failure records.
4. Clear the DTC.
5. Start the vehicle and perform a test drive.
Attempt to duplicate the same operating
conditions observed in failure records (range
attained, transmission temperature, etc.).
NOTE: This DTC indicates an open circuit
condition may exist in the OEM wiring
harness, the internal transmission wiring
harness, or the PSM.
Did DTC P0873 return?

Copyright© 2003 General Motors Corp. 5–207


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0873 (Previously P1712) Transmission Pressure Switch
Solenoid E Circuit High (cont’d)
Step Action Value(s) Yes No
5 1. Turn the ignition OFF. — Go to Step 6 Go to Step 12
2. Disconnect J2 connector from the TCM and
install J 39700 Breakout Box and J 43799
Breakout Box Adapter.
3. Connect J2 connector pin 3 to a known good
ground.
4. Turn the ignition ON.
Does the Scan Tool indicate pressure switch E
status as ON when grounded and OFF when
circuit is open?
6 1. Turn the ignition OFF and reconnect J2 — Go to Step 7 Go to Step 11
connector to the TCM.
2. Disconnect the transmission wiring harness
from the main transmission connector at the
back of the transmission.
3. Turn the ignition ON.
4. Connect wire 203, pin E, on the main
transmission connector to a known good
ground.*
Does the Scan Tool indicate pressure switch E
status as ON when grounded and OFF when
circuit is open?
7 1. Remove the oil pan. Refer to Service Manual — Go to Step 8 Go to Step 10
or Mechanic’s Tips.
2. Disconnect the internal wiring harness from
the PSM and ground pin C.
Does the Scan Tool indicate pressure switch E
status as ON when grounded and OFF when
circuit is open?
8 1. Remove the PSM from the control valve body — Go to Diagnostic Go to Step 9
and leave the internal harness connected. Aids
Refer to Service Manual or Mechanic’s Tips.
2. Provide a ground connection for the PSM to
either the control valve body or the
transmission main case.
3. Use your finger or the eraser end of a pencil
to push gently on the pressure switch E
membrane.
Does the Scan Tool indicate pressure switch E
status as ON when grounded and OFF when
circuit is open?
9 Replace the PSM. Refer to Service Manual or — Go to Step 13 —
Mechanic’s Tips.
Is the replacement complete?
10 Replace the internal wiring harness. Refer to — Go to Step 13 —
Service Manual or Mechanic’s Tips.
Is the replacement complete?

5–208 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0873 (Previously P1712) Transmission Pressure Switch
Solenoid E Circuit High (cont’d)
Step Action Value(s) Yes No
11 NOTE: The vehicle OEM has responsibility — Go to Step 13 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?
12 NOTE: In most cases, the TCM is not at fault. — Go to Step 13 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM.
Is the replacement complete?
13 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under conditions noted in Go to Step 1
failure records.
3. Use the Scan Tool, in the test passed
section, to confirm the diagnostic test was
run.
Did the DTC return?
* If J 39700 and J 44722 are available, they may be used to perform this operation.

Copyright© 2003 General Motors Corp. 5–209


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0875 (Previously P1713) Transmission Reverse Pressure Switch
Circuit Malfunction
TRANSMISSION
HARNESS J2 HARNESS CONNECTOR
CONNECTOR (RED)
K J2-3 J2-2
D J2-4 J2-1

TCM
F
E

TRANSMISSION
BULKHEAD
CONNECTOR
K
D
J2

J1

F
E
NOTE: Letters I, O, and Q are not used.

TCM
201
C A D J2-1
202
D B F J2-2 DIGITAL
TRANSMISSION
203 INTERFACE
E C E J2-3
204
R D K J2-4

E
F
NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH
MANIFOLD
R E D
C
F E D C B A

V06213.01.00

Circuit Description
The Pressure Switch Manifold (PSM) is a multiple switch assembly made up of three normally open (N/O) and one
normally closed (N/C) pressure switches. Fluid pressure is supplied to the reverse pressure switch, holding it open,
when the manual selector valve is in any position except reverse. When the manual selector valve is moved to
Reverse, pressure to the reverse pressure switch is cut off, allowing the switch to close.
Conditions for Running the DTC
• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
• TFT is greater than 0°C (32°F).
• The hydraulic system is pressurized.
• DTC P0708 is not active.

5–210 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Conditions for Setting the DTC
DTC P0875 sets when P (Park), N (Neutral), or a forward range is selected and the reverse pressure switch state
remains in the mechanically closed/electrically ON position for a period of time that is calibration dependent.

Action Taken When the DTC Sets


• When DTC P0875 is active, the following conditions will occur:
— Calibration Dependent — The transmission will either lock-to-neutral or shift to 3rd or 5th range.
— If the shift selector is moved to N (Neutral), the transmission will shift to neutral.
— if the shift selector is moved to R (Reverse), the transmission shifts to reverse.
— If the shift selector is moved to a forward range or reverse and the transmission is compromised by
overspeeding or direction change, the transmission shifts to neutral. If an output speed fault or NSBU fault
is present when this test fails, then hydraulic default is implemented.
• DTC P0875 is stored in TCM history.
• The CHECK TRANS light illuminates on the second occurrence.
• The TCM freezes shift adapts (DNA).
• The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change. It may be necessary to check for shorting to ground at individual wires within a
harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A,
Section B.
• You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc.
This data can be useful in reproducing the failure mode when the DTC was set.
• This DTC could indicate a hydraulic leak path exhausting pressure from the reverse pressure switch (refer to
hydraulic schematic).
• Multiple inactive pressure switch DTCs may be due to a plugged Control Main Filter. Ensure that the initial
8000 km (5,000 mile) filter change was performed. To help reduce multiple pressure switch DTCs from setting
due to a plugged control main filter or slow pump prime, later software levels have a time delay up to
30 seconds before a pressure switch test is enabled.
• If a P0875 (previously P1713) is shown in failure records as being logged first on the failure list followed by
P0872 (previously P1711) combined with P0708, this generally indicates a NSBU internal switch failure. Often
when the codes are cleared they do not return. This may be due to moisture that was present at the time the
code was logged, causing an internal short. Inspect the NSBU switch linkage for proper adjustment and for
signs of damage. If the shift linkage is properly adjusted and no damage is noted, replacement of the switch
may be indicated.

Copyright© 2003 General Motors Corp. 5–211


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Test Description
The numbers below refer to the step numbers on the diagnostic table.

2. This step tests for proper fluid level.


3. This step tests for proper main pressure.
4. This step tests for an active DTC.
5. This step tests the TCM for proper switch status.
6. This step tests for shorts in the OEM wiring harness.
7. This step tests for shorts in the internal wiring harness.
8. This step tests the PSM switch function.
DTC P0875 (Previously P1713) Reverse Pressure Switch Circuit Malfunction
Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Perform the A/T Fluid Checking Procedure — Go to Step 3 Go to A/T Fluid
(Appendix P). Checking
Did you perform the procedure and correct fluid Procedure
level if necessary? (Appendix P)
3 Perform the Main Pressure Check Procedure Refer to Main Go to Step 4 Go to General
(Appendix B). Pressure Table Troubleshooting
Is main pressure within the specified values? (Pages 5–8 (Section 7)
and 5–9)
4 1. Install the Scan Tool. — Go to Step 5 Go to Diagnostic
2. Turn ON the ignition, with the engine OFF. Aids
3. Record the failure records.
4. Clear the DTC.
5. Start the vehicle and perform a test drive.
Attempt to duplicate the same operating
conditions observed in failure records (range
attained, transmission temperature, etc.).
NOTE: This DTC is set when P (Park),
N (Neutral), or a forward range has been
selected and the reverse pressure switch
indicates mechanically closed/electrically
ON for a period of time that is calibration
dependent. This DTC may indicate that a
short circuit condition exists in the OEM
harness, internal transmission harness or
the PSM. A defective NSBU switch may also
set this code. The intent of this DTC is to
detect discrepancies between range
selected at the NSBU and the actual
position of the manual selector valve.
Did DTC P0875 return?

5–212 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0875 (Previously P1713) Reverse Pressure Switch Circuit Malfunction (cont’d)
Step Action Value(s) Yes No
5 1. Turn the ignition OFF. — Go to Step 6 Go to Step 13
2. Remove the J2 connector from the TCM and
install J 39700 Breakout Box and J 43799
Breakout Box Adapter. Leave the vehicle
harness disconnected from the J 43799
Breakout Box Adapter.
3. Connect J2 connector pin 4 on the Breakout
Box panel to a known good ground.
4. Turn the ignition ON.
Does the Scan Tool indicate reverse pressure
switch status as ON when grounded and OFF
when circuit is open?
6 1. Turn the ignition OFF and reconnect the J2 — Go to Step 7 Go to Step 12
connector to the TCM.
2. Disconnect the transmission wiring harness
from the main transmission connector at the
back of the transmission.
3. Connect wire 204 (pin K) at the main
transmission connector to a known good
ground.*
4. Turn the ignition ON.
Does the Scan Tool indicate reverse pressure
switch status as ON when grounded and OFF
when circuit is open?
7 1. Remove the oil pan. Refer to Service Manual — Go to Step 8 Go to Step 11
or Mechanic’s Tips.
2. Disconnect the internal wiring harness from
the PSM and ground pin D.
Does the Scan Tool indicate reverse pressure
switch status as ON when grounded and OFF
when circuit is open?
8 1. Remove the PSM from the control valve body — Go to Step 10 Go to Step 9
and leave the internal harness connected.
Refer to Service Manual or Mechanic’s Tips.
2. Provide a ground connection for the PSM to
either the control valve body or the
transmission main case.
3. Use your finger or the eraser end of a pencil
to push gently on the reverse pressure switch
membrane.
Does the Scan Tool indicate reverse pressure
switch status as ON when grounded and OFF
when circuit is open?
9 Replace the PSM. Refer to Service Manual or — Go to Step 14 —
Mechanic’s Tips.
Is the replacement complete?

Copyright© 2003 General Motors Corp. 5–213


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0875 (Previously P1713) Reverse Pressure Switch Circuit Malfunction (cont’d)
Step Action Value(s) Yes No
10 1. Inspect for a missing or a damaged seal at — Go to Step 14 Go to Diagnostic
the reverse pressure switch assembly. Aids
2. Inspect for loose reverse transfer tube.
3. Inspect for proper shift linkage adjustment.
Shift linkage out of adjustment can allow
pressure to apply the reverse pressure
switch.
Did you find and repair a problem?
11 Replace the internal wiring harness. Refer to — Go to Step 14 —
Service Manual or Mechanic’s Tips.
Is the replacement complete?
12 NOTE: The vehicle OEM has responsibility — Go to Step 14 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?
13 NOTE: In most cases, the TCM is not at fault. — Go to Step 14 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM.
Is the replacement complete?
14 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under conditions noted in Go to Step 1
failure records.
3. Use the Scan Tool, in the test passed
section, to confirm the diagnostic test was
run.
Did the DTC return?
* If J 39700 and J 44722 are available, they may be used to perform this operation.

5–214 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0876 (Previously P1714) Transmission Reverse Pressure Switch Circuit Stuck Open

TRANSMISSION
HARNESS J2 HARNESS CONNECTOR
CONNECTOR (RED)
K J2-3 J2-2
D J2-4 J2-1

TCM
F
E

TRANSMISSION
BULKHEAD
CONNECTOR
K
D
J2

J1

F
E
NOTE: Letters I, O, and Q are not used.

TCM
201
C A D J2-1
202
D B F J2-2 DIGITAL
TRANSMISSION
203 INTERFACE
E C E J2-3
204
R D K J2-4

E
F
NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH
MANIFOLD
R E D
C
F E D C B A

V06213.01.00

Circuit Description
The Pressure Switch Manifold (PSM) is a multiple switch assembly made up of three normally open (N/O) and one
normally closed (N/C) pressure switches. Fluid pressure is supplied to the reverse pressure switch, holding it open,
when the manual selector valve is in any position except reverse. When the manual selector valve is moved to
Reverse, pressure to the reverse pressure switch is cut off allowing the switch to close.
Conditions for Running the DTC
• TFT is greater than 0°C (32°F).
• DTC P0706, P0708, or P0875 is not active.
• There are two cases where this DTC runs.
— Case 1 Ignition voltage is above 9V (12V TCM) or 18V (24V TCM). The PRNDL state and the reverse
pressure switch state do not agree.
— Case 2 Ignition voltage is under 9V (12V TCM) or 18V (24V TCM). All speed sensors are under 50 rpm.

Copyright© 2003 General Motors Corp. 5–215


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Conditions for Setting the DTC
DTC P0876 sets in two cases:
• When PRNDL and reverse pressure switch do not agree. When reverse range is selected and the reverse
pressure switch is detected in the mechanically open/electrically OFF state for more than 1 second.
• When engine shutdown and reverse pressure switch do not agree. When engine shutdown is in process and
the reverse pressure switch is detected in an improper state, mechanically open/electrically OFF, for more than
a period of time that is temperature dependent. The time period is 5 seconds at 35°C (95°F) to 30 seconds at
–20°C (–4°F).

Action Taken When the DTC Sets


• When DTC P0876 is active, the following conditions will occur:
— Calibration Dependent — The transmission will either lock-to-neutral or shift to 3rd or 5th range.
— If the shift selector is moved to N (Neutral), the transmission will shift to neutral.
— if the shift selector is moved to R (Reverse), the transmission shifts to reverse.
— If the shift selector is moved to a forward range or reverse and the transmission is compromised by
overspeeding or direction change, the transmission shifts to neutral. If an output speed fault or NSBU fault
is present when this test fails, then hydraulic default is implemented.
• DTC P0876 is stored in TCM history.
• The CHECK TRANS light illuminates on the second occurrence.
• The TCM freezes shift adapts (DNA).
• The TCM inhibits TCC engagement

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change. It may be necessary to check for shorting to ground at individual wires within a
harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A,
Section B.
• You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc.
This data can be useful in reproducing the failure mode when the DTC was set.
• Multiple inactive pressure switch DTCs may be due to a plugged Control Main Filter. Ensure that the initial
8000 km (5,000 mile) filter change was performed. To help reduce multiple pressure switch DTCs from setting
due to a plugged control main filter or slow pump prime, later software levels have a time delay up to
30 seconds before a pressure switch test is enabled.

5–216 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Test Description
The numbers below refer to the step numbers on the diagnostic table.

2. This step tests for proper fluid level.


3. This step tests for proper main pressure.
4. This step tests for an active DTC.
5. This step tests the TCM for proper switch status.
6. This step tests for an open condition in the OEM wiring harness.
7. This step tests for an open condition in the internal wiring harness.
8. This step tests the PSM switch function.

DTC P0876 (Previously P1714) Reverse Pressure Switch Circuit Stuck Open
Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–
4A)
2 Perform the A/T Fluid Checking Procedure — Go to Step 3 Go to A/T Fluid
(Appendix P). Checking
Did you perform the procedure and correct fluid Procedure
level if necessary? (Appendix P)
3 Perform the Main Pressure Check Procedure Refer to Main Go to Step 4 Go to General
(Appendix B). Pressure Table Troubleshooting
Is main pressure within the specified values? (Pages 5–8 (Section 7)
and 5–9)
4 1. Install the Scan Tool. — Go to Step 5 Go to Diagnostic
2. Turn ON the ignition, with the engine OFF. Aids
3. Record the failure records.
4. Clear the DTC.
5. Start the vehicle and perform a test drive.
Attempt to duplicate the same operating
conditions observed in failure records (range
attained, transmission temperature, etc.).
NOTE: This DTC is set when reverse range
is selected and reverse switch status
remains in the mechanically open/
electrically OFF state for more than a time
that is calibration dependent. This DTC can
also set at engine shutdown when the
reverse pressure switch is detected in the
mechanically open/electrically OFF state for
a period of time that is temperature
dependent. The time period is 5 seconds at
35°C (95°F) to 30 seconds at –20°C (–4°F).
Did DTC P0876 return?

Copyright© 2003 General Motors Corp. 5–217


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0876 (Previously P1714) Reverse Pressure Switch Circuit Stuck Open (cont’d)
Step Action Value(s) Yes No
5 1. Turn the ignition OFF. — Go to Step 6 Go to Step 13
2. Remove the J2 connector from the TCM and
install J 39700 Breakout Box and J 43799
Breakout Box Adapter. Leave the vehicle
wiring harness disconnected from the
J 43799 Breakout Box Adapter.
3. Connect J2 connector pin 4 on the Breakout
Box panel to a known good ground.
4. Turn the ignition ON.
Does the Scan Tool indicate reverse pressure
switch status as ON when grounded and OFF
when circuit is open?
6 1. Turn the ignition OFF and reconnect the J2 — Go to Step 7 Go to Step 12
connector to the TCM.
2. Disconnect the transmission wiring harness
from the main transmission connector at the
back of the transmission.
3. Connect wire 204 (pin K) at the main
transmission connector to a known good
ground.*
4. Turn the ignition ON.
Does the Scan Tool indicate reverse pressure
switch status as ON when grounded and OFF
when circuit is open?
7 1. Remove the oil pan. Refer to Service Manual — Go to Step 8 Go to Step 11
or Mechanic’s Tips.
2. Disconnect the internal wiring harness from
the PSM and ground pin D.
Does the Scan Tool indicate reverse pressure
switch status as ON when grounded and OFF
when circuit is open?
8 1. Remove the PSM from the control valve body — Go to Step 10 Go to Step 9
and leave the internal harness connected.
Refer to Service Manual or Mechanic’s Tips.
2. Provide a ground connection for the PSM to
either the control valve body or the
transmission main case.
3. Use your finger or the eraser end of a pencil
to push gently on the reverse pressure switch
membrane.
Does the Scan Tool indicate reverse pressure
switch status as ON when grounded and OFF
when circuit is open?
9 Replace the PSM. Refer to Service Manual or — Go to Step 14 —
Mechanic’s Tips.
Is the replacement complete?

5–218 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0876 (Previously P1714) Reverse Pressure Switch Circuit Stuck Open (cont’d)
Step Action Value(s) Yes No
10 1. Inspect for a missing or a damaged seal at — Go to Step 14 Go to Diagnostic
the reverse pressure switch assembly. Aids
2. Inspect for loose reverse transfer tube.
3. Inspect for proper shift linkage adjustment.
Shift linkage out of adjustment can allow
pressure to apply the reverse pressure
switch.
Did you find and repair a problem?
11 Replace the internal wiring harness. Refer to — Go to Step 14 —
Service Manual or Mechanic’s Tips.
Is the replacement complete?
12 NOTE: The vehicle OEM has responsibility — Go to Step 14 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?
13 NOTE: In most cases, the TCM is not at fault. — Go to Step 14 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM.
Is the replacement complete?
14 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under conditions noted in Go to Step 1
failure records.
3. Use the Scan Tool, in the test passed
section, to confirm the diagnostic test was
run.
Did the DTC return?
* If J 39700 and J 44722 are available, they may be used to perform this operation.

Copyright© 2003 General Motors Corp. 5–219


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0880 (Previously P1760) TCM Supply Voltage

J1 HARNESS CONNECTOR TCM


(GRAY)
J1-4
J1-5 J1-3
J1-2
J1-1

J2

J1

102
J1-2

104 IGNITION
J1-4
POWER
10a 103 BATTERY
J1-3 POWER TCM
10a 101
J1-1 GND
IGN 105
SWITCH J1-5 GND

+ —
12V/24V
BATTERY
V06215.01.00

Circuit Description
DTC P0880 sets if an abnormal power-down sequence has occurred. This condition means the Transmission
Control Module (TCM) has lost supply voltage (wire 103) before it has finished saving information from that drive
cycle. This process is usually completed in less than 10 seconds.

Conditions for Running the DTC


• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• Loss of TCM supply voltage before drive cycle data is saved.

Conditions for Setting the DTC


DTC P0880 sets during the next ignition cycle if the TCM loses TCM supply voltage less than 10 seconds after the
ignition voltage has been turned off.

Action Taken When the DTC Sets


• DTC P0880 is stored in the TCM history.
• The TCM loses adaptive information for the drive cycle.
• The TCM reverts to previous adaptive settings.

5–220 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Conditions for Clearing the DTC/CHECK TRANS Light
A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
• You may have to drive the vehicle in order to experience a fault.

Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests the system voltage.
4. This step tests the vehicle charging system.
5. This step tests the external wiring harness for shorts or opens.

DTC P0880 (Previously P1760) TCM Supply Voltage


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. 10.5V Go to Step 4 Resolve battery
2. Turn the ignition to the RUN position with the (12V TCM); problem
engine OFF. 22V
3. Record the DTC Failure Record data. (24V TCM)
NOTE: If other DTCs are present refer to the
applicable diagnostic tables before
continuing.
4. Using a DVOM, measure and record voltage
at the battery terminals.
Is voltage greater than the specified value?
3 Start the engine and warm to normal operating — Repair charging Go to Step 4
temperature. system
Is the Alternator/Check Engine lamp ON?
4 1. Increase the engine speed to 13–15V Go to Step 5 Repair charging
1000–1500 rpm. (12V TCM); system
2. Using the Scan Tool, monitor system voltage. 25–30V
Is voltage within the specified value? (24V TCM)

Copyright© 2003 General Motors Corp. 5–221


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P0880 (Previously P1760) TCM Supply Voltage (cont’d)
Step Action Value(s) Yes No
5 1. Turn the ignition OFF. 0.5V Go to Step 6 Go to Step 7
2. Disconnect J1 connector from the TCM and
install J 39700 Breakout Box and J 43799
Breakout Box Adapter.
3. Using a DVOM, measure voltage at
connector J1 pins 1 and 2 with the ignition
ON and J1 connector pins 1 and 3 with the
ignition OFF.
4. Compare the battery voltage to the wire
voltage.
Is the voltage difference greater than the
specified value?
6 NOTE: The vehicle OEM has responsibility — Go to Step 8 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?
7 NOTE: In most cases, the TCM is not at fault. — Go to Step 8 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM.
Is the replacement complete?
8 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Start the engine and warm to normal Go to Step 1
operating temperature.
3. Using the Scan Tool, monitor system voltage.
System voltage should be 9–18V for a
12V TCM or 18–32V for a 24V TCM.
Did the DTC return?

5–222 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P1688 Unmanaged Engine Torque Delivered To TCM Signal

TCM
J1 HARNESS CONNECTOR
(GRAY)
J1-16 J1-09

J2

J1-22 J1

TCM
109
J1-09
ENGINE
CONTROL 116
J1-16 DIGITAL
MODULE INTERFACE
(ECM) 122
J1-22

V06538.01.00

Circuit Description
The GM 8.1 liter gasoline engine is used in some medium duty applications. The 8.1 liter engine uses a 3-wire
system to communicate engine torque data/requests between the powertrain control module (PCM) and the
transmission control module (TCM).

Unmanaged engine torque is sent from the PCM to the TCM over wire 109 (GM wire 2467).

Conditions for Running the DTC


• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM).
• Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
• Pulse Width Modulation (PWM) driver demand torque option is selected in transmission calibration.

Conditions for Setting the DTC


DTC P1688 sets if unmanaged (gross) engine torque signal (circuit 2467) is under 1.5 percent or over 98.5 percent
for more than a 2 second period.

Actions Taken When the DTC Sets


• DTC P1688 is stored in the TCM history.
• The CHECK TRANS light illuminates on the second occurrence.
• The TCM defaults to a calculated unmanaged torque (gross) input value using throttle and engine speed.

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Copyright© 2003 General Motors Corp. 5–223


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Diagnostic Aids
An Intermittent condition may be the cause of the problem. Return the vehicle to the OEM for further
troubleshooting.

DTC P1688 Engine Torque Unmanaged Delivered To TCM Signal


Step Action Yes No
1 Was the Beginning The Troubleshooting Process Go to Step 2 Go to Beginning The
(Paragraph 5–4A) performed? Troubleshooting
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. Go to Step 3 Go to
2. Start the engine. Diagnostic Aids
3. Record DTC failure records.
4. Clear the DTC and drive the vehicle. Attempt to
duplicate the same operating conditions observed in
failure records.
NOTE: This DTC indicates that the unmanaged engine
torque signal sent from the engine PCM to the
transmission TCM is either under or over a set
percentage value for a set period of time.
Did DTC P1688 return?
3 Inspect the routing of wire 109 (GM wire circuit 2467) Go to Step 4 Go to Step 5
between the TCM and PCM.
Was chafing or wire damage found?
4 NOTE: The vehicle OEM has responsibility for all Go to Step 6 —
external wiring harness repair. Harness repairs
performed by ATD distributors and dealers are not
covered by ATD warranty.
Repair or replace the vehicle wiring harness.
Is the repair complete?
5 Return the vehicle to the OEM to troubleshoot for cause of Go to Step 6 —
low or high torque signal. Below are some possible causes
for this DTC.
• Defective engine PCM.
• Circuit fault at wire 109.
• Improper calibration for engine PCM.
Was problem found and repaired?
6 In order to verify your repair: Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under conditions noted in failure Go to Step 1
records.
3. Use the Scan Tool, in the test passed section, to confirm
the diagnostic test was run.
Did the DTC return?

5–224 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P1779 Engine Torque Delivered To TCM Signal

TCM
J1 HARNESS CONNECTOR
(GRAY)
J1-16 J1-09

J2

J1-22 J1

TCM
109
J1-09
ENGINE
CONTROL 116
J1-16 DIGITAL
MODULE INTERFACE
(ECM) 122
J1-22

V06538.01.00

Circuit Description

The GM 8.1 liter gasoline engine is used in some medium duty applications. The 8.1 liter engine uses a 3-wire
system to communicate engine torque data/requests between the powertrain control module (PCM) and the
transmission control module (TCM).
Managed engine torque is sent from the PCM to the TCM over wire 116 (GM wire 464).

Conditions for Running the DTC


• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM).
• Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
• Pulse Width Modulation (PWM) driver demand torque option is selected in transmission calibration.
• No DTC is active at the time of this test.

Conditions for Setting the DTC


DTC P1779 sets if managed engine torque (net) signal (circuit 464) is under 1.5 percent or over 98.5 percent for
more than a 2 second period.

Actions Taken When the DTC Sets


• DTC P1779 is stored in the TCM history.
• The CHECK TRANS light illuminates on the second occurrence.
• The TCM defaults to a calculated managed torque (net) input value using throttle and engine speed.
• The TCM defaults to a calculated unmanaged torque (gross) input value using throttle and engine speed.

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Copyright© 2003 General Motors Corp. 5–225


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Diagnostic Aids
An Intermittent condition may be the cause of the problem. Return the vehicle to the OEM for further
troubleshooting.
.

DTC P1779 Engine Torque Delivered To TCM Signal


Step Action Yes No
1 Was the Beginning The Troubleshooting Process Go to Step 2 Go to Beginning The
(Paragraph 5–4A) performed? Troubleshooting
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. Go to Step 3 Go to
2. Start the engine. Diagnostic Aids
3. Record DTC failure records.
4. Clear the DTC and drive the vehicle. Attempt to
duplicate the same operating conditions observed in
failure records.
NOTE: This DTC indicates that the managed engine
torque signal sent from the engine PCM to the
transmission TCM is either under or over a set
percentage value for a set period of time.
Did DTC P1779 return?
3 Inspect the routing of wire 109 (GM wire circuit 2467) Go to Step 4 Go to Step 5
between the TCM and PCM.
Was chafing or wire damage found?
4 NOTE: The vehicle OEM has responsibility for all Go to Step 6 —
external wiring harness repair. Harness repairs
performed by ATD distributors and dealers are not
covered by ATD warranty.
Repair or replace the vehicle wiring harness.
Is the repair complete?
5 Return the vehicle to the OEM to troubleshoot for cause of Go to Step 6 —
low or high torque signal. Below are some possible causes
for this DTC.
• Defective engine PCM.
• Circuit fault at wire 116.
• Improper calibration for engine PCM.
Was problem found and repaired?
6 In order to verify your repair: Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under conditions noted in failure Go to Step 1
records.
3. Use the Scan Tool, in the test passed section, to confirm
the diagnostic test was run.
Did the DTC return?

5–226 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P1891 Throttle Position Sensor (TPS) Pulse Width Modulation (PWM)
Signal Low Input

TCM
J1 HARNESS CONNECTOR
(GRAY)
J2-16

J2

J1

TCM

PWM 116 DIGITAL


THROTTLE J1-16
INTERFACE
SOURCE

V06228.01.00

Circuit Description
The Transmission Control Module (TCM) can be calibrated to receive throttle information from a Pulse Width
Modulation (PWM) signal.

Conditions for Running the DTC


• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• The components are powered and engine speed is within a 5 rpm range for 5 seconds.

Conditions for Setting the DTC


DTC P1891 sets if the TCM is calibrated to receive the PWM signal and the throttle percentage falls below
5 percent for 5 seconds.

Action Taken When the DTC Sets


• DTC P1891 is stored in the TCM history.
• The TCM uses the default throttle value.
• The TCM freezes shift adapts (DNA).
• The TCM inhibits TCC engagement.
• MY ‘00 through ‘02 — no CHECK TRANS light. MY ‘03 CHECK TRANS light is illuminated.

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Copyright© 2003 General Motors Corp. 5–227


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Diagnostic Aids
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:

— A bent terminal.

— A backed-out terminal.

— A damaged terminal.

— Poor terminal tension.

— A chafed wire.

— A broken wire inside the insulation.


• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
• You may have to drive the vehicle in order to experience a fault.

Test Description

The numbers below refer to the step numbers on the diagnostic table.

2. This step tests the system voltage.

3. This step tests the PWM signal.

4. This step tests for shorts or opens at wire 116.

DTC P1891 Throttle Position Sensor (TPS) Pulse Width Modulation (PWM)
Signal Low Input
Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. 9–18V Go to Step 3 Resolve
2. Start the engine. (12V TCM); voltage problem
3. Record the DTC Failure Record data. 18–32V (Refer to
4. Using the Scan Tool, measure ignition (24V TCM) DTC P0562
voltage. and P0563)
Is voltage within the specified value?
3 1. Install the Scan Tool. — Go to Step 4 —
2. Turn the ignition to the RUN position with the
engine OFF.
3. Record the DTC Failure Record data.
4. Verify that the throttle source is functioning
correctly.
Is PWM signal OK?
4 Check wire 116 for shorts or opens. — Go to Step 5 Go to Step 6
Did you find a problem?

5–228 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P1891 Throttle Position Sensor (TPS) Pulse Width Modulation (PWM)
Signal Low Input (cont’d)
Step Action Value(s) Yes No
5 NOTE: The vehicle OEM has responsibility — Go to Step 9 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?
6 Inspect the TCM and Engine Control Module — Go to Step 7 Go to Step 8
(ECM) connectors and terminals for damage
and/or corrosion.
Did you find a problem?
7 Repair and clean terminals if possible. — Go to Step 9 Go to Step 8
Is the repair complete?
8 NOTE: In most cases, the TCM is not at fault. — Go to Step 9 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM, if necessary.
Is the replacement complete?
9 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under normal operating Go to Step 1
conditions.
3. Using the Scan Tool, monitor throttle position
and engine coolant temperature.
Did the DTC return?

Copyright© 2003 General Motors Corp. 5–229


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P1892 Throttle Position Sensor (TPS) Pulse Width Modulation (PWM)
Signal High Input

TCM
J1 HARNESS CONNECTOR
(GRAY)
J2-16

J2

J1

TCM

PWM 116 DIGITAL


THROTTLE J1-16
INTERFACE
SOURCE

V06228.01.00

Circuit Description
The Transmission Control Module (TCM) can be calibrated to receive throttle information from a Pulse Width
Modulation (PWM) signal.

Conditions for Running the DTC


• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.

Conditions for Setting the DTC


DTC P1892 sets if the TCM is calibrated to receive the PWM signal and the throttle percentage exceeds 95 percent
for 5 seconds.

Action Taken When the DTC Sets


• DTC P1892 is stored in the TCM history.
• The TCM uses the default throttle value.
• The TCM freezes shift adapts (DNA).
• The TCM inhibits TCC engagement.
• MY ‘00 through ‘02 — no CHECK TRANS light. MY ‘03 CHECK TRANS light is illuminated.

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

5–230 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Diagnostic Aids

• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:

— A bent terminal.

— A backed-out terminal.

— A damaged terminal.

— Poor terminal tension.

— A chafed wire.

— A broken wire inside the insulation.


• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
• You may have to drive the vehicle in order to experience a fault.

Test Description

The numbers below refer to the step numbers on the diagnostic table.

2. This step tests the system voltage.

3. This step tests the PWM signal.

4. This step tests for shorts or opens at wire 116.

DTC P1892 Throttle Position Sensor (TPS) Pulse Width Modulation (PWM)
Signal High Input
Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. 9–18V Go to Step 3 Resolve
2. Start the engine. (12V TCM); voltage problem
3. Record the DTC Failure Record data. 18–32V (Refer to
4. Using the Scan Tool, measure ignition (24V TCM) DTC P0562
voltage. and P0563)
Is voltage within the specified value?
3 1. Install the Scan Tool. — Go to Step 4 —
2. Turn the ignition to the RUN position with the
engine OFF.
3. Record the DTC Failure Record data.
4. Verify that the throttle source is functioning
correctly.
Is the PWM signal OK?
4 Check wire 116 for shorts or opens. — Go to Step 5 Go to Step 6
Did you find a problem?

Copyright© 2003 General Motors Corp. 5–231


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P1892 Throttle Position Sensor (TPS) Pulse Width Modulation (PWM)
Signal High Input
Step Action Value(s) Yes No
5 NOTE: The vehicle OEM has responsibility — Go to Step 9 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?
6 Inspect the TCM and Engine Control Module — Go to Step 7 Go to Step 8
(ECM) connectors and terminals for damage
and/or corrosion.
Did you find a problem?
7 Repair and clean terminals if possible. — Go to Step 9 Go to Step 8
Is the repair complete?
8 NOTE: In most cases, the TCM is not at fault. — Go to Step 9 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM, if necessary.
Is the replacement complete?
9 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under normal operating Go to Step 1
conditions.
3. Using the Scan Tool, monitor throttle position
and engine coolant temperature.
Did the DTC return?

5–232 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P2771 (Previously P0836, P1875) Four-Wheel Drive Switch Circuit
(

TCM
J1 HARNESS CONNECTOR
(GRAY)
J1-10

J2

J1-28 J1

4WD Transfer Case Switch

Signal Ground Wire 128


J1-28
TCM

Input Wire 110


J1-10

V06560.01.00

Circuit Description
Detects abnormal conditions for the four-wheel drive indication switch input. Four wheel-drive statuses are
detected using speed and ratios.

Conditions for Running the DTC


• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
• DTCs P0721 and P0722 (output speed sensor circuits) are not active.
• Output speed is above 60 rpm.
• Transmission fluid temperature it between 20°C (68°F) and 130°C (266°F).
• Shift is complete and the range attained is not neutral.

Conditions for Setting the DTC


P2771 sets when one of the following conditions occurs:
• The transfer case switch indicates high range, and the calculated range is low range for 5 seconds or more.
• The transfer case switch indicates low range, and the calculated range is high range for 5 seconds or more.

Actions Taken When the DTC Sets


• DTC P2771 will be stored in the TCM memory.
• The CHECK TRANS light illuminates on the second occurrence.
• The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light


• A Scan Tool can be used to clear the code from the TCM history. The TCM automatically clears the DTC from
the TCM history if the vehicle completes 40 warm-up cycles without a failure.

Copyright© 2003 General Motors Corp. 5–233


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Diagnostics Aids
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
• You may have to drive the vehicle in order to experience a fault.
• Inspect for any transmission DTCs that may have reset.
• When testing for a short or ground, the transmission should be in a range where the switch or solenoid is in the
OFF state. When testing for an open, the transmission should be in a range where the switch or solenoid is in
the ON state.

Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests the status of the 4WD Low switch.
3. This step tests for a 4WD switch failure to ground.
4. This step tests for a short in the wiring harness.
9. This step tests for 4WD switch failure to an open state.
10. This step tests for an open in the wiring harness.

DTC P2771 Four-Wheel Drive Switch Circuit


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Section 5–4A) performed? Beginning The
Troubleshooting
Process
(Section 5–4A)
2 1. Install the Scan Tool. — Go to Go to Step 3
2. Turn the ignition to the RUN position with the Diagnostic Aids
engine OFF.
3. Record the DTC Failure Record data.
4. Using the Scan Tool, monitor 4WD low status
and select 4HI followed by 4LO with the
transfer case selector.
Does the Scan Tool indicate 4WD low status as
NO when 4HI is selected, and YES when 4LO is
selected?
3 Select 4HI followed by 4LO using the transfer — Go to Step 4 Go to Step 9
case selector.
Does the Scan Tool indicate 4WD low status as
YES for both selector positions?

5–234 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P2771 Four-Wheel Drive Switch Circuit (cont’d)
Step Action Value(s) Yes No
4 Remove the connector at the transfer case — Go to Step 5 Go to Step 7
selector.
Does the Scan Tool indicate 4WD low status as
YES?
5 Inspect wire 110 for a short to ground. — Go to Step 6 Go to Step 15
Did you find a problem?
6 Repair the short to ground in wire 110. — Go to Step 16 —
Is the repair complete (refer to OEM repair
procedures)?
7 Inspect the transfer case switch for proper — Go to Step 8 Go to Step 15
operation or a short to ground.
Did you find a problem (refer to OEM repair
procedures)?
8 Repair the short to ground in the switch? — Go to Step 16 —
Is the repair complete?
9 Select 4HI followed by 4LO using the transfer — Go to Step 10 Go to Step 15
case selector.
Does the Scan Tool indicate 4WD low status as
NO for both selector positions?
10 1. Remove the connector at the transfer case — Go to Step 11 Go to Step 13
switch.
2. Ground wire 110 to a known ground.
Does the Scan Tool indicate 4WD low status
as NO?
11 Inspect wire 110 for an open condition. — Go to Step 12 Go to Step 15
Did you find a problem?
12 Repair the open condition in wire 110. — Go to Step 16 —
Is the repair complete (refer to OEM repair
procedures)?
13 Inspect the transfer case switch for an open — Go to Step 14 Go to Step 15
condition.
Did you find a problem?
14 Repair the open condition in the switch? — Go to Step 16 —
Is the repair complete?
15 NOTE: In most cases, the TCM is not at fault. — Go to Step 16 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM.
Is the replacement complete?

Copyright© 2003 General Motors Corp. 5–235


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P2771 Four-Wheel Drive Switch Circuit (cont’d)
Step Action Value(s) Yes No
16 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under normal operating Go to Step 1.
conditions.
3. Using the Scan Tool, monitor the 4WD low
status. The 4WD low status must indicate NO
when 4WDHI is selected, and YES when
4WDLO is selected.
Did the DTC return?

5–236 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P2773 Torque Control Request Ignored — ECM/TCM

NO SCHEMATIC FOR THIS DTC


Circuit Description
Shift Energy Management (SEM) allows the Transmission Control Module (TCM) to request torque reduction from
the engine controller. By reducing torque during upshifts, shifts can be made quicker and at a more consistent
output torque. This increases clutch life by reducing clutch engagement temperatures.

Conditions for Running the DTC


• DTC U2105 CAN bus error is not active.
• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
18V and less than 32V (24V TCM).
• Engine speed is greater than 200 rpm but less than 7500 rpm for 5 seconds.
• SEM has been activated for this vehicle.

Conditions for Setting the DTC


DTC P2773 sets when the TCM detects one of the following conditions for a minimum of four upshifts (consecutive
or nonconsecutive) during one drive cycle:
• Engine ECM is not responding to torque reduction signal request from the TCM.
• A nonapproved J1939 device is interfering with the torque reduction signal request.

Action Taken When the DTC Sets


• The CHECK TRANS light illuminates.
• All 4–5 upshifts and full throttle 3–4 upshifts are inhibited.

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The DTC is cleared if, for one ignition cycle,
actual engine torque follows TCM commanded torque for 20 consecutive upshifts. To be counted as one upshift,
engine torque demand must be above 80 N·m (59 lb ft).

Diagnostic Aids
• It will be necessary to drive the vehicle with heavy to moderate throttle settings for at least four upshift cycles in
order to set a DTC P2773.
• If DTC P2773 becomes active shortly AFTER an engine update and the troubleshooting procedure for P2773
has been performed, see Resetting of TCM Parameters to Support Engine Update, Section 3–7.

Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests for the proper ECM torque request response.
3. This step tests for the device causing the torque request to be ignored.
4. This step tests for the offending device by removing it from the J1939 network.
5. This step tests for the presence of the proper engine controller software.

Copyright© 2003 General Motors Corp. 5–237


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P2773 Torque Control Request Ignored — ECM/TCM


Step Action Yes No
1 Was the Beginning The Troubleshooting Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 This code indicates that the engine controller — Go to Step 5 Go to Step 3
has disregarded the torque request sent by the
TCM. Use the Scan Tool and refer to
Transmission/Engine Torque Reduction Status.
Does the Scan Tool indicate the ECM response
to torque reduction request as incorrect?
3 Use the Scan Tool to identify an unapproved The Scan Tool Go to Step 5 Go to Step 4
torque reduction device. shows the actual
Is the unapproved device one of the following? device at fault
1. Engine
2. Null address or all /any (information not valid)
4 If the Scan Tool is indicating another device — Go to Step 6 —
such as the brakes, cruise control,
transmission, etc., inspect the controller for the
device indicated.
If possible, eliminate the device by
disconnecting it from the J1939 CAN backbone.
It may be possible that the device causing the
interruption is only triggered under certain
conditions. For example, a traction controller
may only send commands under certain road
conditions.
Since these conditions may not be easily
repeatable, replacement of the indicated
controller with a known good controller may be
the only way to verify the failure.
Was the device causing the problem replaced
or repaired?
5 Verify that compatible engine controller — Go to Step 6 —
software is utilized. If the software is correct,
replace the engine controller. If neither solves
the problem, use a lower engine torque/power
rating.
Was the software updated or engine controller
replaced?
6 In order to verify your repair: — Begin the System OK
1. Connect the Scan Tool. diagnosis again.
2. Clear the DTC. Go to Step 1
3. Drive the vehicle under heavy to moderate
throttle settings for at least four upshift
cycles.
Did the DTC return?

5–238 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC P2810 Solenoid G Electrical

TRANSMISSION J2 HARNESS CONNECTOR


HARNESS (RED)
CONNECTOR
S J
R

J2-32
J2-30 TCM
TRANSMISSION J2-29
BULKHEAD
CONNECTOR
S
J R

J2

J1
NOTE: Letters I, O, and Q are not used.

TCM
229
J J2-29
SOL F
(PWM) TRANSMISSION R
230
J2-30
LOCKUP SOL G
232 12V
S J2-32

NOTE: Wire 232 is a 12V DC ignition power source for TCC solenoids F and G.
V08119.00.00

Circuit Description
Solenoid G is a normally closed (N/C) solenoid used to modulate the transmission main pressure schedule. The
TCM commands the G solenoid ON when specific transmission and engine conditions are met. When G solenoid is
applied, pressure is routed to the main regulator valve. This in turn reduces the main pressure schedule and
improves the volume of oil sent through the overage circuit. By modulating main pressure, cooler flow can be
increased, allowing improved cooling and reduced pump noise.

Conditions for Running the DTC


• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
• The TCM must autodetect G solenoid for this test to run.

Conditions for Setting the DTC

DTC P2810 is set when the TCM detects an open circuit, short to ground or short to power at G solenoid circuit for
more than 2 seconds.

Copyright© 2003 General Motors Corp. 5–239


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DIAGNOSTIC TROUBLE CODES (DTC)


Action Taken When the DTC Sets

When DTC P2810 is active, the following conditions will occur:

• DTC P2810 is stored in TCM history.


• The CHECK TRANS light illuminates.

Conditions for Clearing the DTC/CHECK TRANS Light


A scan tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without failure.

Diagnostic Aids
• When this code is set there will be a noticeable reduction of engine performance.
• An intermittent circuit condition may allow this DTC to set. Make sure you check for the following conditions at
the OEM harness first and then at the transmission internal harness.
• Inspect the wiring for poor electrical connections at the TCM connector and the transmission main connector.
Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
— Inspect OEM wiring harness routing, looking for possible contact points where chafing could occur. Moving
parts on the vehicle could be contacting the harness. Check for contact at the parking brake drum, suspen-
sion components, transmission shift linkage etc.
— Inspect the internal transmission wiring harness for possible contact areas where chafing may occur.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change. It may be necessary to check for shorting to ground at individual wires within a
harness to isolate an intermittent condition. Refer to Section 4—Wire Check Procedures.
• You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc.
This data can be useful in reproducing the failure mode where DTC was set.
• If the DTC appears to be temperature related, suspect a defective G solenoid. It is possible for a solenoid to be
temperature sensitive causing resistance values to fluctuate. This may cause an intermittent DTC to be set.

Test Description
The numbers below refer to the step numbers on the diagnostic table.

2. This step tests for the proper ignition voltage.


3. This step tests the TCM for proper command status.
4. This step tests the OEM harness for an open condition.
5. This step tests for the proper resistance at the main transmission connector.
7. This step tests for the proper resistance value at the G solenoid.

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DIAGNOSTIC TROUBLE CODES (DTC)

DTC P2810 Shift Solenoid E Electrical


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. 9–18V Go to Step 3 Resolve
2. Start the engine. (12V TCM); voltage problem
3. Record the DTC Failure Record data. 18–32V (Refer to
4. Using the Scan Tool, measure ignition (24V TCM) DTC P0562
voltage. and P0563)
Is voltage within the specified value?
3 1. Turn the ignition OFF. Battery Voltage Go to Step 4 Go to Step 10
2. Disconnect the J2 connector (RED) at the
TCM.
3. Install J 39700 breakout box and J 43799
breakout box adapter
4. Turn ON the ignition, with the engine OFF.
5. Using the Scan Tool in solenoid test mode,
command G solenoid to ON.
6. Using a DVOM measure the voltage between
J2 terminal 30 and terminal 32.
Is the voltage within the range specified when G
solenoid is commanded ON?
4 NOTE: Review Section 4 — Wire Check Refer to Solenoid Go to Diagnostic Go to Step 5
Procedures before performing the following Resistance Table Aids
steps. (Page 5–12)
1. Turn the ignition OFF.
2. Disconnect J2 connector from TCM. NOTE: To allow
3. Using J 39700 Breakout Box and J 43799 for resistance of
Breakout Box Adapter Harness, connect only harness wire, add
to the J2 harness connector. See Beginning 0.1 Ohms per foot
the Troubleshooting Process, Page 5–4, of length for
Figure 5–2 for diagram of J 43799 adapter 18-gauge wire.
harness hook-ups.
4. Using a DVOM, attach leads to J2 pins 30
and 32.
5. Measure the resistance of the circuit.
Is the resistance within the specified value?

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DIAGNOSTIC TROUBLE CODES (DTC)


DTC P2810 Shift Solenoid E Electrical (cont’d)
Step Action Value(s) Yes No
5 1. Turn the ignition OFF. Refer to Solenoid Go to Step 6 Go to Step 7
2. Disconnect the wiring harness from the main Resistance Table
transmission connector at the back of the (Page 5–12)
transmission.
3. Using J 39700 Breakout Box and J 43799
Breakout Box Adapter, connect only to the
transmission main connector at the rear of
the transmission. Do not attach the other end
of J 44722 to the vehicle transmission
harness connector. See Beginning the
Troubleshooting Process, Page 5–5, Figure
5–3 for diagram of J 44722 transmission
harness hook-ups.
4. Using a DVOM, measure resistance between
pins R and S at the magnetic overlay.
Is the resistance within the specified values?
6 NOTE: The vehicle OEM has responsibility — Go to Step 11 —
for all external wiring harness repair.
Harness repairs performed by ATD
distributors and dealers are not covered by
ATD warranty.
Repair or replace the vehicle wiring harness.
Is the repair complete?
7 1. Remove the oil pan. Refer to Service Manual Refer to Solenoid Go to Step 8 Go to Step 9
or Mechanic’s Tips. Resistance Table
2. Remove the connector from G solenoid. (Page 5–12)
3. Using a DMM, measure the resistance at the
solenoid.
Is the resistance within the specified value?
8 Replace the internal wiring harness. Refer to — Go to Step 11 —
Service Manual or Mechanic’s Tips.
Is the replacement complete?
9 Replace solenoid G. Refer to Service Manual or — Go to Step 11 —
Mechanic’s Tips.
Is the replacement complete?
10 NOTE: In most cases, the TCM is not at fault. — Go to Step 11 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM.
Is the replacement complete?
11 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Drive the vehicle under conditions noted in Go to Step 1
failure records.
3. Use the Scan Tool, in the test passed section,
to confirm the diagnostic test was run.
Did the DTC return?

5–242 Copyright© 2003 General Motors Corp.


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DIAGNOSTIC TROUBLE CODES (DTC)


DTC U0031 (Previously U1300) J1850 (Class 2) Serial Data Communication Link Low

TCM
J1 HARNESS CONNECTOR
(GRAY)

J2

J1-30 J1

J1850 PCM OR ECM


POWERTRAIN CONTROLLER MODULE
OR ENGINE CONTROLLER MODULE
TCM

J1850
PCM 130 CLASS II
or J1-30 J1850
DATA LINK
ECM

V07481.01.00

Circuit Description
Applications that employ J1850 class 2 serial communication use wire 130 to send operational information and
commands among the various control modules. Included modules would be Powertrain Control Module (PCM),
Antilock Brake System (ABS) Controller, Truck Body Controller (TBC), and Instrument Panel Cluster (IPC). Each
controller sends out a state of health (SOH) message approximately once every second. The TCM uses these SOH
messages to monitor the condition of the devices on the class 2 serial link.

Conditions for Running the DTC


The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than
18V and less than 32V (24V TCM).

Conditions for Setting the DTC


DTC U0031 is set when low voltage is detected on the class 2 data circuit for more than 3 seconds. This would
normally indicate a short-to-ground at wire 130.

Action Taken When the DTC Sets


• The CHECK TRANS light does not illuminate.
• DTC U0031 is stored in the TCM history.
• TCM uses default values for missing/erroneous information.
• The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. The TCM self-clears this DTC
when software detects a failure recovery has occurred.

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DIAGNOSTIC TROUBLE CODES (DTC)


Diagnostic Aids
• If communication can be established with the Scan Tool at the OBDII connector, then the U0031 should be
shown in failure records only. This may indicate that an intermittent short-to-ground was present at one time.
Refer to Appendix A—Identification of Potential Circuit Problems.
• It is not possible to communicate with J1850 with this DTC active.
• Use the J 43890 T-harness to communicate with the TCM to determine if the U0031 is still active.
• U0031 in failure records may be present along with a U1000–U1096 that is active. This would indicate that the
malfunction occurred when the ignition was ON.
• This code indicates that voltage is low at wire 130. Normally, this is an indication that a short-to-ground exists
at wire 130. Inspect wire 130 for this condition.
• Inspect wire 130 for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• When this DTC is active an engine no–start condition may exist. Class 2 messages will not be sent to enable
the fuel pump and starter.

Test Description
The numbers below refer to the step numbers on the diagnostic table.

2. This step checks engine data.


3. This step tests for shorts or opens at wire 130.

DTC U0031 (Previously U1300) J1850 (Class 2) Serial Data Communication Link Low
Step Action Yes No
1 Was the Beginning The Troubleshooting Process Go to Step 2 Go to
(Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. Go to Diagnostic Go to Step 3
2. Turn the ignition ON with the engine OFF. Aids
3. Verify engine data is being communicated via J1850.
NOTE: U0031 is set when low voltage is detected on
the J1850 serial communication link by the TCM for a
time exceeding 3 seconds.This may indicate a short-
to-ground exists at wire 130.
Is engine data communicated to the Scan Tool?
3 Inspect wire 130 for a possible short-to-ground. Go to Step 4 Go to Step 5
Did you find a problem?

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DTC U0031 (Previously U1300) J1850 (Class 2) Serial Data Communication Link Low
Step Action Yes No
4 NOTE: The vehicle OEM has responsibility for all Go to Step 6 —
external wiring harness repair. Harness repairs
performed by ATD distributors and dealers are not
covered by ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?
5 Switch the current TCM with a known good unit. Check for Go to Step 6 —
proper communication. If this repairs the condition, reinstall
the “defective” TCM to verify the TCM failure and then
install a new TCM.
Is replacement complete?
6 In order to verify your repair: Begin the System OK
1. Connect the Scan Tool. diagnosis again.
2. Clear the DTC. Go to Step 1
Did the DTC return?

Copyright© 2003 General Motors Corp. 5–245


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DIAGNOSTIC TROUBLE CODES (DTC)


DTC U0032 (Previously U1301) J1850 (Class 2) Serial Data Communication Link High

TCM
J1 HARNESS CONNECTOR
(GRAY)

J2

J1-30 J1

J1850 PCM OR ECM


POWERTRAIN CONTROLLER MODULE
OR ENGINE CONTROLLER MODULE
TCM

J1850
PCM 130 CLASS II
or J1-30 J1850
DATA LINK
ECM

V07481.01.00

Circuit Description

Applications that employ J1850 class 2 serial communication use wire 130 to send operational information and
commands among the various control modules. Included modules would be Powertrain Control Module (PCM),
Antilock Brake System (ABS) Controller, Truck Body Controller (TBC), and Instrument Panel Cluster (IPC). Each
controller sends out a state of health (SOH) message approximately once every second. The TCM uses these SOH
messages to monitor the condition of the devices on the class 2 serial link.

Conditions for Running the DTC

• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).

Conditions for Setting the DTC

DTC U0032 is set when high voltage is detected on the class 2 data circuit for more than 3 seconds. This would
normally indicate a short-to-power at wire 130.

Action Taken When the DTC Sets

• The CHECK TRANS light does not illuminate.


• DTC U0032 is stored in the TCM history.
• TCM uses default values for missing/erroneous information.
• The TCM freezes shift adapts (DNA).

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DIAGNOSTIC TROUBLE CODES (DTC)


Conditions for Clearing the DTC/CHECK TRANS Light
A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. The TCM self-clears this DTC
when software detects a failure recovery has occurred.

Diagnostic Aids
• If communication can be established with the Scan Tool at the OBDII connector, then the U0032 should be
shown in failure records only. This may indicate that an intermittent short-to-power was present at one time.
Refer to Appendix A—Identification of Potential Circuit Problems.
• It is not possible to communicate with J1850 with this DTC active.
• Use the J 43890 T-harness to communicate with the TCM to determine if the U0032 is still active.
• U0032 in failure records may be present along with a U1000–U1096 that is active. This would indicate that the
malfunction occurred when the ignition was ON.
• This code indicates that voltage is high at wire 130. Normally, this is an indication that a short-to-power exists
at wire 130. Inspect wire 130 for this condition.
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• When this DTC is active an engine no-start condition may exist. Class 2 messages will not be sent to enable
the fuel pump and starter.

Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step checks engine data.
3. This step tests for shorts or opens at wire 130.

DTC U0032 J1850 (Class 2) Serial Data Communication Link High


Step Action Yes No
1 Was the Beginning The Troubleshooting Process Go to Step 2 Go to
(Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. Go to Diagnostic Go to Step 3
2. Turn the ignition ON, with the engine OFF. Aids
3. Verify engine data is being communicated via J1850.
NOTE: U0032 is set when high voltage is detected on
the J1850 serial communication link by the TCM for a
time exceeding 3 seconds. This may indicate a short-
to-power exists at wire 130.
Is the engine data communicated to the Scan Tool?

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DIAGNOSTIC TROUBLE CODES (DTC)


DTC U0032 J1850 (Class 2) Serial Data Communication Link High (cont’d)
Step Action Yes No
3 Inspect wire 130 for possible short-to-power. Go to Step 4 Go to Step 5
Did you find a problem?
4 NOTE: The vehicle OEM has responsibility for all Go to Step 6 —
external wiring harness repair. Harness repairs
performed by ATD distributors and dealers are not
covered by ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?
5 Switch the current TCM with a known good unit. Check for Go to Step 6 —
proper communication. If this repairs the condition, reinstall
the “defective” TCM to verify the TCM failure and then
install a new TCM.
Is replacement complete?
6 In order to verify your repair: Begin the System OK
1. Inspect the Scan Tool. diagnosis again.
2. Clear the DTC. Go to Step 1
Did the DTC return?

5–248 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC U0073 (Previously U2104) CAN Bus Reset Counter Overrun

ENGINE (ECM) TRANS (TCM) 9-PIN DDL


CONNECTOR D
J1939 J1939 E C
Data Data
Link Link F A B

G J
H

Pin ID
determined

SHIELD PIN D (–)


PIN C (+)
Attached to

PIN 31
PIN 29
PIN 32

PIN E
by Engine ECM via
OEM Deutsch/P TERMINATION
Should not
triangle 3-pin exceed 1 meter RESISTOR
connector

SHIELD

SHIELD
SHIELD
131 GREEN
129 RED
120Ω 120Ω
RESISTOR SHIELD 132 SHIELD BLACK SHIELD RESISTOR

CONTROLLER AREA NETWORK (CAN)


Should not exceed 40 meters

SAE J1939-11 V06460.01.00

Circuit Description

J1939 is the protocol currently used in medium duty applications to allow communication between an
electronically-controlled engine and the Allison 1000/2000/2400 Series transmission. A signal is sent over a two-
wire network harness that incorporates two 120 Ohm resistors in parallel. There are two versions of J1939
currently in use in the medium duty market. Version J1939-11, the most widely used, incorporates a third shield
wire. There is also J1939-15, which uses a two-wire connection without shielding.

Conditions for Running the DTC


• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.

Conditions for Setting the DTC


DTC U0073 is set when the TCM detects no communication on the Controller Area Network (CAN) backbone
harness for 3 seconds or more. This may be due to a shorted wire to ground or power in the CAN backbone
harness.

Action Taken When the DTC Sets


• DTC U0073 is stored in the TCM history.
• The CHECK TRANS light does not illuminate.
• The TCM defaults to the last-used adaptive shift values and engine throttle percentage is calculated from
torque clip speed.
• The TCM freezes shift adapts (DNA).

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DIAGNOSTIC TROUBLE CODES (DTC)


Conditions for Clearing the DTC/CHECK TRANS Light
A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids
• If communication can be established at the vehicle nine-pin connector and U0073 is listed in failure records,
this indicates an intermittent short condition was present.
• When diagnosing for intermittent shorts-to-ground, massage the wiring harness while watching the test
equipment for a change. Refer to Section 4, Wire Check Procedures.
• If an active U0073 is present, Scan Tool communication will not be possible. The cause of the active DTC must
be discovered and repaired before communication can be established with the TCM.
• A short between wires 129 and 132 within the CAN harness can cause this DTC.
• A short between wires 129 and 131 within the CAN harness can cause this DTC.
• A short to a vehicle ground and wire 129 can cause this DTC.
• A short to vehicle power and wire 132 can cause this DTC.
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• For proper data communications it is necessary to have two 120 Ohm resistors installed in parallel at the J1939
CAN backbone harness.
• If this DTC is present in a new vehicle, harsh shifting may occur due to adaptive function inhibit (DNA).

Test Description
The number below refers to the step number on the diagnostic table.

3. This step inspects the CAN backbone harness for shorts-to-ground or power.
5. This step checks TCM function.

DTC U0073 CAN Bus Reset Counter Overrun


Step Action Yes No
1 Was the Beginning The Troubleshooting Process Go to Step 2 Go to
(Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. Go to Diagnostic Go to Step 3
2. Turn the ignition ON with the engine OFF. Aids
Is Scan Tool communication possible at the diagnostic
connector?

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DIAGNOSTIC TROUBLE CODES (DTC)


DTC U0073 CAN Bus Reset Counter Overrun (cont’d)
Step Action Yes No
3 1. Inspect wires 129 (positive), 132 (negative), 131 (shield) Go to Step 4 Go to Step 5
at engine and transmission connectors for a possible
shorting condition or terminal damage.
NOTE: No Scan Tool communication is possible when
this DTC is active.
2. This DTC indicates that a CAN bus hardware error has
occurred. This may indicate a short-to-power or ground
has occurred at the CAN bus wiring harness.
Was a wiring problem found?
4 NOTE: The vehicle OEM has responsibility for all Go to Step 7 Go to Step 4
external wiring harness repair. Harness repairs
performed by ATD distributors and dealers are not
covered by ATD warranty.
Repair the vehicle J1939 CAN wiring harness.
Is the repair complete?
5 Switch the current TCM with a known good unit. Check for Go to Step 6 —
proper communication. If this repairs the condition, reinstall
the “defective” TCM to verify the TCM failure and then
install a new TCM.
Is replacement complete?
6 In order to verify your repair: Begin the System OK
1. If communication is established with the Scan Tool, clear diagnosis again.
the DTC. Go to Step 1
2. Use the Scan Tool, in the test passed section, to confirm
the diagnostic test was run.
Did the DTC return?

Copyright© 2003 General Motors Corp. 5–251


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC U0100 (Previously U2105) CAN Bus ECM Error

ENGINE (ECM) TRANS (TCM) 9-PIN DDL


CONNECTOR D
J1939 J1939 E C
Data Data
Link Link F A B

G J
H

Pin ID
determined

SHIELD PIN D (–)


PIN C (+)
Attached to

PIN 31
PIN 29
PIN 32

PIN E
by Engine ECM via
OEM Deutsch/P TERMINATION
Should not
triangle 3-pin exceed 1 meter RESISTOR
connector

SHIELD

SHIELD
SHIELD
131 GREEN
129 RED
120Ω 120Ω
RESISTOR SHIELD 132 SHIELD BLACK SHIELD RESISTOR

CONTROLLER AREA NETWORK (CAN)


Should not exceed 40 meters

SAE J1939-11 V06460.01.00

Circuit Description

J1939 is the protocol currently used in medium duty applications to allow communication between an
electronically-controlled engine and the Allison 1000/2000/2400 Series transmission. A signal is sent over a two-
wire network harness that incorporates two 120 Ohm resistors in parallel. There are two versions of J1939
currently in use in the medium duty market. Version J1939-11, the most widely used, incorporates a third shield
wire. There is also J1939-15, which uses a two-wire connection without shielding.

Conditions for Running the DTC


• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.

Conditions for Setting the DTC

DTC U0100 is set when the TCM detects that no engine torque or throttle messages are being received on the
Controller Area Network (CAN) backbone harness for 3 seconds or more.

Action Taken When the DTC Sets


• The CHECK TRANS light illuminates.
• DTC U0100 is stored in the TCM history.
• The TCM defaults to last-used adaptive shift values and engine throttle percentage is calculated from torque
converter slip speed.
• The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light


A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

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Diagnostic Aids
• Often an active U0100 will prevent Scan Tool communication with the TCM. Install J1939 T-adapter harness
J 43890 to confirm that the TCM is operational. This harness is only useful to confirm that the TCM is able to
communicate with the Scan Tool. An active U0100 will be set whenever J 43890 is used.
• When Scan Tool communication with the TCM can be established at the nine-pin vehicle connector and the
U0100 is active, generally it points to an open connection at wires 129 or 132 at the ECM or a terminal in the
wrong location at the engine ECM connector.
• Engine ECM parameters improperly set can cause this DTC to set.
• A missing terminating resistor can cause this DTC to set. This will prevent Scan Tool communication with the
TCM or produce very erratic communication.
• If DTC U0100 becomes active shortly AFTER an engine update and the troubleshooting procedure for U0100
has been performed, see Resetting of TCM Parameters to Support Engine Update, Section 3–7.
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• When diagnosing for an intermittent open, massage the wiring harness while watching the test equipment for a
change. It may be necessary to check for opens at individual wires within a harness to isolate an intermittent
condition. Refer to Section 4, Wire Check Procedures.
• You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc.
This data can be useful in reproducing the failure mode where the DTC was set.
• Intermittent cycling of the TCC could indicate a J1939 wiring problem exists. It is possible to have an open
condition at the CAN backbone harness allowing TCC to cycle without a U0100 setting. For a U0100 to set, an
open condition needs to be present for 3 seconds.
• For proper data communications, it is necessary to have two 120 Ohm resistors installed in parallel at the
J1939 CAN backbone harness.
• If this DTC is present in new vehicle, harsh shifting may occur due to adaptive function inhibit (DNA).

Test Description
The numbers below refer to the step numbers on the diagnostic table.
3. This step inspects the CAN backbone harness for open conditions to ground or terminal damage.
5. This step tests the CAN backbone harness for the proper resistance value.

DTC U0100 CAN Bus ECM Error


Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)

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DIAGNOSTIC TROUBLE CODES (DTC)


DTC U0100 CAN Bus ECM Error (cont’d)
Step Action Value(s) Yes No
2 1. Install the Scan Tool. — Go to Step 3 Go to Diagnostic
2. Turn the ignition ON, with the engine OFF. Aids
Is Scan Tool communication possible at the
diagnostic connector?
3 Inspect wires 129 (positive), 132 (negative), — Go to Step 4 Go to Step 5
and 131 (shield) at engine and transmission
connectors for a possible open condition or
terminal damage.
NOTE: This DTC indicates that the TCM is
not receiving engine information. This may
indicate an open condition has occurred at
the CAN bus wiring harness.
Was a wiring problem found?
4 NOTE: The vehicle OEM has Go to Step 7 —
responsibility for all external wiring
harness repair. Harness repairs
performed by ATD distributors and
dealers are not covered by ATD warranty.
Repair the vehicle wiring harness.
Is the repair complete?
5 Using a DVOM, measure resistance between 60 Ohms Go to Step 6 Go to Step 7
pins C and D at the vehicle 9-pin diagnostic
connector.
Does the resistance match the specified value?
6 NOTE: A resistance reading other than — Go to Step 8 —
60 Ohms indicates that a terminating
resistor is missing or a resistor with an
improper value is installed. There should
be two 120 Ohm resistors wired in parallel
in the J1939 CAN.
Return the vehicle to the OEM for repair.
Is the repair complete?
7 Return the vehicle to OEM for inspection of the — Go to Step 8 —
following:
1. Confirm that the engine ECM is properly set
to broadcast J1939 messages.
2. Improper pin location at the engine ECM.
3. Defective engine ECM.
Is the repair complete?
8 In order to verify your repair: — Begin the System OK
1. If communication is established with the diagnosis again.
Scan Tool, clear the DTC. Go to Step 1
2. Use the Scan Tool, in the test passed
section, to confirm the diagnostic test was
run.
Did the DTC return?

5–254 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC U1000–U1096 Class 2 Controller State of Health Failure

TCM
J1 HARNESS CONNECTOR
(GRAY)

J2

J1-30 J1

POWERTRAIN CONTROLLER MODULE


OR ENGINE CONTROLLER MODULE

ABS

J1850
PCM 130
or J1-30 TCM
ECM

IPC TBC
V07477.01.00

Circuit Description

Applications that employ J1850 class 2 serial communication use wire 130 to send operational information and
commands among the various control modules. The control modules included are the Powertrain Control Module
(PCM), Antilock Brake System Controller (ABS), Truck Body Controller (TBC) and Instrument Panel Cluster (IPC).
Each controller sends out a state of health (SOH) message approximately once every second. The TCM uses
these SOH messages to monitor the condition of the devices on the class 2 serial link.

The following DTCs identify the specific controller noted:

DTC Number Control Module

U1000 Class II–Loss of Serial Data Communication

U1016 Powertrain Control Module (PCM)

U1041 Antilock Brake System Module (ABS)

U1064 Truck Body Controller Module (TBC)

U1096 Instrument Panel Cluster Module (IPC)

Conditions for Running the DTC

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than
18V and less than 32V (24V TCM).

Copyright© 2003 General Motors Corp. 5–255


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


Conditions for Setting the DTC

DTC U1000–U1096 is set when the TCM has not received a state of health (SOH) message from the Control
Module indicated for a period of time exceeding 2 seconds.

Action Taken When the DTC Sets


• The CHECK TRANS light does not illuminate.
• DTC U1000–U1096 is stored in the TCM history.
• TCM uses default values for missing/erroneous information.
• For U1016 only—the TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light

A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. The TCM self-clears the DTC
when the software detects a failure recovery has occurred.

Diagnostic Aids
• An intermittent open between a module and the connector node may cause this DTC to set.
• A poor connection at a module or the connector node may cause this DTC to set.
• An intermittent open in a connector node may cause this DTC to set.
• An open voltage or ground circuit to a module may cause this DTC to set.
• An internal module malfunction may cause this DTC to set.

Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests for proper power inputs at the indicated module.
3. This step tests for an open condition between the controller module and the connection at wire 130.
5. This step tests the module function per OEM procedures.

DTC U1000–U1096 Class 2 Controller State of Health Failure


Step Action Yes No
1 Was the Beginning The Troubleshooting Process Go to Step 2 Go to Beginning The
(Paragraph 5–4A) performed? Troubleshooting
Process
(Paragraph 5–4A)
2 Test the following circuits of the module for an open or a Go to Step 6 Go to Step 3
short to ground:
1. The battery positive (fuses) and ground connections at
the module.
2. The ignition positive (fuses) and ground connections.
NOTE: The DTC set indicates the module for which the
state of health (SOH) message was not detected by the
TCM for a period of time exceeding 2 seconds. This
may indicate an open wire leading to the module, or a
defective module.
Did you find and correct the condition?

5–256 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)


DTC U1000–U1096 Class 2 Controller State of Health Failure (cont’d)
Step Action Yes No
3 Inspect for opens at the connector and the wire connecting Go to Step 4 Go to Step 5
the module to the TCM (wire 130).
Did you find a problem?
4 Repair the module class 2 wiring harness connection. Go to Step 6 —
NOTE: The vehicle OEM has responsibility for all
external wiring harness repairs. Harness repairs
performed by ATD distributors and dealers are not
covered under ATD warranty.
Is the repair complete?
5 Refer to troubleshooting procedures specific to the Go to Step 6 —
controller module indicated.
Replace the module, if defective.
Is replacement or repair complete?
6 In order to verify your repair: Begin the System OK
1. Clear the DTC. diagnosis again.
2. Use the Scan Tool, in the test passed section, to confirm Go to Step 1
the diagnostic test was run.
Did the DTC return?

Copyright© 2003 General Motors Corp. 5–257


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

DIAGNOSTIC TROUBLE CODES (DTC)

NOTES

5–258 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

SECTION 6 — INPUT AND OUTPUT FUNCTIONS

6–1. SPECIAL INPUT AND OUTPUT FUNCTIONS


Each transmission control system provides additional functional control of transmission and/or vehicle operations
tailored to the expected duty of the vehicle. Specific vocational requirements can be satisfied using input and
output functions. Although these features may be used independently to control the function of the TCM, they can
be combined to provide more comprehensive vehicle control functions. An example of the combined use of input
and output functions is the combination of control signals which automatically commands the transmission to
Neutral when a PTO is operated.

NOTE: Wiring diagrams for input and output functions are shown in Appendix N.

A. Input Functions
Input functions are control signals that send vehicle data to the TCM to designate the operating state of
other vehicle systems. “Ground input” control wires activate the programmed function when the input
wire is switched to an isolated circuit ground. “Power input” control wires activate the programmed
function when the input wire is switched to 12V or 24V power. Typical input functions are:

• Secondary Shift Schedule


• PTO Enable
• Auxiliary Function Range Inhibit
• Exhaust Brake and Preselect Request (Standard, Optional, and Special)
• Automatic Neutral for PTO
• Reverse Enable
• Kickdown
• Refuse Packer Step Switch
• Overdrive Disable

B. Output Functions
Output function signals send data from the TCM for use in controlling the operation of non-
transmission components. As determined by programmed logic or attainment of preselected
conditions, the TCM activates the appropriate output control wire (the circuit goes from OPEN to
GROUND). This energizes a customer-supplied relay or switch to complete the external vehicle
circuit.

The output functions may be turned on and off based on the state of the input function signals and the
operating state of the transmission. Typical output functions are:

• Sump Temperature Indicator


• Range Indicator
• Output Speed Indicator

Copyright© 2003 General Motors Corp. 6–1


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

INPUT AND OUTPUT FUNCTIONS

NOTES

6–2 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

SECTION 7 — GENERAL TROUBLESHOOTING OF PERFORMANCE


COMPLAINTS
IMPORTANT:

Make the following general checks before beginning specific troubleshooting, removing the transmission, or
removing attached components.
• Are there active DTCs?
• Is the shift selector lever in N (Neutral), P (Park), or PB (Park Brake Apply) to allow starting the engine?
• Is the battery properly connected and charged?
• Is isolated battery properly connected (if used)?
• Is the fluid level correct?
• Is voltage to the TCM correct?
• Is the engine properly tuned?
• Is fuel flow to the engine correct?
• Are wheel chocks in place?
• Is air flow to the cooler and radiator unrestricted?
• Is the driveline properly connected?
• Are there signs of fluid leakage under the vehicle? What is the origination point?
• Are hydraulic connections correctly made and not leaking?
• Is vehicle acceleration from a stop changed?
• Are electrical connections correctly made?
• Are there any other obvious vehicle or transmission problems?
After making these general checks use the various sections of this manual to isolate the listed problems. The
following charts address specific vehicle complaints. Some complaints involve DTCs, so all troubleshooting checks
should involve checking the system for DTCs.

Copyright © 2003 General Motors Corp. 7–1


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS

Table 7–1. Troubleshooting Performance Complaints

Problem Possible Cause Suggested Remedy

VEHICLE WILL NOT START — Lever shift selector not in Select N (Neutral) and restart
ENGINE WILL NOT CRANK N (Neutral) or P (Park) or
PB (Park Brake Apply)*

Dead battery Recharge battery


Disconnected battery* Reconnect battery

Faulty starter circuit Repair vehicle starter circuit

Faulty NSBU switch* Replace NSBU switch


(refer to Mechanic’s Tips)
Misadjusted NSBU switch* Adjust NSBU switch
(refer to Mechanic’s Tips)

Faulty wiring in vehicle neutral start Repair wiring


circuit*

Connectors not properly seated on Properly install connector


NSBU switch*

CHECK TRANS LIGHT WILL NOT TCM has logged a DTC Install Scan Tool to determine if
GO OUT AT START-UP DTC is present

A. Vehicle Drives Normally Faulty CHECK TRANS light, relay, Replace relay or repair circuit
or circuit.

B. Vehicle Does Not Drive Normally Bad or no calibration in TCM Calibrate TCM via PCCS

Vehicle cannot establish Repair J1939 backbone


communication with TCM

Faulty wiring harness Repair wiring harness (refer to


Section 4 and Appendix E)
Faulty TCM Replace the TCM

CHECK TRANS LIGHT FLASHES Intermittent power to TCM* Check input power to the TCM and
INTERMITTENTLY correct if necessary
Faulty vehicle wiring Repair vehicle wiring

Loose wiring to CHECK TRANS Repair wiring


light
Faulty or incorrect ground wire Repair ground circuit
attachment

Intermittent opening in Circuit 125 Repair Circuit 125

* See Inhibit Section 2–5

7–2 Copyright © 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS


Table 7–1. Troubleshooting Performance Complaints (cont’d)

Problem Possible Cause Suggested Remedy


NO CHECK TRANS LIGHT AT Faulty light bulb or socket Replace light bulb or socket
IGNITION
Incorrect wiring to and from CHECK Repair wiring
TRANS light bulb (refer to Appendix E)

Faulty vehicle wiring Repair vehicle wiring

Circuit 125 open Repair Circuit 125


Faulty TCM Replace TCM

TRANSMISSION WILL NOT Engine rpm too high* Reduce engine rpm (it may be
SHIFT TO FORWARD OR necessary to reselect Neutral also,
REVERSE — STAYS IN and then D or R)
NEUTRAL
Low fluid level* Add fluid to correct level
(refer to Mechanic’s Tips for
proper dipstick calibration)

Faulty throttle sensor or circuit* See throttle sensor section for


installation and operation
information (Appendix F)

Faulty throttle signal from engine Correct engine throttle signal

Faulty or misadjusted shift selector* Repair or adjust shift selector

Faulty speed sensor or circuit* Repair circuit or replace speed


sensor(s) (refer to speed sensor
DTCs and Appendix E)

Mechanical failure to C5 clutch Repair transmission

Mechanical failure in transmission Repair transmission


torque converter, shafts, or
planetaries

Low main pressure* See Low Pressure Section

Faulty wiring in TCM Input/Output Correct circuit wiring


function circuits*

Auxiliary function range inhibit Correct circuit wiring


active*

Misadjusted NSBU switch* Adjust NSBU switch


(refer to Mechanic’s Tips)

* See Inhibit Section 2–5

Copyright © 2003 General Motors Corp. 7–3


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS


Table 7–1. Troubleshooting Performance Complaints (cont’d)

Problem Possible Cause Suggested Remedy


TRANSMISSION WILL NOT STAY Faulty auto-neutral for PTO circuit Repair quick-to-neutral circuit
IN FORWARD OR REVERSE (input function)*

Low fluid level* Add fluid to correct level


(refer to Mechanic’s Tips for
proper dipstick calibration)

Low main pressure* See Low Pressure Section

Faulty solenoid — leaking* Replace solenoid


(refer to Mechanic’s Tips)
TRANSMISSION WILL NOT MAKE Low engine power Correct engine problem
A SPECIFIC SHIFT (refer to engine Service Manual)
Extreme fluid temperature Inspect cooling system and fluid
level

Faulty speed sensor or circuit* Repair circuit or replace speed


sensor(s) (refer to speed sensor
DTCs and Appendix E)

Faulty temperature sensor or circuit Check for temperature reading


which inhibits shifts

Incorrect calibration Install proper calibration

Faulty or misadjusted shift selector* Repair or adjust shift selector

TRANSMISSION DOES Engine idle speed too high (neutral Adjust engine idle speed
NOT SHIFT PROPERLY — to range shift)* (refer to vehicle Service Manual)
ROUGH SHIFTS, SHIFTS
OCCURRING AT TOO LOW Faulty throttle sensor or circuit* See throttle sensor section for
OR TOO HIGH SPEED installation and operation
information (Appendix F)

Faulty or sticking bleed ball in Replace C1 piston housing


C1 piston housing

Excessive clutch running Rebuild transmission and adjust


clearance* clearances

Incorrect TCM calibration Install correct calibration

Instrument panel tachometer Repair or replace tachometer


incorrect

Incorrectly calibrated electronic Calibrate electronic speedometer


speedometer

Faulty speed sensor or circuit* Repair circuit or replace speed


sensor(s) (refer to speed sensor
DTCs and Appendix E)

Degraded fluid Change transmission fluid and filter


(refer to Mechanic’s Tips)
* See Inhibit Section 2–5

7–4 Copyright © 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS


Table 7–1. Troubleshooting Performance Complaints (cont’d)

Problem Possible Cause Suggested Remedy


TRANSMISSION DOES Loose speed sensor Tighten speed sensor retainer bolt
NOT SHIFT PROPERLY —
ROUGH SHIFTS, SHIFTS Incorrect fluid level* Correct fluid level
OCCURRING AT TOO LOW (refer to Mechanic’s Tips for
OR TOO HIGH SPEED (cont’d) proper dipstick calibration)

Low main pressure* See Low Pressure Section

Intermittent problems* Check wiring harnesses and


connectors (refer to Appendix E)

Loose or damaged speed gear Replace speed gear


Sticking valves in control valve Overhaul control valve assembly
assembly*

Leaking trim solenoids* Repair or replace trim solenoids


(refer to Service Manual)

Incorrect TCM calibration Install correct calibration

ABNORMAL TRANSMISSION
ACTIVITIES OR RESPONSES

A. Excessive Creep in First and Engine idle speed too high* Adjust engine idle speed
Reverse Gears (refer to vehicle Service Manual)

B. Vehicle Moves Forward in C1 clutch failed or not released* Rebuild C1 clutch assembly (refer
Neutral to transmission Service Manual)

C. Vehicle Moves Backward in C3 clutch failed or not released* Rebuild C3 clutch assembly (refer
Neutral to transmission Service Manual)

EXCESSIVE FLARE — TPS Adjustment:


ENGINE OVERSPEED ON FULL-
THROTTLE UPSHIFTS — Overstroke — Adjust TPS linkage for proper
stroke (refer to Appendix F)
— Loose — Tighten loose bolts or
connections

Incorrect TCM calibration Install correct calibration

Incorrect fluid level* Correct fluid level


(refer to Mechanic’s Tips for
proper dipstick calibration)

Sticking valves in control valve Rebuild control valve assembly


assembly*

Low main pressure* See Low Pressure Section

* See Inhibit Section 2–5

Copyright © 2003 General Motors Corp. 7–5


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS


Table 7–1. Troubleshooting Performance Complaints (cont’d)

Problem Possible Cause Suggested Remedy


EXCESSIVE FLARE — Leaking trim solenoids* Repair or replace trim solenoids
ENGINE OVERSPEED ON FULL- (refer to Service Manual)
THROTTLE UPSHIFTS (cont’d)

G solenoid mechanical failure Repair or replace trim solenoids


(refer to Service Manual)
Erratic speed sensor signal See speed sensor DTCs

Leaking piston seals or slipping Overhaul transmission (refer to


clutch plates in range involved* transmission Service Manual)

SHUDDER WHEN SHIFTING Intermittent short to ground at F Repair or replace wire 229
INTO FORWARD OR REVERSE (TCC) solenoid circuit (wire 229).
RANGE Could be accompanied by a
P0743—F solenoid electrical DTC.
It is possible to have this complaint
without a DTC setting on earlier
software.*
This complaint is worse with pre-
N04 software levels due to the
different hydraulic schedule.
Reverse range is not fully attainable
due to TCC valve application
blocking C5 feed circuit. This
causes the range inhibit light to
illuminate.

Low main pressure* See Low Pressure Section

Faulty trim solenoid* Replace solenoid (refer to Service


Manual or Mechanic’s Tips)

Sticky trim valve* Rebuild control valve assembly


(refer to Service Manual or
Mechanic’s Tips)
C–1 or C-3 clutch failure* Repair transmission (refer to
Service Manual)

ABNORMAL STALL SPEEDS


(Stall In First Range — Fifth Range)

A. High Stall Speeds Not in gear Select D (Drive)

Low fluid level, aerated fluid* Add fluid to correct level


(refer to Mechanic’s Tips for
proper dipstick calibration)

Faulty torque converter Replace torque converter

Incorrect torque converter Replace torque converter (refer to


transmission Service Manual)
Clutch pressure low* See Low Pressure Section and
Appendix B

* See Inhibit Section 2–5

7–6 Copyright © 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS


Table 7–1. Troubleshooting Performance Complaints (cont’d)

Problem Possible Cause Suggested Remedy


ABNORMAL STALL SPEEDS C1 or C5 clutch slipping* Rebuild C1 or C5 clutch assembly
(Stall In First Range — Fifth Range) Note: Use the Scan Tool to check (refer to transmission Service
(cont’d) turbine speed Manual)

Engine too powerful Confirm proper engine match


B. Low Stall Speeds Engine not performing efficiently Repair engine (refer to engine
(may be due to plugged or Service Manual or vehicle Service
restricted injectors, high altitude Manual)
conditions, dirty air filters, out of
time, throttle linkage, electronic
engine controls problem)
Stall speeds 66 percent of normal Replace converter assembly (refer
implies freewheeling stator to transmission Service Manual)

Engine smoke controls Compare lugback vs. static stall


speed

Incorrect torque converter Install correct torque converter (refer


to transmission Service Manual)

OVERHEATING IN ALL RANGES Aerated fluid — incorrect fluid level* Correct fluid level, check for
defective pump (refer to Mechanic’s
Tips and transmission Service
Manual)

Air flow to cooler obstructed Remove air flow obstruction

Engine overheat Correct overheat situation (refer to


vehicle Service Manual)

Inaccurate temperature gauge or Replace gauge and/or sending unit


sending unit
Inaccurate sump temperature Replace Pressure Switch Manifold
sensor (PSM) or internal harness (refer to
transmission Service Manual)

Inadequate cooler sizing See vehicle OEM for specifications

Excessive cooler circuit pressure Check for plugged cooler, lines too
drop small, collapsed hose, too many
elbows in circuit

Transmission cooler lines reversed Connect cooler lines properly (oil


and water should flow in opposite
directions)

Fluid cooler lines restricted Remove restrictions, clean or


replace lines (refer to Vehicle
Service Manual)

* See Inhibit Section 2–5

Copyright © 2003 General Motors Corp. 7–7


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS


Table 7–1. Troubleshooting Performance Complaints (cont’d)

Problem Possible Cause Suggested Remedy


OVERHEATING IN ALL RANGES Torque converter (wrong converter, Replace or repair converter
(cont’d) no lockup, stuck stator, or slipping assembly (refer to transmission
stator) Service Manual)
Note: Stuck stator will not allow
cool down in neutral
Cooler flow loss due to internal Overhaul transmission (refer to
transmission leakage transmission Service Manual)

INTERMITTENT NOISE — Low fluid level* Add fluid to correct level


BUZZING (refer to Mechanic’s Tips for
proper dipstick calibration)
Air leak in oil suction screen Replace suction filter
canister* (refer to Mechanic’s Tips)

Clogged filter* Replace filter


(refer to Mechanic’s Tips)

Aerated fluid causes noisy pump* Correct fluid level


(refer to Mechanic’s Tips for
proper dipstick calibration)

Low main pressure causes main See transmission Service Manual


regulator valve to oscillate*

LEAKING FLUID — Dipstick loose Tighten cap, replace if necessary


FILL TUBE AND/OR BREATHER
Incorrect fluid level* Correct fluid level
(refer to Mechanic’s Tips for
proper dipstick calibration)

Breather stopped up — clogged Clean or replace breather (refer to


transmission Service Manual)
Fluid contaminated with foreign Drain and replace fluid. Locate and
liquid fix source of additional fluid (refer to
transmission Service Manual)

Dipstick or fill tube seal worn Replace seals or dipstick

Incorrect dipstick marking Calibrate dipstick


(refer to Mechanic’s Tips)
LEAKING FLUID — Faulty or missing seal at output Install new lip-type seal in rear of
TRANSMISSON OUTPUT flange transmission housing
(refer to Mechanic’s Tips)

Machine lead on output flange seal Replace flange


surface

Rear cover porosity Repair or replace cover

* See Inhibit Section 2–5

7–8 Copyright © 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS


Table 7–1. Troubleshooting Performance Complaints (cont’d)

Problem Possible Cause Suggested Remedy


LEAKING FLUID — Flange worn at seal surface Replace flange
TRANSMISSON OUTPUT
(cont’d)

Insufficient seal around seal OD Replace seal


(refer to Mechanic’s Tips)
Damaged, missing, or loose output Replace and/or torque output flange
flange bolt bolts

LEAKING FLUID — Leaking front seal Replace front seal


TRANSMISSION INPUT (refer to Mechanic’s Tips)
Leaking manifold seal Replace manifold seal
(refer to Mechanic’s Tips)

Leaking front support bolt seals Replace bolt seals

Leaking converter Check converter seals, cracked


converter pump tangs, converter
cover, or converter housing
porosity; replace parts as required
(refer to transmission Service
Manual)

Leaking spin-on filter Replace filter


(refer to Mechanic’s Tips)

Leaking main pressure plug Replace or torque main pressure


plug

Worn pump bushing Rebuild and repair pump

DIRTY FLUID Failure to change fluid and filters Change fluid and install new filters
(refer to Mechanic’s Tips)
Excessive heat Check cooling system for
restrictions and proper capacity

Substandard fluid Use recommended fluid


(refer to Mechanic’s Tips)

Clutch/transmission failure* Overhaul transmission (refer to


transmission Service Manual)

* See Inhibit Section 2–5

Copyright © 2003 General Motors Corp. 7–9


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS


Table 7–1. Troubleshooting Performance Complaints (cont’d)

Problem Possible Cause Suggested Remedy

RANGE CLUTCH TROUBLESHOOTING SECTION


EXCESSIVE SLIPPAGE AND Incorrect TCM calibration Install correct calibration
CLUTCH CHATTER

Throttle Position Sensor out of Adjust or replace throttle position


adjustment or failed* sensor (refer to Appendix F)
Incorrect speed sensor readings* See speed sensor DTCs

Incorrect fluid level* Correct fluid level


(refer to Mechanic’s Tips for
proper dipstick calibration)
Low main pressure* See Low Pressure Section
TCC clutch not applied Inspect lockup clutch system wiring,
pressure, and controls; repair as
necessary (refer to transmission
Service Manual and Appendix B)

A. Ranges 1, 2, 3, 4 Only C1 clutch slipping, leaks at rotating Inspect C1 clutch plates,


clutch seals, leaks at piston seals, piston seals, and rotating seals;
C1 clutch plates worn* replace/rebuild as necessary
(refer to transmission Service
Manual and Appendix B)

B. Ranges 4, 5 Only C2 clutch slipping, leaks at rotating Inspect C2 clutch plates,


clutch seals, leaks at piston seals, piston seals, and rotating seals;
C2 clutch plates worn* replace/rebuild as necessary
(refer to transmission Service
Manual and Appendix B)

C. Ranges 3, 5, R Only C3 clutch slipping, leaks at piston Inspect C3 clutch plates and piston
seals, C3 clutch plates worn* seals; replace/rebuild as necessary
(refer to transmission Service
Manual and Appendix B)

D. Range 2 Only C4 clutch slipping, leaks at piston Inspect C4 clutch plates and piston
seals, C4 clutch plates worn* seals; replace/rebuild as necessary
(refer to transmission Service
Manual and Appendix B)
E. Ranges 1, R Only C5 clutch slipping, leaks at piston Inspect C5 clutch plates and piston
seals, C5 clutch plates worn* seals; replace/rebuild as necessary
(refer to transmission Service
Manual and Appendix B)

* See Inhibit Section 2–5

7–10 Copyright © 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS


Table 7–1. Troubleshooting Performance Complaints (cont’d)

Problem Possible Cause Suggested Remedy

LOW PRESSURE SECTION


A. Low or No Main Pressure Incorrect fluid level* Correct fluid level
in All Ranges (refer to Mechanic’s Tips for
proper dipstick calibration)

Clogged or faulty oil filter element* Replace oil filter


(refer to Mechanic’s Tips)

Plugged or faulty suction filter* Clean or replace oil suction filter


element and refill the transmission
(refer to Mechanic’s Tips)
Sticking main pressure regulator Overhaul front support assembly
valve* (refer to transmission Service
Manual)

Leaking solenoids in control valve Repair or replace solenoids


assembly* (refer to Mechanic’s Tips)

G solenoid failure Replace G solenoid. See


transmission Service Manual.

Weak, broken, or missing main Check spring and replace if


pressure regulator valve spring* necessary (refer to transmission
Service Manual)

Control valve body leakage* Replace or rebuild control valve


(loose control valve body bolts) assembly. Care should be taken
when removing and labeling shift
springs (refer to transmission
Service Manual)

Faulty or incorrect fluid pressure Repair or replace gauge


gauge*

Worn or damaged oil pump* Replace or rebuild oil pump (refer to


transmission Service Manual)

Leak in suction circuit* Check suction circuit for leaking


seal, gasket, or mating surface

B. Low Main Pressure in Specific See transmission Service Manual


Ranges, Normal Pressure in
Other Ranges

* See Inhibit Section 2–5

Copyright © 2003 General Motors Corp. 7–11


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS

NOTES

7–12 Copyright © 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDICES — INDEX
APPENDICES

Appendix A Diagnosing Intermittent DTCs

Appendix B Main Pressure Check Procedure

Appendix C Solenoid and Clutch Table

Appendix D Wire/Connector Table

Appendix E Connector Repair Information

Appendix F TPS Adjustment

Appendix G Welding on Vehicle

Appendix H Hydraulic Schematics

Appendix J Wiring Schematics

Appendix K Resistance vs. Temperature

Appendix L Electronic Interference

Appendix M Diagnostic Tool Information

Appendix N Input/Output Function Schematics

Appendix P Fluid Check Procedure

Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDICES

NOTES

Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX A — DIAGNOSING INTERMITTENT DTCS

Intermittent Diagnostic Trouble Codes (DTC) are a result of faults that are detected, logged, and then disappear,
only to recur later. If, when troubleshooting, a DTC is cleared in anticipation of it recurring and it does not, check the
items in the following list for the fault’s source.

A. Circuit Inspection
1. Intermittent power/ground problems — can cause voltage problems during TCM diagnostic checks
which can set various DTCs depending upon where the TCM was in the diagnostic process.
2. Damaged terminals.
3. Dirty or corroded terminals.
4. Terminals not fully seated in the connector. Check indicated wires by uncoupling connector and
gently pulling on the wire at the rear of the connector and checking for excessive terminal
movement.
5. Connectors not fully mated. Check for missing or damaged locktabs.
6. Screws or other sharp pointed objects pushed into or through one of the harnesses.
7. Harnesses which have rubbed through and may be allowing intermittent electrical contact between
two wires or between wires and vehicle frame members.
8. Broken wires within the braiding and insulation.

B. Finding an Intermittent Fault Condition


To find a fault, like one of those listed, examine all connectors and the external wiring harnesses. Harness
routing may make it difficult to see or feel the complete harness. However, it is important to thoroughly
check each harness for chafed or damaged areas. Road vibrations and bumps can damage a poorly
installed harness by moving it against sharp edges and cause some of the faults. If a visual inspection
does not identify a cause, move and wiggle the harness by hand until the fault is duplicated.

The next most probable cause of an intermittent DTC is an electronic part exposed to excessive vibration,
heat, or moisture. Examples of this are:

1. Exposed harness wires subjected to moisture.


2. A defective connector seal allows moisture to enter the connector or part.
3. An electronic part (TCM, solenoid, or throttle sensor) affected by vibration, heat, or moisture may
cause abnormal electrical conditions within the part.
When troubleshooting Item 3, eliminate all other possible causes before replacing any parts.

Another cause of intermittent DTCs is good parts in an abnormal environment. The abnormal environment
will usually include excessive heat, moisture, or voltage. For example, a TCM that receives excessive
voltage will generate a diagnostic code as it senses high voltage in a circuit. The DTC may not be repeated
consistently because different circuits may have this condition on each check. The last step in finding an
intermittent DTC is to observe if the DTC is set during sudden changes in the operating environment.

Troubleshooting an intermittent DTC requires looking for common conditions that are present whenever the
DTC is diagnosed. Use the failure record information from the scan tool to identify the conditions when the
DTC was set.

Copyright© 2003 General Motors Corp. A–1


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX APPENDIX
A — IDENTIFICATION OF POTENTIAL
A — DIAGNOSING CIRCUIT
INTERMITTENT DTCSPROBLEMS

C. Recurring Conditions
A recurring condition might be:

• Rain
• Outside temperature above or below a certain temperature
• Only on right-hand or left-hand turns
• When the vehicle hits a bump, etc.
If such a condition can be related to the DTC, it is easier to find the cause. If the time between DTC
occurrences is very short, troubleshooting is easier than if it is several weeks or more between DTC
occurrences.

• Repair parts for the internal wiring harness will be available through the Allison Transmission Parts
Distribution Center (PDC). Use the P/N from your appropriate parts catalog or from Appendix E in
this manual. Allison Transmission is responsible for warranty on these parts.
• Repair parts for the external harnesses and external harness components must be obtained
through the vehicle OEM and the OEM is responsible for warranty on these parts.

A–2 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX B — MAIN PRESSURE CHECK PROCEDURE

Checking main pressures helps to determine if a transmission malfunction is due to a mechanical or an electrical
problem. Properly making these pressure checks requires transmission and vehicle (or test stand) preparation,
recording of data, and comparing recorded data against specifications provided.

MAIN PRESSURE TAP

BOTTOM VIEW
V05742

Figure B–1. Main Pressure Check Point

Observe safety precautions during hydraulic pressure check procedures. All


personnel must stand clear of the vehicle. Take precautions against movement of the
WARNING! vehicle. Be sure that gauges (vacuum, pressure, tachometer) have extended lines so
that they can be read from inside the vehicle.

1. All transmission fluid level and pressure checks must be made at normal operating temperatures
71–93°C (160–200°F) sump; 82–104°C (180–220°F) converter-out. Check transmission fluid level.
2. Connect a 0–2070 kPa (0–300 psi) oil pressure gauge at the main pressure tap (Figure B–1). Use
the scan tool to check engine rpm. See Table B–1 for main pressure levels.
3. Disconnect the driveshaft.
4. With brakes applied, check main pressure with the engine running at 2100 rpm and 600 rpm.
5. Continue the procedure for all ranges.

Copyright© 2003 General Motors Corp. B–1


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX B — MAIN PRESSURE CHECK PROCEDURE

Table B–1. Main Pressure Test Conditions

(Used Prior To S/N 6310004116)

Range Main Pressure @ 600 rpm Main Pressure @ 2100 rpm

Forward (Converter — Torque


800–1380 kPa (115–200 psi) 1515–1795 kPa (220–260 psi)
Converter Clutch not applied)

Forward (Torque Converter


— 1000–1170 kPa (145–170 psi)
Clutch Applied)

Reverse 800–1380 kPa (115–200 psi) 1515–1795 kPa (220–260 psi)

Neutral/Park 900–1655 kPa (130–240 psi) 1515–1795 kPa (220–260 psi)

(Used Starting With S/N 6310004116)

Range Main Pressure @ 600 rpm Main Pressure @ 2100 rpm

Forward (Converter) 700–1280 kPa (101–186 psi) 1515–1795 kPa (220–260 psi)

Forward (Torque Converter


— 1000–1170 kPa (145–170 psi)
Clutch Applied)

Reverse 700–1280 kPa (101–186 psi) 1515–1795 kPa (220–260 psi)

Neutral/Park 800–1655 kPa (130–240 psi) 1515–1795 kPa (220–260 psi)

Table B–2. Modulated Main Pressure Schedule (Transmissions with Modulated Main G Solenoid)

Range Main Pressure @ 600 rpm Main Pressure @ 2100 rpm


Forward/Reverse Converter with
590–720 kPa (85–105 psi) 634–758 kPa (92–110 psi)
G Solenoid Active
Forward Converter with G Solenoid Inactive 700–1380 kPa (101–200 psi) 1515–1795 kPa (220–260 psi)
Forward Lockup with G Solenoid Active* — 510–627 kPa (74–91 psi)
Forward Lockup with G Solenoid Inactive* — 1000–1170 kPa (145–170 psi)
Neutral/Park with G Solenoid Active 590–720 kPa (85–105 psi) —
Neutral/Park 800–1655 kPa (130–240 psi) 1515–1795 kPa (220–260 psi)
* Medium duty gasoline engines only.

B–2 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX C — SOLENOID AND CLUTCH TABLE

Normal operation of the transmission requires application of two clutches to attain a forward or reverse range. A
unique combination of solenoid and shift valve actuation produces clutch application in a given range. Table C–1
lists the transmission range shifts, the clutches that are applied in each range, and the electrical state (On/Off) of
each solenoid for each range.

C–1. Solenoid and Clutch Table — Software Levels Prior To N04

Clutch Trim Solenoids Shift Solenoids TCC Sol


Range Status Logic To Main A B C D E F
Steady State R — De-energized; Energized; ON ON ON OFF
C3 Applied C5 Applied
Garage Shift R–N — De-energizing; Energizing; ON ON ON OFF
C3 Trimming Off C5 Applied
Garage Shift N–R — Energizing; Energizing; ON ON ON OFF
C3 Trimming On C5 Applied
Steady State N — De-energized; De-energized; ON ON ON OFF
C5 Applied — Exhausted
Garage Shift N–1 — De-energizing; Energizing; ON ON ON OFF
C5 Applied C1 Trimming On
Garage Shift 1–N — De-energizing; Energizing; ON ON ON OFF
C5 Applied C1 Trimming Off
Steady State 1 C1 De-energized; De-energized; OFF ON OFF OFF
C5 Applied C4 Exhausted
Upshift 1–2 C1 Energizing; Energizing; OFF ON OFF OFF
C5 Trimming Off C4 Trimming On
Downshift 2–1 C1 Energizing; Energizing; OFF ON OFF OFF
C5 Trimming On C4 Trimming Off
Steady State 2 C1 Energized; Energized; OFF OFF OFF ON or
C3 Exhausted C4 Applied OFF *
Upshift 2–3 C1 De-energizing; De-energizing; OFF OFF OFF ON
C3 Trimming On C4 Trimming Off
Downshift 3–2 C1 De-energizing; De-energizing; OFF OFF OFF ON
C3 Trimming Off C4 Trimming On
Steady State 3 C1 De-energized; De-energized; ON OFF OFF ON
C3 Applied C2 Exhausted
Upshift 3–4 C1 Energizing; Energizing; ON OFF OFF ON
C3 Trimming Off C2 Trimming On
Downshift 4–3 C1 Energizing; Energizing; ON OFF OFF ON
C3 Trimming On C2 Trimming Off
Steady State 4 C2 Energized; Energized; ON OFF ON ON
C3 Exhausted C1 Applied
Upshift 4–5 C2 De-energizing; De-energizing; ON OFF ON ON
C3 Trimming On C1 Trimming Off
Downshift 5–4 C2 De-energizing; De-energizing; ON OFF ON ON
C3 Trimming Off C1 Trimming On
Steady State 5 C2 De-energized; De-energized; OFF OFF ON ON
C3 Applied
* Depending upon output speed

Copyright© 2003 General Motors Corp. C–1


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX C — SOLENOID AND CLUTCH TABLE

Table C–1. Solenoid and Clutch Table — Software Level N04 And Later

Clutch Trim Solenoids Shift Solenoids TCC Sol


Range Status Logic To Main A B C D E F
Steady State R — De-energized; Energized; ON ON ON OFF
with Throttle C3 Applied C5 Applied
Steady State R — De-energized; Energized; OFF ON ON OFF
at Closed C5 Applied C3 Applied
Throttle
Garage Shift R–N — De-energizing; Energized; OFF ON ON OFF
C3 Trimming Off C5 Applied
Garage Shift N–R — Energizing; Energizing; OFF ON ON OFF
C3 Trimming On C5 Applied
Steady State N — De-energized; De-energized; ON ON ON OFF
C5 Applied — Exhausted
Garage Shift N–1 — De-energizing; Energizing; ON ON ON OFF
C5 Applied C1 Trimming On
Garage Shift 1–N — De-energizing; Energizing; ON ON ON OFF
C5 Applied C1 Trimming Off
Steady State 1 C1 De-energized; De-energized; OFF ON OFF OFF
C5 Applied C4 Exhausted
Upshift 1–2 C1 Energizing; Energizing; OFF ON OFF OFF
C5 Trimming Off C4 Trimming On
Downshift 2–1 C1 Energizing; Energizing; OFF ON OFF OFF
C5 Trimming On C4 Trimming Off
Steady State 2 C1 Energized; Energized; OFF OFF OFF ON or
C3 Exhausted C4 Applied OFF **
Upshift 2–3 C1 De-energizing; De-energizing; OFF OFF OFF ON
C3 Trimming On C4 Trimming Off
Downshift 3–2 C1 De-energizing; De-energizing; OFF OFF OFF ON
C3 Trimming Off C4 Trimming On
Steady State 3 C1 De-energized; De-energized; ON OFF OFF ON
C3 Applied C2 Exhausted
Upshift 3–4 C1 Energizing; Energizing; ON OFF OFF ON
C3 Trimming Off C2 Trimming On
Downshift 4–3 C1 Energizing; Energizing; ON OFF OFF ON
C3 Trimming On C2 Trimming Off
Steady State 4 C2 Energized; Energized; ON OFF ON ON
C3 Exhausted C1 Applied
Upshift 4–5 C2 De-energizing; De-energizing; ON OFF ON ON
C3 Trimming On C1 Trimming Off
Downshift 5–4 C2 De-energizing; De-energizing; ON OFF ON ON
C3 Trimming Off C1 Trimming On
Steady State 5 C2 De-energized; De-energized OFF OFF ON ON
C3 Applied
Beginning with N04 software level, the following throttle-dependent conditions occur in Reverse range:
At closed throttle (idle), C solenoid is OFF, A trim solenoid controls C-5 clutch, and B solenoid controls C-3 clutch.
Above 20 percent throttle*, C solenoid is ON, A trim solenoid controls C-3 clutch, and B solenoid controls C-5.
Under 10 percent throttle*, the TCM reverts to the closed throttle (idle) schedule.
* Values are calibration dependent ** Depending upon output speed

C–2 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX D — WIRE/CONNECTOR TABLES

The connector information in this appendix is provided for the convenience of the servicing technician. The
connector illustration and pin identifications for connection to Allison Transmission components will be accurate.
Allison Transmission components are the TCM, speed sensors, and transmission connectors. Other kinds of
connectors for optional or customer-furnished components are provided based on typical past practice for an
Allison-designed system.

Contact your vehicle manufacturer for information on connectors not found in this appendix.

Copyright© 2003 General Motors Corp. D–1


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX D — WIRE/CONNECTOR TABLES

COLOR CODE RED

16 1

32 17

V06211

Figure D–1. TCM Connector J2


TCM CONNECTOR J2 (RED)
Terminal No. Color Wire No. Description Termination Point(s)
1 Blue 201 PSM Input TRANS-D
2 Pink 202 PSM Input TRANS-F
3 White 203 PSM Input TRANS-E
4 Green 204 PSM Input TRANS-K
5 Blue 205 NSBU Input NSBU-4A
6 Yellow 206 NSBU Input NSBU-4D
7 Gray 207 NSBU Input NSBU-4B
8 White 208 NSBU Input NSBU-4C
9 Blue 209 Throttle Position Sensor TPS-B
10 Tan 210 Sump Temperature Input TRANS-G
11 Orange 211 Retarder Temperature Input RTEMP-A
(optional)
12 Blue 212 Engine Coolant Temperature Input ENGWAT TEMP-A
(optional)
13 Orange 213 Turbine Speed Sensor High NT-A
14 Blue 214 Turbine Speed Sensor Low NT-B
15 Yellow 215 Output Speed Sensor High NO-A
16 Green 216 Output Speed Sensor Low NO-B
17 Tan 217 Engine Speed Sensor High NE-A
18 Orange 218 Engine Speed Sensor Low NE-B
19 Pink 219 Sensor Power TPS-C
20 Green 220 Analog Ground TRANS-H, R-TEMP-B, ENG-WAT
TEMP-B, NSBU-7D, TPS-A
21 Yellow 221 TRANS-T
22 Yellow 222 A Solenoid High (VBS) Variable TRANS-L
Bleed Solenoid
23 White 223 A Solenoid Low (VBS) Variable TRANS-M
Bleed Solenoid
24 Pink 224 B Solenoid High (VBS) Variable TRANS-N
Bleed Solenoid
25 Orange 225 B Solenoid Low (VBS) Variable TRANS-P
Bleed Solenoid
26 Green 226 C Solenoid Low (ON/OFF) TRANS-A
27 Blue 227 D Solenoid Low (ON/OFF) TRANS-B
28 Gray 228 E Solenoid Low (ON/OFF) TRANS-W
29 White 229 F Solenoid Low (PWM) TRANS-J
30 Blue 230 G Solenoid Low (ON/OFF) TRANS-R
31 Tan 231 ON/OFF Solenoid High TRANS-C
32 Green 232 PWM Solenoid High/G Solenoid TRANS-S
D–2 Copyright© 2003 General Motors Corp.
ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX D — WIRE/CONNECTOR TABLES

COLOR CODE GRAY

16 1

32 17

V06212

Figure D–2. TCM Connector J1

TCM CONNECTOR J1 (GRAY)


Terminal No. Color Wire No. Description Termination Point(s)
1 Gray 101 Battery Ground Vehicle System
2 Yellow 102 Ignition Power Vehicle System
3 Pink 103 Battery Power Vehicle System
4 Yellow 104 Ignition Power Vehicle System
5 Gray 105 Battery Ground Vehicle System
6 Blue 106 GPI 1 Vehicle System
7 Orange 107 GPI 2 Vehicle System
8 Green 108 GPI 3 Vehicle System
9 White 109 GPI 4 Vehicle System
10 Yellow 110 GPI 5 Vehicle System
11 Green 111 GPI 6 Vehicle System
12 Blue 112 GPI 7 Vehicle System
13 Pink 113 GPI 8 Vehicle System
14 Orange 114 GPI 9 Vehicle System
15
16 White 116 PWM Throttle Vehicle System
17 Pink 117 Sensor Power (optional) RMR-C
18 Green 118 Analog Ground RMR-A
19 Tan 119 GPO 1 Vehicle System
20 Orange 120 GPO 2 Vehicle System
21 White 121 GPO 3 Vehicle System
22 Blue 122 GPO 4 Vehicle System
23 Pink 123 Range Inhibit Indicator Vehicle System
24 White 124 GPO 6 Vehicle System
25 Green 125 CHECK TRANS Vehicle System
26 Tan 126 Vehicle Speed Vehicle System
27 Pink 127 Vehicle Speed Vehicle System
28 Yellow 128 Digital Ground Vehicle System
29 Red 129 CAN High J1939 A or H
30 Blue 130 ISO 9141 Class II J-1850 Vehicle System
31 Green 131 CAN Shield J1939 C or S
32 Black 132 CAN Low J1939 B or L

Copyright© 2003 General Motors Corp. D–3


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX D — WIRE/CONNECTOR TABLES

TRANSMISSION HARNESS TRANSMISSION BULKHEAD


CONNECTOR CONNECTOR
S K K S
D R
R D
W W
COLOR CODE GREEN

HARNESS DEVICE

T A A
L E E L T
NOTE: Letters I, O, and Q not used V03369.01.00

Figure D–3. Delphi-Packard Main Transmission Connector

DELPHI-PACKARD MAIN TRANSMISSION CONNECTOR


Terminal No.* Color Wire No. Description Termination Point(s)*
A Green 226 C Solenoid Low (ON/OFF) TCM J2-26
B Yellow/Black 227 D Solenoid Low (ON/OFF) TCM J2-27
C Pink 231 ON/OFF Solenoid High TCM J2-31
D Light Green 201 PSM Input TCM J2-1
E Red 203 PSM Input TCM J2-3
F Dark Blue 202 PSM Input TCM J2-2
G Yellow 210 Sump Temperature Input TCM J2-10
H Black 220 Analog Ground TCM J2-20
J Brown 229 F Solenoid Low (PWM) TCM J2-29
K Tan 204 PSM Input TCM J2-4
L Red/Black 222 A Solenoid High Variable Bleed TCM J2-22
Solenoid (VBS)
M Light Blue 223 A Solenoid Low Variable Bleed TCM J2-23
Solenoid (VBS)
N Gray 224 B Solenoid High Variable Bleed TCM J2-24
Solenoid (VBS)
P Purple 225 B Solenoid Low Variable Bleed TCM J2-25
Solenoid (VBS)
R Blue 230 G Solenoid Low (ON/OFF) TCM J2-30
S Black 232 PWM Solenoid High/F, G Solenoid TCM J2-32
T White 221 TCM J2-21
U Dark Green — — —
V Dark Green — — —
W Black/White 228 E Solenoid Low (ON/OFF) TCM J2-28

* Terminal number and termination points shown only apply when an Allison Transmission recommended harness
configuration and bulkhead connector are used.
D–4 Copyright© 2003 General Motors Corp.
ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX D — WIRE/CONNECTOR TABLES

PIN A PIN B

B A

RECEPTACLE
PLUG
V05738

Figure D–4. Speed Sensor Connector

ENGINE SPEED SENSOR CONNECTOR


Terminal No. Color Wire No. Description Termination Point(s)
A Tan 217 Engine Speed Sensor Hi TCM J2-17
B Orange 218 Engine Speed Sensor Lo TCM J2-18

TURBINE SPEED SENSOR CONNECTOR


Terminal No. Color Wire No. Description Termination Point(s)
A Orange 213 Turbine Speed Sensor Hi TCM J2-13
B Blue 214 Turbine Speed Sensor Lo TCM J2-14

OUTPUT SPEED SENSOR CONNECTOR


Terminal No. Color Wire No. Description Termination Point(s)
A Yellow 215 Output Speed Sensor Hi TCM J2-15
B Green 216 Output Speed Sensor Lo TCM J2-16

Copyright© 2003 General Motors Corp. D–5


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX D — WIRE/CONNECTOR TABLES

A C

PIN C PIN B PIN A


B
PLUG
RECEPTACLE
V05739

Figure D–5. TPS Connector

THROTTLE POSITION SENSOR CONNECTOR


Terminal No. Color Wire No. Description Termination Point(s)
A Green 220 Analog Ground TCM J2-20
B Blue 209 TPS Signal TCM J2-9
C Pink 219 TPS Hi TCM J2-19

D–6 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX D — WIRE/CONNECTOR TABLES

A or H B or L

B or L C or S A or H C or S
MALE CONNECTOR FEMALE CONNECTOR
V06532

Figure D–6. J1939 Interface Connector

J1939 INTERFACE CONNECTOR


J1939 Connector TCM Connector
Terminal No. Color Wire No. Description Terminal No. Color
A or H Yellow 129 J1939 Controller, High TCM J1-29 Red
B or L Green 132 J1939 Controller, Low TCM J1-32 Black
C or S Uninsulated 131 J1939 Shield/Ground TCM J1-31 Green

Copyright© 2003 General Motors Corp. D–7


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX D — WIRE/CONNECTOR TABLES

PIN 7A PIN 7G

4C
7G 7A 4A

4D PIN 7E
PIN 7D
4B
7E 7D

7-WAY RECEPTACLE 4-WAY RECEPTACLE PIN 4C


PIN 4A
PIN 4D
PIN 4B

PLUG
V05740

Figure D–7. NSBU Switch Connectors

NSBU SWITCH CONNECTOR


Terminal No. Color Wire No. Description Termination Point(s)
4A Blue 205 NSBU Output TCM J2-5
4B Gray 207 NSBU Output TCM J2-7
4C White 208 NSBU Output TCM J2-8
4D Yellow 206 NSBU Output TCM J2-6
7A — — — —
7B Tan — NSBU Input Park Accessory
7C Blue — NSBU Output Reverse and Park
Accessory Feed
7D Green 220 Analog Ground TCM J2-20
7E Yellow — NSBU Output Park and Neutral Start
Feed
7F Pink — NSBU Input Reverse Lamps
7G Orange — NSBU Input Starter Solenoid/Starter
Relay

D–8 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX D — WIRE/CONNECTOR TABLES

PIN 12

12
PIN 11

6
11

PIN 6
PIN 7
3

PIN 3 7

PIN 1

PIN LOCATION ON
NSBU SWITCH

CONNECTOR
END VIEW

SINGLE CONNECTOR
NILES NSBU SWITCH
(P/N 29541852) V08100.00.00

Figure D–8. Single Connector NSBU

NSBU SWITCH CONNECTOR


Terminal No. Color Wire No. Description Termination Point(s)
1 Orange — NSBU Input Starter Solenoid/Starter
Relay
2 and 3 — — — —
4 Yellow 206 NSBU Output TCM J2-6
5 Blue 205 NSBU Output TCM J2-5
6 Gray 207 NSBU Output TCM J2-7
7 Green 220 Analog Ground TCM J2-20
8 White 208 NSBU Output TCM J2-8
9 — — — —
10 Pink — NSBU Input Reverse Lamps
11 Blue — NSBU Output Reverse and Park
Accessory Feed
12 Yellow — NSBU Output Park and Neutral Start
Feed

Copyright© 2003 General Motors Corp. D–9


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX D — WIRE/CONNECTOR TABLES

D
E
C

F A B

J
G
H

9-PIN
V06481

Figure D–9. Deutsch DDR Connector

SAE STD 9-PIN DIAGNOSTIC (J1939 DIAGNOSTIC LINK) CONNECTOR


Terminal No. Color Wire No. Description Termination Point(s)
A Determined By OEM — Battery Ground (–) Vehicle System
B Determined By OEM — Ignition Power (+) Vehicle System
B (Optional) Determined By OEM — Battery Power (+) Vehicle System
C Yellow 129 J1939 High J1939 Backbone A
D Green 132 J1939 Low J1939 Backbone B
E Uninsulated 131 J1939 Shield/Ground J1939 Backbone C
F Determined By OEM — Serial Communication (+) Vehicle System
G Determined By OEM — Serial Communication (–) Vehicle System

D–10 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX D — WIRE/CONNECTOR TABLES

SOL C
AB

GRAY MAIN
TRANSMISSION
CONNECTOR
SOL G
AB

A
B
C
D
E
F
PSM SOL A
GRAY 2 1

LOCKARM
SOL B 2 1

LOCKARM
SOL E
AB

SOL D
SOL F AB
GRAY
BA

GRAY
BLUE V07482.04.00

Figure D–10. Transmission Internal Harness

TRANSMISSION INTERNAL HARNESS CONNECTORS


Main Connector
Connector Name Connector Pin No. Pin No. Wire Color TCM Pin No.
Solenoid A 1 M Light Blue J2–23
2 L Red/Blk Strp J2–22
Solenoid B 1 N Gray J2–24
2 P Purple J2–25
Solenoid C A C Pink J2–31
B A Dark Green J2–26
Solenoid D A C Pink J2–31
B B Yellow/Blk Strp J2–27
Solenoid E A C Pink J2–31
B W Black/Wht Strp J2–28
Solenoid F A S Black J2–32
B J Brown J2–29
Solenoid G A S Black J2–32
B R Orange J2–30
Pressure Switch Manifold A D Light Green J2–1
B F Dark Blue J2–2
C E Red J2–3
D K Tan J2–4
E G Yellow J2–10
F H,T (Trans ID) Blk (H), White (T) J2–20, J2–21

Copyright© 2003 General Motors Corp. D–11


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX D — WIRE/CONNECTOR TABLES

NOTES

D–12 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E — CONNECTOR REPAIR INFORMATION

Contents Page
List of Special Tools Required To Service 1000/2000/2400 Series Wiring Harnesses . . . . . . . . E–2
1–1. Delphi-Packard Micro Pack 100W Connectors (TCM J1 and J2, Main Transmission E–5
Connector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1–2. Delphi-Packard Metri-Pack 150 Series Connectors — Pull-to-Seat (Speed Sensors) . . . . . . . . . E–9
1–3. Delphi-Packard Metri-Pack 150 Series Connectors — Push-to-Seat (NSBU Switch). . . . . . . . . . E–13
1–4. Internal Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–16
1–5. Delphi-Packard WeatherPack Connectors (TPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–19
1–6. Deutsch IPD/ECD (J1939 Diagnostic 9-Way Connector Link Connector). . . . . . . . . . . . . . . . . . . E–23
1–7. Deutsch DT Series Connectors (3-Way J1939 Connector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–27
1–8. Repair of a Broken Wire with In-Line Butt Splice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–29
1–9. List of 1000 Series™/2000 Series™/2400 Series™ Connector Parts. . . . . . . . . . . . . . . . . . . . . . E–31

NOTE: Allison Transmission is providing for service of wiring harnesses and wiring harness
components as follows:

• Repair parts for the internal wiring harness will be available through the Allison Transmission
Parts Distribution Center (PDC). Use the P/N from your appropriate parts catalog or from
Appendix E in this manual. Allison Transmission is responsible for warranty on these parts.
• Repair parts for the external harnesses and external harness components must be obtained
through the vehicle OEM and the OEM is responsible for warranty on these parts.

Copyright© 2003 General Motors Corp. E–1


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E — CONNECTOR REPAIR INFORMATION

List Of Special Tools Required To Service


1000 Series™, 2000 Series™, 2400 Series™ Wiring Harnesses

Tool Number Tool Type Paragraph Reference


23046604 Splice, Sealed (14–16 AWG) 1–8
23046605 Splice, Sealed (18–22 AWG) 1–8
J 25070 Heat Gun 1–8
J 34182 Crimper 1 1–6, 1–7
J 34513 Remover 1 1–6
J 35123 Crimper (Alternate) 1–2, 1–3
J 35606 Crimper (Alternate) 1–5
J 35615 Wire Stripper 1 1–2, 1–3, 1–8
J 35689-A Remover 1–2, 1–3
J 38125-10 Remover 1–5
J 38125-6 Crimper 1–5
J 38125-7 Crimper 1–2
J 38125-8 Crimper 1–8
J 38582-3 Remover 1–6
J 38852 Crimper (Alternate) 1–5
J 39227 Remover 1–1
J 41194 Extractor/Inserter 1–6
J 42215 Crimper 1–1

E–2 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E — CONNECTOR REPAIR INFORMATION

RETAINER

SOCKET TERMINAL (FEMALE)

CONNECTOR

TYPICAL WIRE

SEAL

LOCKTAB (SECURES
RETAINER)

TERMINAL LOCKING
FINGER
LOCKING POST

STRAIN RELIEF

LOCKTABS

CAVITY PLUG

Lock terminal
here
SOCKET TERMINAL

WIRE

J 42215 CRIMPING TOOL


V03419

Figure E–1A. Delphi-Packard Micro Pack Connector (TCM J1 and J2)

Copyright© 2003 General Motors Corp. E–3


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E — CONNECTOR REPAIR INFORMATION

J 39227
REMOVAL
TOOL

MATING CONNECTOR
WITH FEMALE (SOCKET)
TEMINALS

SECONDARY LOCK
VIEW A

LOCKING
FINGERS WIRE

WIRE SEAL
VIEW A

CAVITY PLUG

CONDUIT CLIP

SOCKET
TERMINAL

Lock terminal here


PIN TERMINAL

WIRE

J 42215 CRIMPING TOOL


V05743

Figure E–1B. Delphi-Packard Micro Pack Connector (Main Transmission Connector)

E–4 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E — CONNECTOR REPAIR INFORMATION

1–1. DELPHI-PACKARD MICRO PACK 100W CONNECTORS


(TCM J1 AND J2, MAIN TRANSMISSION CONNECTOR)
A. Connector/Terminal Repairs

Required Tools
Crimping Tool J 42215
Remover Tool J 39227
Use Description Manufacturers P/N
Main Transmission Connector Connector, 20F MIC/P 100W Gray 12160280
Lock, Secondary 20F Green 12160494
Terminal, Socket 100W 12084912
Cavity Plug, 100W 12129557
Conduit Clip, 13mm Black 12176394

B. Terminal Removal
1. TCM Harness Connectors (Figure E–1A)
a. Use a small-bladed screwdriver to gently release the locktabs at the splitline of the strain relief.
b. Spread the strain relief open.
c. Remove the retainer from the connector by using a small-bladed screwdriver to depress the
locktabs on the side of the connector.
d. Remove a selected terminal by pushing forward on the wire or by lifting the locking finger and
pulling the wire and terminal rearward out of the connector.
2. Main Transmission Connectors (Figure E–1B)
a. Use a small bladed screw driver to gently release the locktabs at the split line of the conduit
clamp.
b. Remove conduit clamp.
c. Use a small-bladed screw driver to gently release the locktab remove the lock assembly.
d. Remove a selected terminal by pushing forward on the wire or by lifting the locking finger and
pulling the wire and terminal rearward out of the connector.

C. Terminal Crimping
1. Carefully strip 5.0 mm ±0.5 mm (0.20 ±0.02 inch) of insulation from the end of the wire.
2. Insert the new terminal to be crimped in the J 42215 crimping tool. There is a spring-loaded
terminal positioner at the front of the tool to hold the terminal in place. Squeeze the crimper
handles for a few clicks to start the crimping process but leave room to insert the wire end.
3. Insert the bare wire end into the terminal. Squeeze the crimper handles to complete the crimping
process and until the crimper handles open when released to remove the terminal/wire from the
tool.

Copyright© 2003 General Motors Corp. E–5


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E — CONNECTOR REPAIR INFORMATION

C. Terminal Crimping (cont’d)


4. Complete terminal installation for Main Transmission Connector as follows: (Figure E–1B)
a. Insert the wire seal in the back of the connector.
b. Push the terminal/wire assembly through the proper hole in the back of the wire seal. Push the
wire in until the terminal clicks into position. Gently pull rearward on the wire to be sure that the
terminal is fully seated. Install cavity plugs as needed.
c. Install the lock assist or secondary lock into the connector body.
d. Close the conduit clip around the conduit and lock the clip into the rear of the connector body.
5. Complete terminal installation of the TCM Connectors as follows: (Figure E–1A)
a. Align the locking posts on the connector with the seal and push the locking posts through the
seal into the mating holes in the strain relief (if the connector was removed from the strain
relief).
b. Push the terminal/wire assembly through the proper hole in the back of the seal. Push the wire
in until the terminal clicks into position.

NOTE: All terminals must be properly positioned to install the retainer in Step (5c).

c. Install the retainer on the connector body to lock the terminals in position. Pull gently on the wire
to be sure that the terminal is fully seated. Install cavity plugs as needed.
d. Position the conduit inside the strain relief and snap the strain relief halves together.

E–6 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E — CONNECTOR REPAIR INFORMATION

NOTES

Copyright© 2003 General Motors Corp. E–7


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E — CONNECTOR REPAIR INFORMATION

RETAINER Seal plug


butts up here

CONNECTOR

Remove in J 35689-A
this direction

Seat in
WIRE AND this direction
TERMINAL

Insertion of removal tool (J 35689-A) forces


lock tang toward body of terminal

VIEW A

Butt wire against terminal holder

Use wire gauge 18-16 slot

WIRE SIDE
18-16
22-20
E
C
A

J 38125-7
D

TERMINAL
B

VIEW B
Push lock to insert
terminal end

J 35123
WIRE SIDE

TERMINAL HOLDER
18-16
22-20

VIEW C V05744

Figure E–2. Delphi-Packard Metri-Pack 150 Series Connectors — Pull-to-Seat


(Speed Sensors)

E–8 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E — CONNECTOR REPAIR INFORMATION

1–2. DELPHI-PACKARD METRI-PACK 150 SERIES CONNECTORS — PULL-TO-SEAT


(SPEED SENSORS)
A. Connector/Terminal Repairs

Required Tools
Crimping Tool J 38125-7
Wire Crimp Anvil “E”
Insulation Crimp Anvil “C”
Alternate Crimping Tool J 35123
Remover Tool J 35689-A
Automatic Wire Stripper J 35615
Use Description Manufacturers P/N
Engine Speed (Ne) Sensor Connector 12162193
Terminal 12103881
Turbine Speed (Nt) Sensor Connector 12162193
Terminal 12103881
Output Speed (No) Sensor Connector 12162193
Terminal 12103881

B. Terminal Removal

NOTE: Do not solder crimps.

1. Insert the needle end of terminal remover J 35689-A into the small notch between the connector
and the terminal to be removed (Figure E–2, View A). Push the lock tang toward the terminal.
2. Push the wire and terminal out of the connector (this is a “pull-to-seat” terminal).
3. Pull the terminal as far as necessary from the connector. This will be limited by the number of other
wires inserted into the connector and by the distance between the back side of the connector and
the beginning of the harness covering.
4. If a terminal is to be replaced, cut the terminal between the core and the insulation crimp to
minimize wire loss.

C. Terminal Crimping — Speed Sensor Terminals (Standard Crimping Tool)


1. If a spare wire is used, the wire should be pushed through the proper hole in the strain relief
(if used), through the wire seal, and out the other side of the connector before stripping.
2. Carefully strip 4.5 mm ±0.5 mm (0.18 ±0.02 inch) of insulation from the end of the wire. Unless the
insulation crimp is overtight, Automatic Wire Stripper J 35615 will remove the insulation and crimp
from an old terminal without damaging the wire.
3. Place the core crimp portion of the terminal on the bed of anvil “E” and squeeze the crimper
enough to keep the terminal from dropping (Figure E–2, View B).
4. Position the wire core in the terminal and squeeze the crimper tool to complete the core crimp.
Be sure to orient the terminal so that it is properly aligned with the terminal cavity in the
connector. The terminal should be positioned so that the lock tang is on the side of the cavity
which has the notch in the middle (for the remover tool).

Copyright© 2003 General Motors Corp. E–9


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E — CONNECTOR REPAIR INFORMATION

C. Terminal Crimping — Speed Sensor Terminals (Standard Crimping Tool) (cont’d)


5. Position the insulation crimp of the terminal on anvil “C” so that the entire insulation crimp area and
a portion of the terminal between the core and insulation crimp areas are supported by the anvil.
Complete the insulation crimp.
6. Be sure the lock tang is lifted to allow proper reseating of the terminal.
7. Pull on the wire to pull the terminal completely into the cavity. (A click will be heard and the
terminal should stay in place if the wire is pushed.)

D. Terminal Crimping Using Alternate Tool J 35123


1. If a spare wire is used, the wire should be pushed through the proper hole in the strain relief (if
used) and the wire seal, and out the other side of the connector prior to stripping.
2. Insert the remover tool in the front side of the connector to release the locktab, and push the
terminal out the front of connector. Pull the terminal and wire out the front of the connector to
complete Steps (3) through (7).
3. Push open the terminal holder on the crimper tool J 35123 and insert a terminal into the opening
marked 18–16 (Figure E–2, View C) so that the crimp ends point up. Release the terminal holder.
4. Slightly close the crimping tool (close until one click is heard) but do not start to crimp the terminal.
Place the terminal on the wire so it is in the same position as it will be when pulled back into the
connector. The terminal should be positioned so that the lock tang is on the side of the cavity which
has the notch in the middle (for the remover tool).
5. Insert the wire into the terminal until the wire contacts the holder. (By doing this, the core and
insulation should be properly positioned for the core and insulation crimp wings.)
6. Squeeze the crimper fully until it opens when released.
7. Open the terminal holder and remove the wire and terminal from the crimping tool.
8. Pull on the terminal to assure a tight crimp.
9. Be sure the lock tang is lifted to allow proper reseating of the terminal.
10. Pull on the wire to pull the terminal completely into the cavity. (A click will be heard and the ter-
minal should stay in place if the wire is pushed.)

E–10 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E — CONNECTOR REPAIR INFORMATION

NOTES

Copyright© 2003 General Motors Corp. E–11


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E — CONNECTOR REPAIR INFORMATION

Install in
this direction

SECONDARY LOCK

Remove in
this direction

WIRE AND TERMINAL

Insertion of removal tool (J 35689)


forces lock tang toward body
D of terminal

B
A
C

J 35689-A
VIEW A

Butt wire against


terminal holder

Use wire gauge


18-16 slot

WIRE SIDE
E
C
A

J 38125-7
18-16
22-20
D
B

VIEW B TERMINAL

Push lock to
insert terminal
end
J 35123
WIRE SIDE

TERMINAL
HOLDER
18-16
22-20

VIEW C V05745

Figure E–3. Delphi-Packard Metri-Pack 150 Series Connectors — Push-to-Seat (NSBU Switch)

E–12 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E — CONNECTOR REPAIR INFORMATION

1–3. DELPHI-PACKARD METRI-PACK 150 SERIES CONNECTORS — PUSH-TO-SEAT


(NSBU SWITCH)
A. Connector/Terminal Repairs

Required Tools
Crimping Tool J 38125–7
Wire Crimp Anvil “E”
Insulation Crimp Anvil “C”
Alternate Crimping Tool J 35123
Remover Tool J 35689–A
Automatic Wire Stripper J 35615
Use Description Manufacturers P/N
NSBU Switch 4 Way Tower Connector 12191757
Wire Type Seal, Dk Red 12048086
150f Terminal 12048074

B. Terminal Removal

NOTE: Do not solder crimps.

1. Remove the secondary lock.


2. Insert the needle end of terminal remover J 35689-A into the small notch between the connector
and the terminal to be removed (Figure E–3, View A). Push the lock tang toward the terminal.
3. Pull the wire and terminal out the rear of the connector (this is a “push-to-seat” terminal).
4. Pull the terminal as far as necessary from the connector. This will be limited by the number of other
wires inserted into the connector and by the distance between the back side of the connector and
the beginning of the harness covering.
5. If a terminal is to be replaced, cut the terminal between the core and the insulation crimp to
minimize wire loss.

C. Terminal Crimping
1. Carefully strip 4.5 mm ±0.5 mm (0.18 ±0.02 inch) of insulation from the end of the wire. Unless the
insulation crimp is overtight, Automatic Wire Stripper J 35615 will remove the insulation and crimp
from an old terminal without damaging the wire.
2. Place the core crimp portion of the terminal on the bed of anvil “E” and squeeze the crimper
enough to keep the terminal from dropping (Figure E–3, View B).
3. Position the wire core in the terminal and squeeze the crimper tool to complete the core crimp.
Be sure to orient the terminal so that it is properly aligned with the terminal cavity in the
connector. The terminal should be positioned so that the lock tang is on the side of the cavity
which has the notch in the middle (for the remover tool).
4. Position the insulation crimp of the terminal on anvil “C” so that the entire insulation crimp area and
a portion of the terminal between the core and insulation crimp areas are supported by the anvil.
Complete the insulation crimp.

Copyright© 2003 General Motors Corp. E–13


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E — CONNECTOR REPAIR INFORMATION

C. Terminal Crimping (cont’d)


5. Be sure the lock tang is lifted to allow proper reseating of the terminal.
6. Push on the wire until the terminal is completely into the cavity. (A click will be heard and the
terminal should stay in place when the wire is lightly pulled.)

D. Terminal Crimping Using Alternate Tool J 35123


1. Insert the remover tool in the front side of the connector to release the locktab, and pull the
terminal out the rear of the connector. Pull the terminal and wire out the rear of the connector to
complete Steps (3) through (7).
2. Push open the terminal holder on the crimper tool J 35123 and insert a terminal into the opening
marked 18–16 (Figure E–3, View C) so that the crimp ends point up. Release the terminal holder.
3. Slightly close the crimping tool (close until one click is heard) but do not start to crimp the terminal.
Place the terminal on the wire so it is in the same position as it will be when pulled back into the
connector. The terminal should be positioned so that the lock tang is on the side of the cavity which
has the notch in the middle (for the remover tool).
4. Insert the wire into the terminal until the wire contacts the holder. (By doing this, the core and
insulation should be properly positioned for the core and insulation crimp wings.)
5. Squeeze the crimper fully until it opens when released.
6. Open the terminal holder and remove the wire and terminal from the crimping tool.
7. Pull on the terminal to assure a tight crimp.
8. Be sure the lock tang is lifted to allow proper reseating of the terminal.
9. Push on the wire until the terminal is completely into the cavity. (A click will be heard and the
terminal should stay in place if the wire is lightly pulled.)

E–14 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E — CONNECTOR REPAIR INFORMATION

NOTES

Copyright© 2003 General Motors Corp. E–15


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E — CONNECTOR REPAIR INFORMATION

V06482.01.00

Figure E–4. Internal Wiring Harness

E–16 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E — CONNECTOR REPAIR INFORMATION

1–4. INTERNAL WIRING HARNESS


Service with internal wiring harness assembly P/N 15321154 (Figure E–4).

Copyright© 2003 General Motors Corp. E–17


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E — CONNECTOR REPAIR INFORMATION

WIRE SEAL
CONNECTOR
TERMINAL SECONDARY LOCK

THROTTLE POSITION SENSOR


CONNECTOR

J 38125-10
REMOVER TOOL

VIEW A VIEW B

WIRE SEAL
CORE CRIMP

INSULATED WIRE

STRIPPED WIRE

VIEW C

WIRE SEAL
CORE CRIMP

TERMINAL
INSULATION & SEAL CRIMP

VIEW D
5
3
1

J 38125-6
3
1
4
2

4
2

VIEW E
V01689

Figure E–5A. Delphi-Packard WeatherPack Connectors (TPS)

E–18 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E — CONNECTOR REPAIR INFORMATION

1–5. DELPHI-PACKARD WEATHERPACK CONNECTORS (TPS)


A. Connector/Terminal Repairs

Required Tools
Crimping Tool J 38125-6
Wire Crimp Anvil “2”
Insulation Crimp Anvil “5”
Alternate Crimping Tool J 35606 or J 38852
Remover Tool J 38125-10
Use Description Manufacturers P/N
Throttle Position Sensor (TPS) Connector 12015793
Terminal 12089040
Wire Seal 12089444

B. Terminal Removal
1. Unlatch and open the secondary lock on the connector (Figure E–5A, View A).
2. From the front of the connector, insert remover tool J 38125-10 over the terminal. Push the tool
over the terminal and pull the terminal out the back of the connector (Figure E–5A, View B).
3. If a terminal is to be replaced, cut the terminal between the core and the insulation crimp to
minimize wire loss.

NOTE: Two special tools are available for this operation — tool J 38125-6 (Paragraph C) and tool J 35606
or J 38852 (Paragraph D).

C. Terminal Crimping Using Crimping Tool J 38125-6


1. Place the wire seal onto the wire before stripping the wire (Figure E–5A, View C).
2. Strip 6.0 ±0.25 mm (0.24 ±0.01 inch) of insulation from the end of the wire.
3. Place the terminal onto crimping tool J 38125-6 (Figure E–5A, View E), anvil “2.”
4. Slightly close the crimping tool to hold the terminal steady.
5. Insert the wire so that the stripped portion of the wire is in the core crimp area and the insulated
portion of the wire is in the insulation crimping area (Figure E–5A, View C).
6. Crimp the stripped section of the wire.
7. Remove the terminal from the crimping tool.
8. Push the wire seal onto the terminal (Figure E–5A, View D). The second crimp will wrap around
the wire seal. This will seal the insulated area of the wire.
9. Use a pair of needle nose pliers, if necessary, to squeeze the terminal wings together to fit in
anvil “5.”
10. Crimp the wire seal in anvil “5.”
11. Tug on the terminal to be sure the crimp is tight.

Copyright© 2003 General Motors Corp. E–19


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E — CONNECTOR REPAIR INFORMATION

C. Terminal Crimping Using Crimping Tool J 38125-6 (cont’d)


12. Insert the terminal into the connector. The terminal will click into place and should not pull out.
13. Secure the secondary lock. Both sides of the connector must be latched.

D. Terminal Crimping Using Alternate Crimper Pliers J 35606 or J 38852


1. Place the wire seal onto the wire before stripping the wire (Figure E–5A, View C).
2. Strip 6.0 ±0.25 mm (0.24 ±0.01 inch) of insulation from the end of the wire.
3. Insert terminal into crimping tool J 35606 (Figure E–5B, View A), opening marked 18–20.
4. Position the terminal so the crimp wings are pointing up from the bottom jaw of the crimper and are
properly positioned.
5. Slightly close the crimping tool to hold the terminal steady.
6. Slide the wire seal to the edge of the insulation and insert the wire and seal into the terminal
(Figure E–5B, View B).
7. Position the wire and seal and squeeze the crimping tool until it opens when released.
8. Tug on the terminal to be sure the crimp is tight.
9. Insert the terminal into the connector. The terminal will click into place and should not pull out.
10. Secure the secondary lock. Both sides of the connector must be latched.

Figure E–5B. Terminal Crimping With Tool J 35606

E–20 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E — CONNECTOR REPAIR INFORMATION

NOTES

Copyright© 2003 General Motors Corp. E–21


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E — CONNECTOR REPAIR INFORMATION

9-PIN RECEPTACLE

PIN REMOVER
J 34513

WIRES

VIEW C

CONNECTOR

RECEPTACLE

REMOVER
J 34513

REMOVER
J 38582-3 VIEW A

J 34182 CRIMPER
TERMINAL EXTRACTOR / INSERTER
J 41194 TO ROT
ISE A
RA

TE

INSPECTION HOLE SEL


NO.

PIN TERMINAL TERMINAL WIRE SIZE


INSPECTION HOLE INDICATOR

SOCKET TERMINAL

LOCKING RING
;;
;
CAVITY PLUG DEPTH ADJUSTMENT SCREW

VIEW B

V05748

Figure E–6. Deutsch IPD/ECD Connectors (9-Way DDR)

E–22 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E — CONNECTOR REPAIR INFORMATION

1–6. DEUTSCH IPD/ECD CONNECTORS (J1939 DIAGNOSTIC LINK 9-WAY DDR)


A. Connector/Terminal Repairs

Required Tools
Crimping Tool J 34182
Extractor/Inserter Tool J 41194 (18 GA ECD Bulkhead)
Remover Tool Set J 34513
Remover Tool (DDR Connector) J 38582-3 (12–14 GA)
Use Description Manufacturers P/N
J1939 Diag Link (9-Way DDR) 9-Way Receptacle HD10-9-1939P

NOTE: If difficulty is encountered in removing or installing the plug backshell, insert the plug into the
receptacle, do not lock it into place, and loosen the backshell.

B. Terminal Removal (Figure E–6, View A)

NOTE: When using remover/inserter tool J 41194, take care not to break the tip of the tool. Lay the wire
in the widest part of the wire slot and work toward the tool tip.

1. Loosen and slide the backshell along the convolute conduit.


2. Remove the convolute conduit from the base of the backshell follower. Peel enough conduit from
the harness to allow working access.
3. Slide the backshell follower clear of the connector housing.
4. Remove as much tape wrap as necessary to allow working access.
5. Fully insert the proper remover/extractor tool into the back of the connector until it releases the
terminal.
6. Pull the terminal, wire, and tool out the back of the connector.
7. If replacing a terminal, cut the wire through the middle of the terminal crimp to minimize wire loss.

C. Terminal Crimping (Figure E–6, View B)


1. Strip approximately 6–8 mm (0.236–0.315 inch) of insulation from the end of the wire.
2. Set the crimping tool wire size to number 12. To set the wire size, remove the retainer pin. Lift and
rotate the indicator until the number 12 is aligned with the SEL NO. arrow. Reinstall the retainer
pin.
3. Insert the contact end of the terminal into crimping tool J 34182. To adjust the crimping tool depth,
loosen the locking ring until the depth adjusting screw is free. Turn the adjusting screw until the top
of the terminal is just above flush with the top of the crimping hole (the crimp jaws will contact the
middle of the terminal barrel). Tighten the locking ring to retain the adjustment.
4. Fully insert the wire into the terminal so that the stripped portion of the wire is in the crimp area.
A small section (0.5–1.0 mm (0.02–0.04 inch)) of wire will be visible above the terminal barrel.

Copyright© 2003 General Motors Corp. E–23


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E — CONNECTOR REPAIR INFORMATION

C. Terminal Crimping (Figure E–6, View B) (cont’d)


5. Squeeze the crimping tool handle until it releases. The terminal is now crimped onto the wire.
6. Remove the terminal and wire from the crimping tool.
7. Tug on the terminal to be sure the crimp is tight.
8. Install a 25 mm (one inch) long piece of heat shrink tubing over the wire insulation just behind the
terminal. Apply heat to shrink and lock the tubing to the insulation.

D. Terminal Insertion (all connectors except ECD bulkhead)


1. Insert the terminal and attached wire through the proper hole in the grommet.
2. Push on the terminal and wire until the terminal clicks into position. Pull gently on the wire to be
sure that the terminal is fully seated.

E–24 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E — CONNECTOR REPAIR INFORMATION

NOTES

Copyright© 2003 General Motors Corp. E–25


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E — CONNECTOR REPAIR INFORMATION

WEDGELOCK

CONNECTOR SEAL

CONNECTOR

Shrink tubing goes here

STANDARD SOCKET
TERMINAL

Extended terminal for


uninsulated shield wire

J 34182 CRIMPER

TO ROT
ISE A
RA

TE

SEL
NO.

WIRE SIZE INDICATOR


TERMINAL

LOCKING RING ;;
;;
DEPTH ADJUSTMENT SCREW

V03424

Figure E–7. Deutsch DT Series Connector (3-Way J1939 Interface)

E–26 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E — CONNECTOR REPAIR INFORMATION

1–7. DEUTSCH DT SERIES CONNECTORS (3-WAY J1939 INTERFACE)


A. Connector/Terminal Repair

Required Tools
Crimping Tool J 34182
Use Description Manufacturers P/N
J1939 Interface Connector, Plug, 3-Way DT06-3S-E008
Wedgelock, Plug W3S-1939
Contact, Socket (Standard) 3662-204-1690
Contact, Socket (Extended) 0462-221-1631
Cable, J1939 Databus 23-000-13

B. Terminal Removal (Figure E–7)


1. Use a small-bladed screwdriver to remove the wedgelock that holds the terminals in place.
2. Use a sharp knife to carefully remove the shrink tubing from the rear of the connector plug.
3. Use a small screwdriver to release the locking lever for all of the terminals. Pull the wire and
terminal out the rear of the connector.
4. Slide a new piece of shrink tubing over the removed terminals and onto the cable.
5. If replacing a terminal, cut the wire through the middle of the terminal crimp to minimize wire loss.

C. Terminal Crimping (Figure E–7)


1. Strip approximately 6–8 mm (0.24–0.31 inch) of insulation from the end of the wire. (There is no
insulation on the shield wire.)
2. Set the crimping tool wire size to number 18. To set the wire size, remove the retainer pin. Lift and
rotate the indicator until the number 18 is aligned with the SEL NO. arrow. Reinstall the retainer
pin.
3. Insert the contact end of the terminal down into crimping tool J 34182. To adjust the crimping tool
depth, loosen the locking ring until the depth adjusting screw is free. Turn the adjusting screw until
the wire end of the terminal is just above flush with the top of the crimping hole. The depth
adjustment screw will need to be backed out a large amount to accept the extended shield
terminal. The crimp jaws will now contact the middle of the terminal barrel. Tighten the locking ring
to retain the adjustment.
4. Fully insert the wire into the terminal so that the stripped portion of the wire is in the crimp area.
A small section (0.5–1.0 mm (0.02–0.04 inch)) of wire will be visible above the terminal barrel.
5. Squeeze the crimping tool handle until it releases. The terminal is now crimped onto the wire.
6. Remove the terminal and wire from the crimping tool.
7. Tug on the terminal to be sure the crimp is tight.

Copyright© 2003 General Motors Corp. E–27


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E — CONNECTOR REPAIR INFORMATION

D. Terminal Insertion
1. Insert the terminal and attached wire into the back of the connector.
2. Push on the terminal and wire until the terminal clicks into position. Check the front of the
connector to see that the terminal is at the same height as other terminals. Pull gently on the wire
to be sure that the terminal is fully seated.
3. Insert the wedge lock to hold the terminals in place. Slide the sealing plug back into place at the
rear of the connector.
4. Slide the shrink tubing over the raised area at the rear of the connector. Use a heat gun to shrink
the tubing into position over the connector and cable.

E–28 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E — CONNECTOR REPAIR INFORMATION

1–8. REPAIR OF A BROKEN WIRE WITH IN-LINE BUTT SPLICE


A. Connector Check Before Repair

NOTE: Before repairing or replacing wiring harness, sensor, solenoid, switch, or TCM as indicated for a
diagnosed problem, follow the procedure below:

1. Disconnect the connector or connectors associated with the problem and inspect for:
• Bent terminals
• Broken terminals
• Dirty terminals
• Pushed back terminals
• Missing terminals
• Condition of mating tabs
• Condition of mating terminals
Ensure that terminals are secure in the connector. Clean, straighten, or replace parts as required.

2. Reconnect all previous unmated connectors. Ensure connectors are fully inserted or twisted until
they lock in place. Connectors with locking tabs make an audible click when the lock is engaged.
3. If the trouble recurs after starting the vehicle, follow the repair procedures for the trouble code or
complaint.
4. If the trouble does not recur, or if the appropriate repairs and/or replacements have been made,
the problem should be corrected.

B. Special Tools
• Heat Gun, J 25070 or equivalent
• Crimping Tool for Pre-insulated Crimp J 38125-8 (Figure E–8)

NOTE: Use crimping anvils “F” and “G.”

• Wire Strippers, J 35615


• Splices P/N 23046604 14–16 AWG
• Splices P/N 23046605 18–22 AWG

NOTE: Each splice must be properly crimped and then heated to shrink the covering to protect and
insulate the splice. Insulation-piercing splice clips should not be used.

Copyright© 2003 General Motors Corp. E–29


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E — CONNECTOR REPAIR INFORMATION

J 38125-8

F
G
V01694

Figure E–8. Crimper J 38125-8

C. Straight Lead Repair Procedure


1. Locate the damaged wire.
2. Remove 8.0 mm (0.3 inch) of insulation from the end of each segment of the damaged wire.
3. Insert the stripped end of one wire into the crimp barrel of the splice, and crimp.
4. Insert the stripped end of the other wire into the other end of the crimp barrel, and crimp.
5. Pull on the connection to be sure of crimping integrity.
6. Heat the splice with a heat gun until the covering shrinks and adhesive flows from under the
covering.
7. The splice is now sealed and insulated. Electrical tape is not necessary and should not be used.

E–30 Copyright© 2003 General Motors Corp.


MATING
CONNECTOR MFG. P/N PART NAME MANUFACTURER CONFIG MFG. P/N MATING PART NAME
P/N

ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL


TCM J2 15336800 STRAIN RELIEF, 32-WAY RED DELPHI-PACKARD 1-PC/TCM J2 12186041 12186041 TCM HEADER
TCM J2 15305333 SEAL, 32-WAY DELPHI-PACKARD 1-PC/TCM J2
TCM J2 15305371 INNER CONNECT, 32-WAY DELPHI-PACKARD 1-PC/TCM J2
TCM J2 12129024 TPA, 32-WAY RED DELPHI-PACKARD 1-PC/TCM J2
TCM J2 12084912 TERMINAL, SOCKET 100W DELPHI-PACKARD 1-PC/TCM J2
TCM J2 12129557 CAVITY PLUG, 100W DELPHI-PACKARD 1-PC/TCM J2

APPENDIX E — CONNECTOR REPAIR INFORMATION


TCM J2 12177289 CPA, 32-WAY RED DELPHI-PACKARD 1-PC/TCM J2
TCM J1 12191002 STRAIN RELIEF, 32-WAY GRAY DELPHI-PACKARD 1-PC/TCM J1 12186043 12186043 TCM HEADER
TCM J1 15305333 SEAL, 32-WAY DELPHI-PACKARD 1-PC/TCM J1
TCM J1 15305371 INNER CONNECT, 32-WAY DELPHI-PACKARD 1-PC/TCM J1
TCM J1 12129022 TPA, 32-WAY GRAY DELPHI-PACKARD 1-PC/TCM J1
TCM J1 12084912 TERMINAL, SOCKET 100W DELPHI-PACKARD 1-PC/TCM J1
Copyright© 2003 General Motors Corp.

TCM J1 12129557 CAVITY PLUG, 100W DELPHI-PACKARD 1-PC/TCM J1


TCM J1 12177289 CPA, 32-WAY RED DELPHI-PACKARD 1-PC/TCM J1
TCM J1 12084913 TERMINAL, SOCKET 100W DELPHI-PACKARD 1-PC/TCM J1
GP19 15300027 CONNECTOR, 2-WAY DELPHI-PACKARD 1-PC/COMP J1 15300002 15300002 CONNECTOR, 2-WAY
GP19 12077411 TERMINAL, SOCKET DELPHI-PACKARD 1-PC/COMP J1 12048159 12048159 TERMINAL, PIN
GP19 12089444 SEAL, WIRE TYPE, SILICONE DELPHI-PACKARD 1-PC/COMP J1 12089444 12089444 SEAL, WIRE TYPE, SILICONE
GP19 15300014 LOCK, SECONDARY DELPHI-PACKARD 1-PC/COMP J1 15300014 15300014 LOCK, SECONDARY
J1939 DT06-3S-E008 CONNECTOR, PLUG 3-WAY DEUTSCH 1-PC/COMP J1 DT04-3P-E008 CONNECTOR, REC., 3-WAY
J1939 W3S WEDGELOCK, PLUG DEUTSCH 1-PC/COMP J1 W3P WEDGELOCK, RECEPTACLE
J1939 29511366 CONTACT, SOCKET #16 DEUTSCH 1-PC/COMP J1 29511369 3660-201-1690 CONTACT, PIN #16
J1939 29538614 CONTACT, EXTENDED SOCKET DEUTSCH 1-PC/COMP J1 0460-247-1631 CONTACT, EXTENDED PIN
J1939 CABLE, J1939 DATABUS 1-PC/COMP J1
VIW X 12160542 CONN 20M MIC/P 100W GRAY DELPHI-PACKARD 1-PC/COMP J1 12160280 12160280 CONN 20F MIC/P 100W GRAY
VIW X 12110693 CABLE SEAL, 14M GREEN DELPHI-PACKARD 1-PC/COMP J1 15304882 15304882 CABLE SEAL, 14F GRAY
VIW X 12191178 LOCK ASSIST/SEAL, 20M WHITE DELPHI-PACKARD 1-PC/COMP J1 12191173 12191173 LOCK, SECONDARY 20F WHITE
VIW X 12160551 TERMINAL, PIN 100W DELPHI-PACKARD 1-PC/COMP J1 12084912 12084912 TERMINAL, SOCKET 100W
VIW X 12129557 CAVITY PLUG, 100W DELPHI-PACKARD 1-PC/COMP J1 12129557 12129557 CAVITY PLUG, 100W
VIW X 12176394 CONDUIT CLIP, 13 mm BLACK DELPHI-PACKARD 1-PC/COMP J1 12176394 12176394 CONDUIT CLIP, 13 mm BLACK
VIW Y 12160280 CONN 20F MIC/P 100W GRAY DELPHI-PACKARD 1-PC/COMP J1 12160280 12160280 CONN 20F MIC/P 100W GRAY
VIW Y 15304882 CABLE SEAL, 16F RED DELPHI-PACKARD 1-PC/COMP J1 15304882 15304882 CABLE SEAL, 14F GRAY
VIW Y 12191172 LOCK SECONDARY, 20F BLUE DELPHI-PACKARD 1-PC/COMP J1 12191172 12191172 LOCK, SECONDARY 20F BLUE
VIW Y 12084912 TERMINAL, SOCKET 100W DELPHI-PACKARD 1-PC/COMP J1 12084912 12084912 TERMINAL, SOCKET 100W
VIW Y 12129557 CAVITY PLUG, 100W DELPHI-PACKARD 1-PC/COMP J1 12129557 12129557 CAVITY PLUG, 100W
VIW Y 12176394 CONDUIT CLIP, 13 mm BLACK DELPHI-PACKARD 1-PC/COMP J1 12176394 12176394 CONDUIT CLIP, 13 mm BLACK
RMR 12015795 CONNECTOR, 3-WAY DELPHI-PACKARD 1-PC/COMP J1 12015092 12015092 CONNECTOR, SHROUD 3-WAY
RMR 12089040 TERMINAL, PIN DELPHI-PACKARD 1-PC/COMP J1 12089188 12089188 TERMINAL, SOCKET
E–31

RMR 12089444 SEAL, WIRE TYPE, SILICONE DELPHI-PACKARD 1-PC/COMP J1 12089444 12089444 SEAL, WIRE TYPE, SILICONE
E–32

MATING
CONNECTOR MFG. P/N PART NAME MANUFACTURER CONFIG MFG. P/N MATING PART NAME
P/N

ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL


NE 12162193 CONNECTOR, 2-WAY DELPHI-PACKARD 1-PC/COMP J2 12066016 ENGINE SPEED SENSOR
NE 12103881 TERMINAL, 150F DELPHI-PACKARD 1-PC/COMP J2 Actual sensor uses molded receptacle similar to 12066016
NO 12162193 CONNECTOR, 2-WAY DELPHI-PACKARD 1-PC/COMP J2 OUTPUT SPEED SENSOR
NO 12103881 TERMINAL, 150F DELPHI-PACKARD 1-PC/COMP J2 Actual sensor uses molded receptacle similar to 12066016
NT 12162193 CONNECTOR, 2-WAY DELPHI-PACKARD 1-PC/COMP J2 TURBINE SPEED SENSOR
NT 12103881 TERMINAL, 150F DELPHI-PACKARD 1-PC/COMP J2 Actual sensor uses molded receptacle similar to 12066016

APPENDIX E — CONNECTOR REPAIR INFORMATION


TPS 12015793 CONNECTOR, 3-WAY DELPHI-PACKARD 1-PC/COMP J2 TPS HEADER
TPS 12089040 TERMINAL, PIN DELPHI-PACKARD 1-PC/COMP J2 TPS header similar to 12010717 connector with 12089188 sockets
TPS 12089444 SEAL, WIRE TYPE, SILICONE DELPHI-PACKARD 1-PC/COMP J2 molded into the TPS.
H2OT 12015792 CONNECTOR, TOWER, 2-WAY DELPHI-PACKARD ADAPTER (MDR) 12010973 12010973 CONNECTOR, SHROUD, 2-WAY
H2OT 12089040 TERMINAL, PIN DELPHI-PACKARD ADAPTER (MDR) 12089188 12089188 TERMINAL, SOCKET
H2OT 12089444 SEAL, SILICONE DELPHI-PACKARD ADAPTER (MDR) 12089444 12089444 SEAL, WIRE TYPE, SILICONE
Copyright© 2003 General Motors Corp.

NSBU 12191757 CONNECTOR, TOWER, 4-WAY DELPHI-PACKARD 1-PC/COMP J2 12459915 NSBU


NSBU 12048086 SEAL, WIRE TYPE, DK RED DELPHI-PACKARD 1-PC/COMP J2
NSBU 12129802 TERMINAL, 150F DELPHI-PACKARD 1-PC/COMP J2
NSBU 15416722 CONNECTOR, 12-WAY DELPHI-PACKARD 1-PC/COMP J2
NSBU 15441828 BACKSHELL DELPHI-PACKARD 1-PC/COMP J2
NSBU 12191819 18 GAUGE, 18AWG TXL DELPHI-PACKARD 1-PC/COMP J2
NSBU 12191818 20 GAUGE, 20AWG TXL DELPHI-PACKARD 1-PC/COMP J2
NSBU 15366684 14 GAUGE, 14AWG TXL DELPHI-PACKARD 1-PC/COMP J2
NSBU 15304719 18 GAUGE, 18AWG TXL DELPHI-PACKARD 1-PC/COMP J2
NSBU 15304718 20 GAUGE, 20AWG TXL DELPHI-PACKARD 1-PC/COMP J2
TLCT 12160280 CONN 20F MIC/P 100W GRAY DELPHI-PACKARD 1-PC/COMP J2 12160782 CONN 20M MIC/P 100W
TLCT 12177159 CABLE SEAL, 20F ORANGE DELPHI-PACKARD 1-PC/COMP J2 15317365 LOCK ASST/SEAL 20M MIC/P100W
TLCT 12160494 LOCK, SECONDARY 20F GREEN DELPHI-PACKARD 1-PC/COMP J2
TLCT 12084912 TERMINAL, SOCKET 100W DELPHI-PACKARD 1-PC/COMP J2 12160551 TERMINAL, PIN 100W
TLCT 12129557 CAVITY PLUG, 100W DELPHI-PACKARD 1-PC/COMP J2
TLCT 12176394 CONDUIT CLIP, 13MM BLACK DELPHI-PACKARD 1-PC/COMP J2
BLKHD RCP 29511368 CONNECTOR, REC., 31-WAY DEUTSCH TCM J2/COMP 29511365 CONNECTOR, PLUG, 31-WAY
BLKHD RCP 29511369 CONTACT, PIN #16 DEUTSCH TCM J2/COMP 29511366 CONTACT, SOCKET #16
BLKHD RCP 29511371 SEALING PLUG DEUTSCH TCM J2/COMP 29511371 SEALING PLUG
BLKHD RCP 29514041 HOUSING, BACKSHELL, 24/19 DEUTSCH TCM J2/COMP 29514041 HOUSING, BACKSHELL, 24/19
BLKHD RCP 29514042 FOLLOWER, BACKSHELL, 24/19 DEUTSCH TCM J2/COMP 29514042 FOLLOWER, BACKSHELL, 24/19
BLKHD RCP 29514043 GROMMET, BACKSHELL #24 DEUTSCH TCM J2/COMP 29514043 GROMMET, BACKSHELL, 24/19
BLKHD RCP 29527000 NUT, PANEL DEUTSCH TCM J2/COMP —
BLKHD RCP 29512839 O-RING DEUTSCH TCM J2/COMP —
BLKHD PGP 29511855 CONNECTOR, PLUG, 31-WAY DEUTSCH COMP J2 29511854 CONNECTOR, REC., 31-WAY
BLKHD PGP 29511369 CONTACT, PIN #16 DEUTSCH COMP J2 29511366 CONTACT, SOCKET #16
BLKHD PGP 29511371 SEALING PLUG DEUTSCH COMP J2 29511371 SEALING PLUG
BLKHD PGP 29514041 HOUSING, BACKSHELL, 24/19 DEUTSCH COMP J2 29514041 HOUSING, BACKSHELL, 24/19
MATING
CONNECTOR MFG. P/N PART NAME MANUFACTURER CONFIG MFG. P/N MATING PART NAME
P/N

ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL


BLKHD PGP 29514042 FOLLOWER, BACKSHELL, 24/19 DEUTSCH COMP J2 29514042 FOLLOWER, BACKSHELL
BLKHD PGP 29514043 GROMMET, BACKSHELL #24 DEUTSCH COMP J2 —
BLKHD RCS 29511854 CONNECTOR, REC., 31-WAY DEUTSCH TCM J2/COMP 29511855 CONNECTOR, PLUG, 31-WAY
BLKHD RCS 29511366 CONTACT, SOCKET #16 DEUTSCH TCM J2/COMP 29511369 CONTACT, PIN #16
BLKHD RCS 29511371 SEALING PLUG DEUTSCH TCM J2/COMP 29511371 SEALING PLUG
BLKHD RCS 29514041 HOUSING, BACKSHELL, 24/19 DEUTSCH TCM J2/COMP 29514041 HOUSING, BACKSHELL, 24/19

APPENDIX E — CONNECTOR REPAIR INFORMATION


BLKHD RCS 29514042 FOLLOWER, BACKSHELL, 24/19 DEUTSCH TCM J2/COMP 29514042 FOLLOWER, BACKSHELL, 24/19
BLKHD RCS 29527000 NUT, PANEL DEUTSCH TCM J2/COMP —
BLKHD RCS 29512839 O-RING DEUTSCH TCM J2/COMP —
BLKHD PGS 29511365 CONNECTOR, PLUG, 31-WAY DEUTSCH COMP J1 29511368 CONNECTOR, REC., 31-WAY
BLKHD PGS 29511366 CONTACT, SOCKET #16 DEUTSCH COMP J1 29511369 CONTACT, PIN #16
BLKHD PGS 29511371 SEALING PLUG DEUTSCH COMP J1 29511371 SEALING PLUG
Copyright© 2003 General Motors Corp.

BLKHD PGS 29514041 HOUSING, BACKSHELL, 24/19 DEUTSCH COMP J1 29514041 HOUSING, BACKSHELL, 24/19
BLKHD PGS 29514042 FOLLOWER, BACKSHELL, 24/19 DEUTSCH COMP J1 29514042 FOLLOWER, BACKSHELL, 24/19
BLKHD PGS 29514043 GROMMET, BACKSHELL #24 DEUTSCH COMP J1 29514043 GROMMET, BACKSHELL, #24
E–33
ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX E — CONNECTOR REPAIR INFORMATION

NOTES

E–34 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX F — TPS ADJUSTMENT

A. Description of Operation
1. To properly communicate throttle position to the TCM, the throttle position sensor must convert
mechanical movement to an electrical form the TCM can understand. To accomplish this, contacts
move across a resistive strip inside the sensor which translates position into voltage (Figure F–1).

THROTTLE POSITION LINKAGE

CONTACTS

RESISTIVE STRIP

V00656.01

Figure F–1. Throttle Position-to-Voltage Conversion

2. Each position gives a different voltage. The TCM then converts this voltage into throttle percent.
Each millimeter of travel converts to approximately 0.110 volts. Figure F–2 diagrams the voltage
and throttle movement relationship.

Adjust so total stroke is within


0 Volt
8.9 mm – 35.7 mm band 5 Volts
0.98 volts – 3.921 volts
0.550 Volts 4.750 Volts
ERROR ERROR
ZONE 0.979 Volts 3.927 Volts ZONE
APPROX.
19 mm (0.75 in.) STROKE

CLOSED WIDE OPEN


THROTTLE THROTTLE
FULLY FULLY
RETRACTED 8.9 mm 35.7 mm EXTENDED
(AT REST) (0.35 in.) Total Stroke (1.4 in.)
CT–WOT
2.5 mm 40.6 mm
(0.1 in.) 15.2 mm–22.9 mm (1.6 in.)
0 mm
(0.63 in.–0.9 in.) 45.7 mm
1.667–2.549 Volts (1.8 in.)

V05746.00.01

Figure F–2. Throttle Position Determination Diagram

3. Throttle percent is proportional to the amount of travel of the throttle position sensor. Therefore
a small amount of travel corresponds to a low throttle percentage, and a large amount of travel cor-
responds to a high throttle percentage (Table F–1, Page F–3).

Copyright© 2003 General Motors Corp. F–1


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX F — TPS ADJUSTMENT

4. The throttle position sensor is self-calibrating within its normal range of operation. Each time the
vehicle is started and the TCM is initialized, the idle position that is stored for closed throttle is in-
creased from its previous lowest reading. Also, the wide open throttle position is reduced from its
previous highest reading. Once the new position is read from the TPS, the idle and wide open
throttle set points are continuously readjusted to the lowest and highest points, respectively. This
compensates for fuel control system wear or previous mechanical adjustment. One area of partic-
ular concern is when the throttle sensor extends into the error zone. This indicates a TPS misad-
justment to the TCM, and 100 percent throttle is assumed until readjustment is performed. Simply
clearing the DTC will not resolve the situation; use the Scan Tool to reset the TPS calibrations after
a TPS adjustment.

B. Throttle Position Sensor (TPS) Adjustment


When properly installed by the equipment manufacturer (Figure F–3), the TPS should not require
adjustment. Confirm that the throttle sensor is installed to manufacturer specifications before
adjusting the throttle position sensor. The idle position should be approximately 8.9 mm or 0.98 volts
or higher, and the full throttle position should be approximately 35.7 mm or 3.921 volts or lower. The
TPS is self-calibrating, meaning there is no optimum closed throttle or wide open position. As long as
the travel is within the 8.5–35.7 mm range the TPS is set properly. A total stroke of 15.2–22.9 mm
must be maintained. Watch the movement of the throttle sensor as the controls move it through the
full stroke. Make certain the idle and full throttle positions are not in the error zones (refer to
Figure F–2). The error zones occur when the idle position is less than 2.5 mm, or when the full throttle
position is more than 40.6 mm. When idle or wide open throttle positions are in the error zones, the
TCM will log a code. When a TPS code is logged the TCM assumes a default throttle setting which will
negatively affect shift quality.

NOTE: Use Test Harness J 41339 for measuring voltages.

F–2 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX F — TPS ADJUSTMENT

Table F–1. Distance (mm) of Travel Versus Volts

mm Volts mm Volts
0 0 24 2.634
1 0.110 25 2.744
2 0.220 26 2.854
3 0.329 27 2.964
4 0.439 28 3.073
5 0.549 29 3.183
6 0.659 30 3.293
7 0.768 31 3.403
8 0.878 32 3.512
9 0.988 33 3.622
10 1.098 34 3.732
11 1.207 35 3.842
12 1.317 36 3.951
13 1.427 37 4.061
14 1.537 38 4.171
15 1.646 39 4.281
16 1.756 40 4.390
17 1.866 41 4.500
18 1.976 42 4.610
19 2.085 43 4.720
20 2.195 44 4.829
21 2.305 45 4.939
22 2.415 46 5.049
23 2.524

Copyright© 2003 General Motors Corp. F–3


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX F — TPS ADJUSTMENT

MOUNTING PROVISION: BENDING LOAD


Use M6 x 1.00 or 1⁄4-20 in. series bolts APPLIED
3 places
Torque M6 x 1.00 bolt to 10–13 N•m (84–120 lb in.)
1
Torque ⁄4-20 in. series bolts to 13–14 N•m (108–132 lb in.) UNACCEPTABLE INSTALLATION
Mount to a solid frame member. Flatness of
chassis mounting surface must not exceed 10.0° MAX INSTALLED
0.8 mm (0.03 in.). OPERATING ANGLE
IN ALL DIRECTIONS

LOADING IN
TENSION ONLY

ACCEPTABLE INSTALLATION
Attachment must provide freedom
of motion to allow cable loading in
tension only (no bending loads).
WIRING HARNESS
55.0 mm (2.17 in.)
MIN REQUIRED Fuel control must not move
the throttle sensor beyond R 152.0 mm (6.00 in.) MIN
FOR CONNECTION
the closed throttle position ALLOWANCE RADIUS
REMOVAL
at any time.
FULLY EXTENDED
FORCE REQUIRED FULLY
26.7 N (6.0 LB) MAX RETRACTED

MOUNTING (NOTE: Mounting length


47.5 mm (1.87 in.) CLOSED THROTTLE LENGTH + 50.8 mm (2 inches) equals
95.2 mm (3.75 in.) cable length)
FULL THROTTLE
118.1 mm (4.65 in.)
OPERATING BAND 15.2 – 22.9 mm
118.1 mm (0.6 – 0.9 in.)
(4.65 in.) The location of the
95.2 mm clamping bracket relative
(3.75 in.) to the fuel lever at closed
throttle must be maintained
within this range.

Attach to engine or governor


30.2 mm (1.19 in.) 93.45 mm (3.679 in.)housing using clamp and shims as
87.15 mm (3.431 in.)required. Clamp must positively
lock in cable groove.
Fuel lever attachment linkage or bracket must HITCH PIN CLIP
allow fuel lever to return to closed throttle position
ENGINE FUEL LEVER
when sensor rod is maintained at full throttle position.
Attach the throttle sensor directly to the engine fuel
lever with no breakover or yield linkages between the
engine fuel lever shaft and the attachment point of the
throttle sensor. CLOSED THROTTLE 183.1 mm (7.21 in.) MAX
FULL THROTTLE
SAME AS WITHOUT 160.2 mm (6.31 in.) MIN
SLIP LINK
FULLY EXTENDED

38.1 mm (1.50 in.)

HITCH PIN CLIP


FULLY RETRACTED

OPTIONAL THROTTLE SENSOR ASSEMBLY WITH SLIP LINK V00430.05

Figure F–3. Throttle Position Sensor Adjustment

F–4 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX G — WELDING ON VEHICLE/VEHICLE INTERFACE MODULE

1–1. WELDING ON VEHICLE


When frame or other welding is required on the vehicle, take the following precautions to protect the electronic
control components:

1. Disconnect the wiring harness connectors at the transmission control module (TCM).
2. Disconnect the positive and negative battery connections, and any electronic control ground wires con-
nected to the frame or chassis.
3. Cover electronic control components and wiring to protect them from hot sparks, etc.
4. Do not connect welding cables to electronic control components.

Do not jump start a vehicle with arc welding equipment. Arc welding
WARNING! equipment’s dangerously high currents and voltages cannot be reduced to safe
levels.

Copyright© 2003 General Motors Corp. G–1


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX G — WELDING ON VEHICLE/VEHICLE INTERFACE MODULE

NOTES

G–2 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX H — HYDRAULIC SCHEMATICS

HYDRAULIC SCHEMATIC – NEUTRAL / PARK G Solenoid Added–3rd Quarter 2003


1000 SERIES™, 2000 SERIES™, 2400 SERIES™ G Solenoid Lowers Main Pressure
PRE-BLOCK 1
And Increases Cooler Flow
GAIN VALVE When Energized (Typically at
AND A TRIM Low Throttle, Low Speed)
N/C A Trim Accumulator B Trim Accumulator
SOLENOID Solenoid Solenoid
W/O SPRING (Shown Energized)
B
N/C Solenoid N/O
F Trim Filter C Shift D Shift E Shift G Mod Main
Solenoid Solenoid Solenoid Solenoid Solenoid

N/C N/C N/C N/C N/C

CONTROL MAIN CONTROL MAIN


EBF B TRIM
PRESSURE
CONV – IN
MAIN

A TRIM Selector D N R
PRESSURE Valve

MAIN
PRESSURE CONV – OUT
TAP C1
MAIN
C1
TCC SIGNAL Clutch
Valve
IDLE COOLING MAIN
MAIN TO OVERAGE VALVE C2
LEAKAGE
EXHAUST Control
Main
Filter
Control
Main Control PSC
Main Valve Main Relief
Regulator Valve
Valve C3

MODULATED MAIN PRESSURE


(G SOLENOID) C4

PSE C5
OVERAGE TCC C
Shift PSD
CONV – OUT TO COOLER Valve E Shift
Converter Valve
Relief
Valve OVERAGE D Shift
Charging Valve
Pump Exhaust
CONV – IN Backfill
TCC SIGNAL Valve
SUMP Cooler

LUBE Converter
Flow PSR
Valve
Lube Blocked At
Regulator Separator Plate For MAIN PRESSURE EXHAUST BACKFILL
Valve Modulated Main Pressure CONTROL MAIN PRESSURE SUCTION
CONVERTER–IN/OVERAGE A TRIM SIGNAL
Main Filter CONVERTER–OUT REVERSE SIGNAL
TORQUE CONVERTER CLUTCH (TCC) C5
LUBRICATION/COOLER A TRIM PRESSURE
EXHAUST
V06914.03.00

Figure H–1. Hydraulic Schematic — Neutral/Park

Copyright © 2003 General Motors Corp. H–1/H–2


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX H — HYDRAULIC SCHEMATICS

HYDRAULIC SCHEMATIC – REVERSE (PRIOR TO, AND INCLUDING, NO4* SOFTWARE WITH THROTTLE APPLIED)
1000 SERIES™, 2000 SERIES™, 2400 SERIES™ G Solenoid Added–3rd Quarter 2003

G Solenoid Lowers Main Pressure


PRE-BLOCK 1
And Increases Cooler Flow
GAIN VALVE When Energized (Typically at
AND A TRIM Low Throttle, Low Speed)
N/C A Trim Accumulator B Trim Accumulator
SOLENOID Solenoid Solenoid
W/O SPRING (Shown De-energized)
B
N/C Solenoid N/O
F Trim Filter C Shift D Shift E Shift G Mod Main
Solenoid Solenoid Solenoid Solenoid Solenoid

N/C N/C N/C N/C N/C

CONTROL MAIN CONTROL MAIN


EBF B TRIM
PRESSURE
CONV – IN
MAIN

A TRIM Selector D N R
PRESSURE Valve

MAIN
PRESSURE CONV – OUT
TAP C1
MAIN
C1
Clutch
Valve
TCC SIGNAL
MAIN C2

EXHAUST Control
Main
Filter
Control
Main Control PSC
Main Valve Main Relief
Regulator Valve
Valve C3

MODULATED MAIN PRESSURE


(G SOLENOID) C4

PSE C5
OVERAGE TCC C
Shift PSD
CONV – OUT TO COOLER Valve E Shift
Converter Valve
Relief
Valve OVERAGE D Shift
Charging Valve
Pump Exhaust
CONV – IN Backfill
TCC SIGNAL Valve
SUMP Cooler

LUBE Converter
Flow PSR
Valve
Lube Blocked At
Regulator Separator Plate For MAIN PRESSURE SUCTION
Valve Modulated Main Pressure CONTROL MAIN PRESSURE A TRIM SIGNAL
CONVERTER–IN/OVERAGE B TRIM SIGNAL
Main Filter CONVERTER–OUT REVERSE SIGNAL
TORQUE CONVERTER CLUTCH (TCC) C3
LUBRICATION/COOLER C5
EXHAUST A TRIM PRESSURE
*EFFECTIVE JANUARY 1, 2001 EXHAUST BACKFILL B TRIM PRESSURE V04755.03.00

Figure H–2. Hydraulic Schematic — Reverse (Prior To Software Level N04)


Copyright © 2003 General Motors Corp. H–3/H–4
ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX H — HYDRAULIC SCHEMATICS

HYDRAULIC SCHEMATIC – REVERSE – CLOSED THROTTLE (WITH NO4* SOFTWARE AND LATER)
1000 SERIES™, 2000 SERIES™, 2400 SERIES™ G Solenoid Added–3rd Quarter 2003
PRE-BLOCK 1 G Solenoid Lowers Main Pressure
GAIN VALVE And Increases Cooler Flow
AND A TRIM When Energized (Typically at
N/C A Trim Accumulator B Trim Accumulator
SOLENOID Solenoid Solenoid Low Throttle, Low Speed)
W/O SPRING
B (Shown Energized)
N/C Solenoid N/O
F Trim Filter C Shift D Shift E Shift G Mod Main
Solenoid Solenoid Solenoid Solenoid Solenoid

N/C N/C N/C N/C N/C

CONTROL MAIN CONTROL MAIN


EBF B TRIM
PRESSURE
CONV – IN
MAIN

A TRIM Selector D N R
PRESSURE Valve

MAIN
PRESSURE CONV – OUT
TAP C1
MAIN
C1
TCC SIGNAL Clutch
Valve
IDLE COOLING MAIN
MAIN TO OVERAGE VALVE C2
LEAKAGE
EXHAUST Control
Main
Filter
Control
Main Control PSC
Main Valve Main Relief
Regulator Valve
Valve C3

MODULATED MAIN PRESSURE


(G SOLENOID) C4

PSE C5
OVERAGE TCC C
Shift PSD
CONV – OUT TO COOLER Valve E Shift
Converter Valve
Relief
Valve OVERAGE D Shift
Charging Valve
Pump Exhaust
CONV – IN Backfill
TCC SIGNAL Valve
SUMP Cooler

LUBE Converter
Flow PSR
Valve
Lube
Regulator Blocked At MAIN PRESSURE SUCTION
Valve Separator Plate For CONTROL MAIN PRESSURE A TRIM SIGNAL
Modulated Main Pressure
CONVERTER–IN/OVERAGE B TRIM SIGNAL
Main Filter CONVERTER–OUT C3
TORQUE CONVERTER CLUTCH (TCC) C5
LUBRICATION/COOLER A TRIM PRESSURE
EXHAUST B TRIM PRESSURE
*EFFECTIVE JANUARY 1, 2001 EXHAUST BACKFILL V06874.03.00

Figure H–3. Hydraulic Schematic — Reverse (Software Level N04 And Later)

Copyright © 2003 General Motors Corp. H–5/H–6


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX H — HYDRAULIC SCHEMATICS

HYDRAULIC SCHEMATIC – 1st RANGE G Solenoid Added–3rd Quarter 2003


1000 SERIES™, 2000 SERIES™, 2400 SERIES™ G Solenoid Lowers Main Pressure
PRE-BLOCK 1
And Increases Cooler Flow
GAIN VALVE When Energized (Typically at
AND A TRIM Low Throttle, Low Speed)
N/C A Trim Accumulator B Trim Accumulator
SOLENOID Solenoid Solenoid
W/O SPRING (Shown Energized)
B
N/C Solenoid N/O
F Trim Filter C Shift D Shift E Shift G Mod Main
Solenoid Solenoid Solenoid Solenoid Solenoid

N/C N/C N/C N/C N/C

CONTROL MAIN CONTROL MAIN


EBF B TRIM
PRESSURE
CONV – IN
MAIN

A TRIM Selector D N R
PRESSURE Valve

MAIN
PRESSURE CONV – OUT
TAP C1
MAIN
C1
TCC SIGNAL Clutch
Valve
IDLE COOLING MAIN
MAIN TO OVERAGE VALVE C2
LEAKAGE
EXHAUST Control
Main
Filter
Control
Main Control PSC
Main Valve Main Relief
Regulator Valve
Valve C3

MODULATED MAIN PRESSURE


(G SOLENOID) C4

PSE C5
OVERAGE TCC C
Shift PSD
CONV – OUT TO COOLER Valve E Shift
Converter Valve
Relief
Valve OVERAGE D Shift
Charging Valve
Pump Exhaust
CONV – IN Backfill
TCC SIGNAL Valve
SUMP Cooler

LUBE Converter
Flow PSR
Valve
Lube
Regulator Blocked At MAIN PRESSURE EXHAUST BACKFILL
Valve Separator Plate For CONTROL MAIN PRESSURE SUCTION
Modulated Main Pressure
CONVERTER–IN/OVERAGE A TRIM SIGNAL
Main Filter CONVERTER–OUT REVERSE SIGNAL
TORQUE CONVERTER CLUTCH (TCC) C1
LUBRICATION/COOLER C5
EXHAUST A TRIM PRESSURE
V06915.03.00

Figure H–4. Hydraulic Schematic — 1st Range

Copyright © 2003 General Motors Corp. H–7/H–8


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX H — HYDRAULIC SCHEMATICS

HYDRAULIC SCHEMATIC – 5th RANGE G Solenoid Added–3rd Quarter 2003


1000 SERIES™, 2000 SERIES™, 2400 SERIES™ G Solenoid Lowers Main Pressure
PRE-BLOCK 1
And Increases Cooler Flow
GAIN VALVE When Energized (Typically at
AND A TRIM Low Throttle, Low Speed)
N/C A Trim Accumulator B Trim Accumulator
SOLENOID Solenoid Solenoid
W/O SPRING (Shown De-energized)
B
N/C Solenoid N/O
F Trim Filter C Shift D Shift E Shift G Mod Main
Solenoid Solenoid Solenoid Solenoid Solenoid

N/C N/C N/C N/C N/C

CONTROL MAIN CONTROL MAIN


EBF B TRIM
PRESSURE
CONV – IN
MAIN

A TRIM Selector D N R
PRESSURE Valve

MAIN
PRESSURE CONV – OUT
TAP C1
MAIN
C1
Clutch
Valve
TCC SIGNAL
MAIN C2

EXHAUST Control
Main
Filter
Control
Main Control PSC
Main Valve Main Relief
Regulator Valve
Valve C3

MODULATED MAIN PRESSURE


(G SOLENOID) C4

PSE C5
OVERAGE TCC C
Shift PSD
CONV – OUT TO COOLER Valve E Shift
Converter Valve
Relief
Valve OVERAGE D Shift
Charging Valve
Pump Exhaust
CONV – IN Backfill
TCC SIGNAL Valve
SUMP Cooler

LUBE Converter
Flow PSR
Valve
Lube Blocked At
Regulator Separator Plate For MAIN PRESSURE EXHAUST BACKFILL
Valve Modulated Main Pressure CONTROL MAIN PRESSURE SUCTION
CONVERTER–IN/OVERAGE A TRIM SIGNAL
Main Filter CONVERTER–OUT B TRIM SIGNAL
TORQUE CONVERTER CLUTCH (TCC) REVERSE SIGNAL
LUBRICATION/COOLER C2
EXHAUST C3
A TRIM PRESSURE V06919.03.00

Figure H–5. Hydraulic Schematic — 2nd Range

Copyright © 2003 General Motors Corp. H–9/H–10


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX H — HYDRAULIC SCHEMATICS

HYDRAULIC SCHEMATIC – 3rd RANGE G Solenoid Added–3rd Quarter 2003


1000 SERIES™, 2000 SERIES™, 2400 SERIES™ G Solenoid Lowers Main Pressure
PRE-BLOCK 1
And Increases Cooler Flow
GAIN VALVE When Energized (Typically at
AND A TRIM Low Throttle, Low Speed)
N/C A Trim Accumulator B Trim Accumulator
SOLENOID Solenoid Solenoid
W/O SPRING (Shown De-energized)
B
N/C Solenoid N/O
F Trim Filter C Shift D Shift E Shift G Mod Main
Solenoid Solenoid Solenoid Solenoid Solenoid

N/C N/C N/C N/C N/C

CONTROL MAIN CONTROL MAIN


EBF B TRIM
PRESSURE
MAIN

A TRIM Selector D N R
PRESSURE Valve

MAIN
PRESSURE CONV – OUT
TAP C1
MAIN
C1
Clutch
Valve
TCC SIGNAL
MAIN C2

EXHAUST Control
Main
Filter
Control
Main Control PSC
Main Valve Main Relief
Regulator Valve
Valve C3

MODULATED MAIN PRESSURE


(G SOLENOID) C4

PSE C5
OVERAGE TCC C
Shift PSD
CONV – OUT TO COOLER Valve E Shift
Converter Valve
Relief
Valve OVERAGE D Shift
Charging Valve
Pump Exhaust
CONV – IN Backfill
TCC SIGNAL Valve
SUMP Cooler

LUBE Converter
Flow PSR
Valve
Lube
Regulator Blocked At MAIN PRESSURE EXHAUST BACKFILL
Valve Separator Plate For CONTROL MAIN PRESSURE SUCTION
Modulated Main Pressure
CONVERTER–IN/OVERAGE A TRIM SIGNAL
Main Filter CONVERTER–OUT REVERSE SIGNAL
TORQUE CONVERTER CLUTCH (TCC) C1
LUBRICATION/COOLER C3
EXHAUST A TRIM PRESSURE
V06917.03.00

Figure H–6. Hydraulic Schematic — 3rd Range

Copyright © 2003 General Motors Corp. H–11/H–12


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX H — HYDRAULIC SCHEMATICS

HYDRAULIC SCHEMATIC – 4th RANGE G Solenoid Added–3rd Quarter 2003


1000 SERIES™, 2000 SERIES™, 2400 SERIES™ G Solenoid Lowers Main Pressure
PRE-BLOCK 1
And Increases Cooler Flow
GAIN VALVE When Energized (Typically at
AND A TRIM Low Throttle, Low Speed)
N/C A Trim Accumulator B Trim Accumulator
SOLENOID Solenoid Solenoid
W/O SPRING (Shown De-energized)
B
N/C Solenoid N/O
F Trim Filter C Shift D Shift E Shift G Mod Main
Solenoid Solenoid Solenoid Solenoid Solenoid

N/C N/C N/C N/C N/C

CONTROL MAIN CONTROL MAIN


EBF B TRIM
PRESSURE
CONV – IN
MAIN

A TRIM Selector D N R
PRESSURE Valve

MAIN
PRESSURE CONV – OUT
TAP C1
MAIN
C1
Clutch
Valve
TCC SIGNAL
MAIN C2

EXHAUST Control
Main
Filter
Control
Main Control PSC
Main Valve Main Relief
Regulator Valve
Valve C3

MODULATED MAIN PRESSURE


(G SOLENOID) C4

PSE C5
OVERAGE TCC C
Shift PSD
CONV – OUT TO COOLER Valve E Shift
Converter Valve
Relief
Valve OVERAGE D Shift
Charging Valve
Pump Exhaust
CONV – IN Backfill
TCC SIGNAL Valve
SUMP Cooler

LUBE Converter
Flow PSR
Valve
Lube Blocked At
Regulator Separator Plate For MAIN PRESSURE EXHAUST BACKFILL
Valve Modulated Main Pressure CONTROL MAIN PRESSURE SUCTION
CONVERTER–IN/OVERAGE B TRIM SIGNAL
Main Filter CONVERTER–OUT REVERSE SIGNAL
TORQUE CONVERTER CLUTCH (TCC) C1
LUBRICATION/COOLER C2
EXHAUST B TRIM PRESSURE
V06918.03.00

Figure H–7. Hydraulic Schematic — 4th Range

Copyright © 2003 General Motors Corp. H–13/H–14


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX H — HYDRAULIC SCHEMATICS

HYDRAULIC SCHEMATIC – 5th RANGE G Solenoid Added–3rd Quarter 2003


1000 SERIES™, 2000 SERIES™, 2400 SERIES™ G Solenoid Lowers Main Pressure
PRE-BLOCK 1
And Increases Cooler Flow
GAIN VALVE When Energized (Typically at
AND A TRIM Low Throttle, Low Speed)
N/C A Trim Accumulator B Trim Accumulator
SOLENOID Solenoid Solenoid
W/O SPRING (Shown De-energized)
B
N/C Solenoid N/O
F Trim Filter C Shift D Shift E Shift G Mod Main
Solenoid Solenoid Solenoid Solenoid Solenoid

N/C N/C N/C N/C N/C

CONTROL MAIN CONTROL MAIN


EBF B TRIM
PRESSURE
CONV – IN
MAIN

A TRIM Selector D N R
PRESSURE Valve

MAIN
PRESSURE CONV – OUT
TAP C1
MAIN
C1
Clutch
Valve
TCC SIGNAL
MAIN C2

EXHAUST Control
Main
Filter
Control
Main Control PSC
Main Valve Main Relief
Regulator Valve
Valve C3

MODULATED MAIN PRESSURE


(G SOLENOID) C4

PSE C5
OVERAGE TCC C
Shift PSD
CONV – OUT TO COOLER Valve E Shift
Converter Valve
Relief
Valve OVERAGE D Shift
Charging Valve
Pump Exhaust
CONV – IN Backfill
TCC SIGNAL Valve
SUMP Cooler

LUBE Converter
Flow PSR
Valve
Lube Blocked At
Regulator Separator Plate For MAIN PRESSURE EXHAUST BACKFILL
Valve Modulated Main Pressure CONTROL MAIN PRESSURE SUCTION
CONVERTER–IN/OVERAGE A TRIM SIGNAL
Main Filter CONVERTER–OUT B TRIM SIGNAL
TORQUE CONVERTER CLUTCH (TCC) REVERSE SIGNAL
LUBRICATION/COOLER C2
EXHAUST C3
A TRIM PRESSURE V06919.03.00

Figure H–8. Hydraulic Schematic — 5th Range

Copyright © 2003 General Motors Corp. H–15/H–16


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX H — HYDRAULIC SCHEMATICS

HYDRAULIC SCHEMATIC – HYDRAULIC DEFAULT FORWARD (3rd RANGE "LIMP HOME")


1000 Series™, 2000 Series™, 2400 Series™ G Solenoid Added–3rd Quarter 2003
G Solenoid Lowers Main Pressure
And Increases Cooler Flow
A Trim Accumulator B Trim Accumulator When Energized (Typically at
Solenoid Solenoid Low Throttle, Low Speed)
B (Shown De-energized)
N/C Solenoid N/O C On/Off D On/Off E On/Off
F Trim Filter Shift Shift Shift G Mod Main
Solenoid Solenoid Solenoid Solenoid Solenoid

N/C N/C N/C N/C N/C

CONTROL MAIN CONTROL MAIN


EBF B TRIM
PRESSURE
CONV – IN
MAIN

A TRIM Selector D N R
PRESSURE Valve

MAIN
PRESSURE CONV – OUT
TAP C1
MAIN
C1
Clutch
Valve
TCC SIGNAL
MAIN C2

EXHAUST Control
Main
Filter
Control
Main Control PSC
Main Valve Main Relief
Regulator Valve
Valve C3

MODULATED MAIN PRESSURE


(G SOLENOID) C4

PSE C5
OVERAGE TCC C
Shift PSD
CONV – OUT TO COOLER Valve E Shift
Converter Valve
Relief
Valve OVERAGE D Shift
Charging Valve
Pump Exhaust
CONV – IN Backfill
TCC SIGNAL Valve
SUMP Cooler

LUBE Converter
Flow PSR
Valve
Lube Blocked At
Regulator Separator Plate For MAIN PRESSURE EXHAUST BACKFILL
Valve Modulated Main Pressure CONTROL MAIN PRESSURE SUCTION
CONVERTER–IN/OVERAGE A TRIM SIGNAL
Main Filter CONVERTER–OUT REVERSE SIGNAL
TORQUE CONVERTER CLUTCH (TCC) C1
LUBRICATION/COOLER C3
EXHAUST A TRIM PRESSURE
V07738.03.00

Figure H–9. Hydraulic Schematic — Hydraulic Default Forward

Copyright © 2003 General Motors Corp. H–17/H–18


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX H — HYDRAULIC SCHEMATICS

HYDRAULIC SCHEMATIC – HYDRAULIC DEFAULT REVERSE ("LIMP HOME") G Solenoid Added–3rd Quarter 2003
1000 SERIES™, 2000 SERIES™, 2400 SERIES™ G Solenoid Lowers Main Pressure
PRE-BLOCK 1
And Increases Cooler Flow
GAIN VALVE When Energized (Typically at
AND A TRIM Low Throttle, Low Speed)
N/C A Trim Accumulator B Trim Accumulator
SOLENOID Solenoid Solenoid
W/O SPRING (Shown De-energized)
B
N/C Solenoid N/O
F Trim Filter C Shift D Shift E Shift G Mod Main
Solenoid Solenoid Solenoid Solenoid Solenoid

N/C N/C N/C N/C N/C

CONTROL MAIN CONTROL MAIN


EBF B TRIM
PRESSURE
CONV – IN
MAIN

A TRIM Selector D N R
PRESSURE Valve

MAIN
PRESSURE CONV – OUT
TAP C1
MAIN
C1
Clutch
Valve
TCC SIGNAL
MAIN C2

EXHAUST Control
Main
Filter
Control
Main Control PSC
Main Valve Main Relief
Regulator Valve
Valve C3

MODULATED MAIN PRESSURE


(G SOLENOID) C4

PSE C5
OVERAGE TCC C
Shift PSD
CONV – OUT TO COOLER Valve E Shift
Converter Valve
Relief
Valve OVERAGE D Shift
Charging Valve
Pump Exhaust
CONV – IN Backfill
TCC SIGNAL Valve
SUMP Cooler

LUBE Converter
Flow PSR
Valve
Lube Blocked At
Regulator Separator Plate For MAIN PRESSURE SUCTION
Valve Modulated Main Pressure CONTROL MAIN PRESSURE A TRIM SIGNAL
CONVERTER–IN/OVERAGE B TRIM SIGNAL
Main Filter CONVERTER–OUT C3
TORQUE CONVERTER CLUTCH (TCC) C5
LUBRICATION/COOLER A TRIM PRESSURE
EXHAUST B TRIM PRESSURE
*EFFECTIVE JANUARY 1, 2001 EXHAUST BACKFILL V07739.03.00

Figure H–10. Hydraulic Schematic — Hydraulic Default Reverse

Copyright © 2003 General Motors Corp. H–19/H–20


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX J — WIRING SCHEMATICS

1000 Series“, 2000 Series“, 2400 Series“ WIRING SCHEMATIC


TCM CONNECTOR TCM CONNECTOR ALLISON ALLISON
ALLISON ALLISON "J2" (RED)
"J1" (GRAY) RECOMMENDED RECOMMENDED
RECOMMENDED RECOMMENDED
SWITCHED COLOR WIRE NO. WIRE NO. COLOR
POWER
CHECK TRANS GREEN 125 TRANSMISSION CONTROL MODULE 215 YELLOW No HIGH
25 No 15 A
(TCM) No LOW
OUTPUT SPEED
OUTPUT FUNCTION 1 TAN 119 216 GREEN B SENSOR
19 16
OUTPUT FUNCTION 2 ORANGE 120 A 213 ORANGE NT HIGH
20 NT 13 A
TURBINE SPEED
OUTPUT FUNCTION 3 WHITE 121 214 BLUE NT LOW B SENSOR
21 14
OUTPUT FUNCTION 4 BLUE 122 L A 217 TAN N E HIGH
22 NE 17 A ENGINE SPEED
RANGE INHIBIT INDICATOR PINK 123 218 ORANGE N E LOW B SENSOR
23 18
SOL A (PCS)
OUTPUT FUNCTION 6 WHITE 124 A 223 WHITE
24 23 M
SIGNAL RETURN YELLOW 128 L 222 YELLOW
28 22 L
SOL B (PCS)
INPUT FUNCTION 9 ORANGE 114 D 224 PINK
14 BAT 24 N
INPUT FUNCTION 8 PINK 113 225 ORANGE P
13 25
INPUT FUNCTION 7 BLUE 112 L 231 TAN
12 12V or 24V 31 C
INPUT FUNCTION 6 (A) SOL C ON/OFF
GREEN 111 226 GREEN
11 26 A
INPUT FUNCTION 5 SOL D ON/OFF
YELLOW 110 227 BLUE
10 27 B
INPUT FUNCTION 4 DIGITAL GRAY SOL E ON/OFF
WHITE 109 L 228
9 INTERFACE 28 W
INPUT FUNCTION 3 SOL F (PWM) LOCKUP
GREEN 108 229 WHITE
8 29 J
INPUT FUNCTION 2 ORANGE 107 230 BLUE SOL G ON/OFF
7 30 R
INPUT FUNCTION 1 BLUE 106 232 GREEN
6 12V or 24V (B) 32 S
MODULATED MAIN SOLENOID
IGNITION POWER YELLOW 102 221 YELLOW
2 21 T
IGNITION POWER 104 201 BLUE C
YELLOW 12V or 24V (A) AND (B) 1 D A
4
BATTERY POWER 202 PINK D
PINK 103 2 F B
3
TCM GROUND POWER E
GRAY 101 SUPPLY 203 WHITE
1 3 E C
10A R
GRAY 105 A D L 204 GREEN
5 4 K D
DIAGNOSTIC CLASS II: PRESSURE SWITCH
BLUE 130 11
TOOL/ENGINE 30 J1850 DATA LINK MANIFOLD
INTERFACE GREEN 131 or ISO 9141 DATA LINK 210 TAN
31 10 G E
10A SUMP TEMP
RED 129 ANALOG 219 PINK H F
29 CAN 2.08 5V 19
J1939 INTERFACE 209 BLUE
BLACK 132 9 MAIN TRANSMISSION CONNECTOR
32 DATA LINK
IGNITION WHITE 116 12 C
SWITCH PWM 16
THROTTLE SPEEDO 2 (ZERO CROSSING) PINK 127 HARDWARE 220 GREEN THROTTLE
27 20 B POSITION
PULSES/REV SAME AS WIRE 126 DIVIDE A
TAN 126 TRANS 205 BLUE SENSOR
SPEEDO 1 (NON ZERO CROSSING) 26 OUTPUT 5 A
IGN TPU CALC/ SPEED 206 YELLOW
8, 16, 20 OR 40 PULSES/REV 17 5V SYNTHESIS DIGITAL 6
INTERFACE 207 GRAY
15 7
ANALOG 208 WHITE
GREEN 118 8
18 INTERFACE STARTER
12V OPTIONAL SPEEDO A 10 AWG ORANGE
or SIGNAL RETURN SOLENOID/STARTER
24V RELAY

NSBU SWITCH 10 AWG YELLOW PARK AND NEUTRAL


NSBU SWITCH P/N 29540193 START FEED
P/N 29541852 (P/N 29540479 KIT)
SAE J1939 BACKBONE
REFERENCE: FIG. J-2 WHITE 208 WHITE
P PINK
8 4C REVERSE LAMPS
GRAY 207 C GRAY
LEGEND 6 4B

4
YELLOW 206 B
4D
YELLOW
L = LOGIC GROUND BLUE REVERSE AND PARK
BLUE 205 A BLUE ACCESSORY FEED
ENGINE SAE STD 9-PIN 5 4A
INTERFACE DIAGNOSTIC CONNECTOR GREEN 220 GREEN
A = ANALOG GROUND 7 7D

9 7A TAN
PARK ACCESSORY
D = DIGITAL GROUND ORANGE 10 AWG ORANGE
1 7G

12
YELLOW 10 AWG 7E
YELLOW
PINK PINK
10 7F

11
BLUE 7C
BLUE
TAN
2 7B

3 V07485.01.01

NSBU WITH NSBU WITH


12-PIN CONNECTOR 4 AND 7-PIN CONNECTORS

Figure J–1. 1000/2000/2400 Series Wiring Schematic

Copyright © 2003 General Motors Corp. J–1/J–2


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX J — WIRING SCHEMATICS

ENGINE (ECM) TRANS (TCM) 9-PIN DDL


CONNECTOR D
J1939 J1939 E C
Data Data
Link Link F A B

G J
H

Pin ID
determined

SHIELD PIN D (–)


PIN C (+)
Attached to

PIN 31
PIN 29
PIN 32

PIN E
by Engine ECM via
OEM Deutsch/P TERMINATION
Should not
triangle 3-pin exceed 1 meter RESISTOR
connector
SHIELD

SHIELD
SHIELD
131 GREEN
129 RED
120Ω 120Ω
RESISTOR SHIELD 132 SHIELD BLACK SHIELD RESISTOR

CONTROLLER AREA NETWORK (CAN)


Should not exceed 40 meters

SAE J1939-11 V06460.01.00

Figure J–2. J1939 Backbone (CAN Bus)

Copyright© 2003 General Motors Corp. J–3


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX J — WIRING SCHEMATICS

NOTES

J–4 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX K — RESISTANCE VS. TEMPERATURE

42
MAX
NOM
37
MIN

SOLENOID RESISTANCE: Ohms


32
C, D, E, and G Solenoids
27

22

17
F Solenoid
12

A and B Solenoids
7

2
0 40 80 120

32 104 176 248


V06484.01.00

Figure K–1. Solenoid Resistance vs. Temperature Graph

Table K–1. Solenoid Resistance vs. Temperature

Solenoid A, B Solenoid C, D, E, G Solenoid F


Sump Temperature Resistance Resistance Resistance
(°C) (°F) (Ω) (Ω) (Ω)
0 32 4.5 20.0 9.5

20 68 5.5 22.0 10.5


40 104 6.5 24.5 11.5
80 176 7.5 27.0 12.5
120 248 8.5 29.5 13.5

Copyright© 2003 General Motors Corp. K–1


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX K — RESISTANCE VS. TEMPERATURE

RESISTANCE – TEMPERATURE
CHARACTERISTIC CHART
1000000

100000

Sensor Resistance (Ohms)


Trans Fluid Temp
10000

1000
Nominal Resistance
100

10

1
-45 -30 -15 0 15 30 45 60 75 90 105 120 135 150
Temperature (C)

-49 -22 5 32 59 86 113 140 167 194 221 248 275 302
Temperature (F)
V05749

Figure K–2. Transmission Fluid Temperature Sensor Resistance vs. Sump Temperature Graph

NOTE: Look carefully at the graph. The scale for the resistance (on the left side) is not constant (linear).
It is logarithmic which means it can display a great range of values within a small space. Each
section of the graph is ten units, but the units vary from 1 to 100 000 Ohms.

Table K–2. Transmission Fluid Temperature Sensor Resistance vs. Temperature


Temperature Temperature Minimum Resistance Nominal Resistance Maximum Resistance
(°C) (°F) (Ω) (Ω) (Ω)
–45 –49 128 565 141 951 155 338
–40 –40 95 826 100 735 105 644
–35 –31 68 952 72 315 75 679
–30 –22 50 153 52 480 54 807
–25 –13 36 854 38 478 40 103
–20 –4 27 345 28 488 29 631
–15 5 20 476 21 286 22 097
–10 14 15 467 16 045 16 624
–5 23 11 781 12 197 12 612
0 32 9045 9345 9646
5 41 6998 7219 7441

K–2 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX K — RESISTANCE VS. TEMPERATURE

Table K–2. Transmission Fluid Temperature Sensor Resistance vs. Temperature (cont’d)
Temperature Temperature Minimum Resistance Nominal Resistance Maximum Resistance
(°C) (°F) (Ω) (Ω) (Ω)
10 50 5458 5623 5787
15 59 4291 4413 4536
20 68 3398 3490 3582
25 77 2710 2779 2849
30 86 2173 2228 2282
35 95 1754 1797 1840
40 104 1424 1459 1493
45 113 1163 1191 1218
50 122 955.0 977.1 999.2
55 131 788.6 806.5 824.5
60 140 654.7 669.3 683.9
65 149 546.3 558.3 570.2
70 158 458.1 467.9 477.8
75 167 385.9 394.1 402.2
80 176 326.6 333.3 340.1
85 185 277.5 283.2 288.9
90 194 236.5 241.6 246.7
95 203 202.4 206.9 211.5
100 212 173.8 177.9 182.0
105 221 149.8 153.6 157.3
110 230 129.7 133.0 136.4
115 239 112.6 115.6 118.7
120 248 98.17 100.88 103.6
125 257 85.87 88.29 90.71
130 266 75.35 77.52 79.69
135 275 66.34 68.27 70.21
140 284 58.58 60.31 62.04
145 293 51.88 53.42 54.97
150 302 46.08 47.46 48.84
155 311 41.04 42.27 43.50
160 320 36.65 37.74 38.84

Copyright© 2003 General Motors Corp. K–3


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX K — RESISTANCE VS. TEMPERATURE

1000/2000/2400 Series™ Transmission


Speed Sensor Resistance Values
4500

4000

OHMS 3500

3000

2500
Max Ohms
2000 Nominal Ohms
Min Ohms
1500
–25 0 25 50 75 100 125 150
TEMPERATURE (°C)

–13 32 77 122 167 212 257 302


TEMPERATURE (°F)
V06096

Figure K–3. Speed Sensor Resistance vs. Temperature Graph

Table K–3. Speed Sensor Resistance vs. Temperature


Temperature Temperature Minimum Resistance Nominal Resistance Maximum Resistance
(°C) (°F) (Ω) (Ω) (Ω)
–25 –13 1929 2143 2358
0 32 2157 2397 2637
25 77 2340 2600 2860
50 122 2614 2904 3195
75 167 2842 3158 3474
100 212 3071 3412 3753
125 257 3299 3666 4032
150 302 3483 3870 4257

K–4 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX L — ELECTRONIC INTERFERENCE

1–1. ELECTROMAGNETIC INTERFERENCE (EMI)/RADIO FREQUENCY


INTERFERENCE (RFI)
All electrical and electronic systems generate electromagnetic fields that can interfere with other electronic
systems. Allison Transmission electronic transmission controls comply with Federal Communications Commission
(FCC) regulations and other guidelines concerning emitted radio frequency interference for transportation
electronics. The position of Allison Transmission Division of General Motors is that manufacturers and installers of
Electromagnetic Interference (EMI)/Radio Frequency Interference (RFI) emitting equipment are responsible for
adhering to FCC regulations and other guidelines concerning emitted radio frequency interference for
transportation electronics.

Some radio-telephone or two-way communication radios (land-mobile radio), or the manner in which they are
installed, can adversely affect vehicle operation or be affected by other vehicle components. Expenses incurred to
protect vehicle-related systems from EMI/RFI emissions by radio-telephone or two-way communications radios
(land-mobile radio) or to integrate such devices into vehicles are not the responsibility of Allison Transmission.

1–2. GENERAL GUIDELINES FOR RADIO EQUIPMENT INSTALLATION


The following general guidelines for installing radio-telephone or two-way communications radios (land-mobile
radio) in a vehicle supplement, but DO NOT replace, detailed instructions provided by the radio equipment
manufacturer. Detailed installation instructions are the sole responsibility of the radio equipment manufacturer.

Experience has shown that most EMI/RFI problems can be prevented or eliminated by following the guidelines. If
EMI/RFI problems persist after following the guidelines and after ensuring the installation conforms to the
guidelines, contact the vehicle and radio equipment manufacturers for additional installation or equipment
operation instructions.

A. Transmitter Installation
1. Locate remote radio transmitters as far away from other electronic devices and as near to the side
of the vehicle body as possible.
2. Mount transceivers (transmitter and receiver in one box) under the dash so as not to interfere with
vehicle controls or passenger movement.

B. Antenna Installation
Each vehicle and body style reacts differently to radio frequency energy. When dealing with an
unfamiliar vehicle, test various antenna locations by using a magnetic mount antenna and checking
for adverse effects. Antenna location is a major factor in EMI/RFI problems.

C. Antenna Cable Routing


1. Use high quality, 95 percent shield coverage, coaxial (coax) cable. Route the coax well away from
any electronic components.
2. Route antenna cables as far away from vehicle wiring as possible to reduce the likelihood of the
vehicle wiring acting as an antenna for interference.

D. Radio Wiring and Connector Location


1. Connect transmitter power leads directly to the battery.
2. For transceivers (transmitter and receiver in one box) with ignition control, place a 12V power con-
tactor at the vehicle battery. Drive the contactor coil, through an appropriate in-line fuse, from an
ignition circuit not powered during engine cranking.
3. Any negative lead from a handset or control unit must return to battery negative.
4. Connect the positive lead from a handset or control unit directly to battery.
5. Fuse handset or control unit positive and negative leads separately from the transceiver negative
and positive leads. Use correctly rated fuses.

Copyright© 2003 General Motors Corp. L–1


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX L — ELECTRONIC INTERFERENCE

E. Power and Ground Wire Routing


Route radio power and ground wires as far away as possible from electronic control modules.

F. Troubleshooting
The following are common causes of EMI/RFI problems:
• Power leads connected to points other than the battery
• Improper antenna location
• Poor shielding or connections to antenna cable
• Transmitter or transceiver wiring too close to vehicle electronics

1–3. EXTERNALLY-GENERATED SPEED SENSOR SIGNALS


A. Checking for Externally-Generated Speed Sensor Signals
Use the following procedures to determine if speed sensor signals generated by a source external to
the transmission or wiring harness are present:
1. Turn the ignition ON.
2. Keep the engine OFF.
3. If the TCM is ON, connect the Allison DOC™ diagnostic tool.

NOTE: If false speed signals were present at the previous shutdown, the TCM might still be “ON” even
though the ignition is “OFF”. The Allison DOC™ diagnostic tool is powered by ignition power
so the ignition must be “ON” to use the Allison DOC™ to read the speed signals.

4. Read the speed sensor signals.


5. If a speed sensor signal is other than one (1), then there is a short to another circuit that is carrying
an AC or PWM signal.
6. Check resistance of the sensor.
7. Check for shorts to other circuits within the harness or transmission connector.
8. Check to ensure there is no conductive material inside the connector.
9. Check to be sure the speed sensor circuit wires are a twisted pair.
10. Check to ensure a properly grounded drain wire.
11. Check for the presence of a strong external AC signal.
12. Repair or replace parts as required.

L–2 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL

NOTE: Instructions for using the Allison DOC™ Diagnostic Tool when performing 1000/2000/2400 Series
On-Highway transmission electronic controls diagnostics, are included in Appendix M. Refer to
the Allison DOC™ for PC User Guide GN3433EN for complete Allison DOC™ instructions.

1. INTRODUCTION
The Allison Diagnostic Optimized Connection for PC™ tool (Allison DOC™ for PC) is a diagnostic system
designed for use with Allison’s 1000/2000/2400 Series™ transmissions. This PC-based diagnostic program is
capable of reading from a 1000/2000/2400 Series™ Transmission Control Module (TCM) using J1939/J1850
communication protocols.
Allison DOC™ for PC performs the following:
• Monitors 1000/2000/2400 Series™ Transmission Control Module (TCM) data
• Displays multiple transmission parameters.
• Displays a graphical instrument panel with analog and digital gauges.
• Displays a graphical strip chart.
• Records and plays back diagnostic sessions.
• Prints diagnostic reports.
• Reprograms selected TCM settings (requires completion of ATD training).
Allison DOC™ for PC provides the following features:
• A Microsoft Windows®/PC look and feel.
• Security measures to control reprogramming TCM parameters.
• Integrated Help.
• Diagnostic Trouble Code information with a direct link to the 1000/2000/2400 Series™ Troubleshooting
Manual.
• A demo mode using prerecorded data.
• SmartConnect for detecting the PC-to-vehicle translation device.
• Allison DOC™ for PC is compliant with applicable TMC Recommended Practices, GM Online Standards,
SAE Standards, and CE Standards.
• Allison DOC™ for PC is RP1210A compliant.

2. WARNINGS AND NOTES

To avoid personal injury, the vehicle operator must not use or read the
WARNING! diagnostic tool while the vehicle is moving. Doing so may result in loss of
vehicle control, which may cause personal injury and vehicle damage.

WARNING! Personnel other than the vehicle operator must use the diagnostic tool.

The vehicle operator must maintain control of the vehicle while an assistant
WARNING! performs the diagnostic evaluations.

NOTE: Allison DOC™ for PC users are assumed to have a basic working knowledge of the Microsoft
Windows 95®/98®/NT/XP® Operating System(s) and Adobe® Acrobat ® Reader®.

Copyright© 2003 General Motors Corp. M–1


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL

Trademark Information
• Windows 95®, Windows 98®, Windows ME®, Windows 2000®, Windows NT®, Windows Explorer®,
XP® Professional and Windows Media Player® are registered trademarks of Microsoft Corporation
• Adobe® Acrobat® is a registered trademark of Adobe Corporation
• Pentium® and Pentium II® are registered trademarks of Intel Corporation
• MPSI MagiKey® and MPSI PDM® are registered trademarks of NEXIQ Technologies Incorporated
• Dearborn Group Dearborn Protocol Adapter (DPA) II® and Dearborn In-line Adapter II® are registered
trademarks of Dearborn Group Technology
• Allison Diagnostic Optimized Connection™ and Allison DOC™ for PC are trademarks of General Motors
Corporation
• 1000 Series™, 2000 Series™, and 2400 Series™ are trademarks of General Motors Corporation
• SPX J1850® is a registered trademark of SPX Corporation
• InstallShield® is a registered trademark of InstallShield Software Corporation

3. TEXT CONVENTIONS USED IN THIS GUIDE


The following text conventions are used in this Guide to more clearly describe using Allison DOC™ for PC:
• Screen button and keyboard key names are in bold capitals—OK, RETURN.
• Menu names are presented as displayed—File, Edit, etc.
• Menu items are presented as displayed—Exit.
• File names that may change with use are in lowercase italics—snapshot.log.
• Filenames, usually system files, that do not change are in initial capitals—Acrobat.pdf.
• Titles of windows are as they appear in the window.

6. ALLISON DOC™ FOR PC OVERVIEW


Allison DOC™ for PC has been designed to aid you, the technician, in troubleshooting and maintaining 1000/2000/
2400 Series™ Allison transmissions. Allison DOC™ for PC can be used with a desktop PC or a laptop PC in the
cab of a vehicle.

To avoid personal injury, the vehicle operator must not use or read the
WARNING! diagnostic tool while the vehicle is moving. Doing so may result in loss of
vehicle control, which may cause personal injury and property damage.

Allison DOC™ for PC aids you by providing:


• Displays of real-time and saved transmission operating data that include:
— Trouble codes — Range selected/attained
— Sump temperature — Configuration data
— Retarder temperature, if applicable — TPS percentage
— Percent of retarder application, — Input speed
if applicable — Turbine speed
— Shift inhibit indicator — Output speed

M–2 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL

• The ability to clear active and inactive trouble codes


• Access to TCM configuration data
• With ATD approved training, the ability to change TCM configuration
• A graphic data display
• Strip chart data graphing
• A variety of reports such as:
— 1000/2000/2400 Series™ — Diagnostic Data
Failure Records — Customer Modifiable Constants
— Shift Inhibits — Trouble Codes
— ATD I/O Wires — DTC Test

NOTE: Contact your nearest Allison Distributor for additional Allison DOC™ for PC training. Allison
distributors are listed on the Allison website at www.allisontransmission.com.

6–1. ALLISON DOC™ FOR PC NAVIGATION, CONTROLS, AND STATUS INFORMATION


Allison DOC™ for PC displays the following navigation, control, and status information items regardless of what is
displayed in the main Allison DOC™ for PC window.

a. Status Bar
The status bar provides information about the connection between Allison DOC™ for PC and the TCM. It is located
in the upper portion of the main Allison DOC™ for PC window. The fields in the primary status bar are not labeled,
but their content adequately indicates their purpose.

(Transmission and CIN)


Transmission Control System and Calibration Identification Number.
Example: WTEC III 00T12352300

(Connection)
Describes the connection between Allison DOC™ for PC and an TCM. Descriptions are:
• Connected—Allison DOC™ for PC is actively connected to an TCM and receiving live data.
• Off-Line—The connection between Allison DOC™ for PC and TCM is not live and no data is being received.
• Playback—The displayed data is part of a snapshot and is not current.
• Demo—Displayed data is part of the demo program.

(Active Code)
Indicates the presence of an active Trouble Code. Indicators are:
• Active Codes
• No Active Codes

Copyright© 2003 General Motors Corp. M–3


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL

b. Menus
The menu bar at the top of the Allison DOC™ for PC window, above the Primary Status bar, displays the following
drop-down menus:

File
• Run
• Print—displays the Print Report window
• Exit—exits the Allison DOC™ for PC program

TCM Interface
• Connect/Disconnect—displays the Connect/Disconnect window

Diagnostic
• Trouble Code—displays the Trouble Code window
• Performance Complaint—displays the Performance Complaint window
• Data Monitor—displays the Data Monitor window
• TCM/Calibration Information—displays the TCM/Calibration Information window
• Custom Data Monitor—displays the Custom Data Monitor data selection window
• Graphics Monitor—displays the Graphics Monitor window
• Strip Chart—displays the Select the Data to Graph on the Strip Chart window
• Data Bus Viewer—displays the data stream being sent to Allison DOC™ for PC from the TCM.

Action Request
• Clutch Test Enabled—enables the Clutch Test
• C Solenoid Test
• Reset Adapted Shifts
• Reset Throttle Calibrations—resets TPS calibration
• Engineering Calculations—provides means to calculate converter speed ratio, vehicle speed, and acceleration
in g’s

Snapshots
• Record
• Record Options—displays the recording options window
• Stop Recording—halts recording
• Add Bookmark—displays the bookmark window

Playback
• Open Playback File—displays the Open window and the content of the Log folder.
• Play—plays a recorded data file.
• Rewind—starts the playback at the beginning.
• Stop—stops a playback.
• Fast Forward—plays a recorded data file at four times the normal speed.
• Continuous—plays a recorded data file continuously, a looped playback.
• Email—displays the Compose Email window.

M–4 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL

Options
• Application Configuration—displays the Application Configuration tabs.

Help
• Help Topics—displays the Help Topics window.
• Demo—displays the Choose Demo window.
• 1000/2000/2400 Series™ Troubleshooting Manual—activates the Adobe® Acrobat reader to display the 1000/
2000/2400 Series™ Troubleshooting Manual.
• Access to ATD Website —connects to the ATD website, www.allisontransmission.com. Requires Internet con-
nection and login ID and Password to access the extranet.
• Video-based Training Materials
— 1K2K NSBU Switch
— 1K2K Internal Wiring Harness
— 1K2K Electronic Controls
— 1K2K Breakout Box
— Circuit Checks
— Circuit Basics
— Allison DOC™ Training Videos
• Hydro Schematics—displays hydraulic schematics
• ATD Calc—displays the Application Engineering Installation Design Calculations window
— Multiple-Joint Driveline Analysis
— Oil-to-Water (OTW) Cooling Analysis
— Oil-to-Air (OTA) Cooing Analysis
— OTW and OTA Combination Cooling Analysis
— Hose and Fitting Pressure Drop Analysis
• About Allison Transmission Diagnostic (Scan) Tool

c. Button and Keyboard Shortcuts


The following buttons are always available in the primary Allison DOC™ for PC window. Clicking the button or
pressing the associated function key displays the listed menu.

F1–Help
Accesses the Help system

F2–File
• Print
• Exit

F3–Diagnostic
• Trouble Code
• Performance Complaints
• Data Monitor
• TCM/Calibration Information
• Custom Data Monitor
• Graphics Monitor

Copyright© 2003 General Motors Corp. M–5


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL

• Strip Chart
• Data Bus Viewer

F4–Snapshot
Start or stop recording snapshots.

F5–Connect
Establish or break the connection between Allison DOC™ for PC and the TCM.

F6–Fire Trigger
Inserts a “bookmark” in the data stream during a recording session. Bookmarks are sequentially numbered by the
system when F6–Fire Trigger is used.

F7–Stop Recording
Stops a snapshot recording
Accelerator keys—On screen buttons have shortcuts known as accelerator keys. An underlined character in the
button text identifies the button’s accelerator keyboard key. Pressing the accelerator key activates the function
associated with the button. For example, on the button below, the P keyboard key is the accelerator key. Drop-
down menu items accelerator keys require pressing ALT before pressing the accelerator key. After pressing the
ALT/ACCELERATOR KEY combination that menu displays.

When this button is visible, and you press the P key, you activate a print function.\

M–6 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL

8. STARTING ALLISON DOC™ FOR PC

8–1. STARTING THE PROGRAM


There are two ways to start Allison DOC™ for PC:
• Double-click the Allison DOC™ for PC tool icon on your PC desktop,
or,
• From your PC’s Start menu, select Programs_ Allison Transmission_ Allison DOC. If you stored Allison DOC™
for PC in another location, follow the path to that location and select Allison DOC.

8–2. 30-DAY TRIAL


A 30-Day trial is included as part of Allison DOC™ for PC. The 30-day trial window appears each time Allison
DOC™ for PC is started, unless the activation password has been entered. The 30-day trial window displays the
number of days remaining in the trial period. At any time before the trial period ends you may enter the activation
password. The Allison DOC™ for PC application will not function after 30 days if a valid activation password has
not been entered. Contact your Allison Support Representative to obtain the product activation password.
• Once you have the password, enter it into the Password field of the 30-Day Trial window and press OK.
• During the 30-day trial period, press CANCEL to run the Allison DOC™ for PC program.

Copyright© 2003 General Motors Corp. M–7


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL

8–3. AT START-UP
When you start Allison DOC™ for PC, a brief animation sequence plays (stop the 13 seconds sequence by
pressing the SPACEBAR). When the animation sequence ends, the Warning window displays (if the activation
password has been entered, otherwise the 30-Day Trial window displays). The Warning window lists basic
transmission troubleshooting tasks and outlines basic safety considerations (see Warnings and Notes). The
CONNECT TO VEHICLE button initiates the software connection to a vehicle and the DEMO button starts Allison
DOC™ for PC Demos.

10. USING THE ALLISON DOC™ FOR PC

10–1. CONNECTING/DISCONNECTING

a. Connecting
NOTE: Allison DOC™ for PC supports only RP1210A compliant devices.
The Connect/Disconnect window establishes the software connection between Allison DOC™ for PC and the TCM
through a PC-to- TCM data translator. In order for Allison DOC™ for PC to read information from the TCM, both the
vehicle ignition and the PC-to-vehicle translator must be powered on. Upon successful connection, the Trouble
Code window automatically displays. Any logged Diagnostic Trouble Code information is displayed in the Trouble
Code window.
To establish a connection between Allison DOC™ for PC and TCM:
1. From the Warnings window of Allison DOC™ for PC, click the button or select
Connect/Disconnect from the TCM Interface drop-down menu, or click the F5–Connect button, or
press the F5 key—The Connect/Disconnect window appears.

M–8 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL

2. To have Allison DOC™ for PC automatically select the translation device:


• Click the SmartConnect check box.
• Select a transmission series from the Transmission drop down menu.
• Click the button. Upon successful connection, a Trouble Code window
displays.

Copyright© 2003 General Motors Corp. M–9


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL

3. To select the translation device manually:


• If SmartConnect is selected, click the SmartConnect checkbox to deselect
SmartConnect.
• Select the TCM Vendor from the drop-down Vendor list. If the Vendor line is blank, verify
that the PC-to-vehicle translator’s driver software has been installed on your PC.
• Select the translator device connecting the PC to the TCM from the drop-down Device list.
If a connection is not established, the Connect Failure window displays.

b. Disconnecting

NOTE: Disconnection breaks the Allison DOC™ for PC to TCM connection; it does not deactivate the
Allison DOC™ for PC software.
To break the connection between Allison DOC™ for PC and TCM:

1. Select Connect/Disconnect from the TCM Interface drop-down menu, click the but-
ton, or press the F5 key—the Transmission Connect/ Disconnect window appears.

2. Click the button—Allison DOC™ for PC/vehicle communications stop.

10–2. VIEWING DIAGNOSTIC DATA


Diagnostic data can be displayed in any of seven different formats. Each transmission type displays data
differently. The same seven formats are available to all transmission types. The seven formats appear in the
Diagnostic Options window. Access a format by clicking on the format name or typing the first letter of the format
name. The transmission type selected during the Connect process determines what data is displayed.

M–10 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL

c. 1000/2000/2400 Series™ Diagnostic Trouble Codes


A 1000/2000/2400 Series™ Diagnostic Trouble Code consists of the letter “P” or “U” followed by four or five
numbers. A “P” indicates a transmission internal problem, while a “U” indicates a problem in a vehicle system or
the transmission-to-vehicle interface.

1000/2000/2400 Series™ Diagnostic Trouble Code View

DTC
The 1000/2000/2400 Series uses a five character, a letter and four numbers, diagnostic trouble code. Any DTC
that is unknown to the system generates a message stating that the DTC is unsupported and to call Allison
Transmission.

Active
Y/N (Yes/No) indicates if the Trouble Code is active. When a code is logged by the TCM and the condition causing
the code still exists, that code is said to be active; otherwise the trouble code is inactive.

Historic
Y/N (Yes/No) indicates if the Trouble Code is active. When a code is logged by the TCM and the condition causing
the code still exists, that code is said to be active, otherwise the trouble code is historic.

Check Trans
A “Y” indicates the CHECK TRANS light is illuminated.

Copyright© 2003 General Motors Corp. M–11


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL

Failure Record
A “Y” indicates that a failure record has been generated for the DTC.

Description
Describes the DTC.

Clear DTC information


Clears DTC information for a selected DTC row.

Cal ID
Calibration Identification.

Software Level
Software version loaded into the TCM.

Serial Number
The TCM’s serial number. If a nonprintable character is encountered, the character is represented by *. The TCM
serial number consists of the following components:
• Product Code
• Broadcast code
• Supplier Code
• Supplier Manufacturing Code
• Last Digit of the calendar year
• Julian day of the year
• Serial Number

HCN
Hardware Compatibility Number.

Sump Temp
Temperature in the transmission sump.

PRNDL A
Status of NSBU switch A.

PRNDL B
Status of NSBU switch B.

PRNDL C
Status of NSBU switch C.

PRNDL P
Status of NSBU switch P.

M–12 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL

Gear Select/Attain
The range selected at the shift selector and the actual range attained by the transmission.

TCM Input Volts


The TCM input voltage.

c–1. Viewing Troubleshooting Manual Information for a Trouble Code


In the Trouble Code window of Allison DOC™ for PC, double-click the DTC or DTC Description for which more
information is needed. Adobe Acrobat® displays the 1000/2000/2400 /2400 Series™ Troubleshooting Manual
page appropriate for the DTC.

c–2. Clearing Active Codes


1. In the Trouble Code window, click the button.
A window appears displaying the message, “Clear Active Codes Request Completed Successfully!”
2. Click the OK button.
Active Trouble Codes and associated information are cleared from the Allison DOC™ for PC window. If the cause
of the Trouble Code is not corrected, the Trouble Code may immediately reappear.

NOTE: To clear active Trouble Codes, the vehicle must be stopped and in Neutral. If these conditions are
not met. A message “Request Denied. Output Speed not less than maximum allowable value.” or
“Neutral not attained.” displays.

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d. Displaying Failure Records


You can view the last five DTC failure records by double clicking on a DTC row in the Failure Record Available
column of the DTC grid or by selecting the Failure Record item from the Diagnostic main menu. A message
displays if Failure Records cannot be displayed.

Failure Record Display

e. Performance Complaint
The Performance Complaint function assists you in diagnosing a problem by selecting a symptom.
1. Select the Diagnostic drop-down menu or click the F3–Diagnostic button, or press the F3 key.
2. Select Performance Complaint—The Performance Complaint window displays.

3. Select the appropriate Vehicle Complaint from the drop-down list.


4. Click OK—the appropriate Troubleshooting Manual pages display information relevant to the se-
lected Vehicle Complaint.

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f. Diagnostic Data Monitor

f–1. Displaying the Diagnostic Data Monitor


The Data Monitor allows you to view TCM information in a table format. The data displayed is dynamic. Speed and
other data changes are displayed as they occur.
To display the Data Monitor:
1. Click the button, or select Data Monitor from the Diagnostics drop-down menu, or
press the F3 key.
The diagnostic options window appears.

2. Click Data Monitor—the appropriate Diagnostic Data Monitor appears.

h. 1000/2000/2400 Series™ Data Monitor


The 1000/2000/2400 Series™ Data Monitor can display diagnostic data for TCMs with Configuration Identification
Numbers (CIN) starting with 11, 12, and 13 in four different vocations.
These vocations are:
• Standard—displays data for standard North American vocations
• Euro Bus—displays data for European bus vocations
• Euro Truck—displays data for European truck vocations
• Medium Duty Gas—displays data for medium-duty gasoline engine vocations
A vocation menu displays to allow selecting a vocation.

NOTE: Be sure to select the appropriate vocation to display the correct data.

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1000/2000/2400 Series™ Standard Data Monitor

The 1000/2000/2400 Series™ Data Monitor displays data in two sections:


• Diagnostic Data
• ATD Wire Data

h–1. Diagnostic Data


• Diagnostic Data—A brief description of the diagnostic data being measured.
• Value—The value of the associated diagnostic data.
• Units—units of measure for the value.

h–2. ATD Wire Data


• ATD Wire #—The wire circuit number of the programmed function.
• Input/Output Function.
• State—On/Off.

i. TCM Calibration Information


To display current TCM and Calibration information:
1. Select the Diagnostic drop-down menu or click the F3–Diagnostic button, or press the F3 key.
2. Select TCM/Calibration Information.

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1000/2000/2400 Series™ TCM Calibration Information

j. The Custom Data Monitor


You may select the information to be displayed in the Custom Data Monitor window by adding or removing data
types to the display. Data types are added or removed in the Custom Data Monitor data selection window. The
Custom Data Monitor window is the same as the Data Monitor window, except that only the selected data is
displayed. Selected data types must be re-selected each time the Custom Data Monitor is displayed unless a
Custom Data List is saved.
To select Custom Data Monitor data types:
1. Select the Diagnostic drop-down menu or click the F3–Diagnostic button, or press the F3 key.
2. Select Custom Data Monitor—the Custom Data Monitor data selection window displays.

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3. Select the desired Diagnostic Data type(s); up to eight data types may be selected from the left-
hand column.
4. Click the button or double click the selection—the selected data types appear in the right-
hand column.
5. Click the OK button—the selected data types appear in the Custom Data Monitor window.

1000/2000/2400 Series™ Custom Data Monitor

To remove Customer Data Monitor data types:


1. Select the Diagnostic drop-down menu, or click the F3–Diagnostic button, or press the F3 key.
2. Select Custom Data Monitor—the Select Diagnostic Data to Track window displays.
3. Select the desired Diagnostic Data types from the right-hand column.
4. Click the button—the selected data types are restored to the left-hand column.
5. Click the OK button—the deleted data types no longer appear in the Custom Data Monitor window
and the window closes.

j–1. Custom Data List


You can save a list of data to display in the Custom Data Monitor by using the Custom Data List feature.
1. Move data to track into the right-hand window.
2. Click the SAVE button—the Custom Data Monitor List Save window displays

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3. Type a name for the list


4. Click the OK button—the list is saved under the name you entered.
To use the saved data list:
1. Click on the Select One drop-down arrow in the data select window.
2. Highlight a list name—the Load and Delete buttons become active.
3. Click either Load, to load the list, or Delete, to delete the list.

k. The Graphics Monitor


The Graphics Monitor displays diagnostic data using gauges, thermometers, indicator lights, text boxes, and a
scrollable ATD Wire # data display.

k–1. Displaying the Graphics Monitor


To display the Graphics Monitor:
1. Select the Diagnostic drop-down menu, or click the F3–Diagnostic button, or press the F3 key.
2. Select Graphics Monitor—the Graphics Monitor window displays.

1000/2000/2400 Series™ Graphics Monitor

The following information is included in the Graphics Monitor:

NOTE: A gauge can be expanded to a full-screen display by double-clicking on the gauge. Return the
display to normal by pressing the ESC key or double clicking in the expanded display.

Engine Speed
RPM indicated by needle gauge and digital readout.

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Output Speed
RPM indicated by needle gauge and digital readout.

Turbine Speed
RPM indicated by needle gauge and digital readout.

TPS %
The TPS Percentage is indicated by needle gauge.

Gear Selected
The selected range displays.

Gear Attained
The attained range displays.

PRNDL Switch States


On/off position of the PRNDL switches.

Sump Oil Temperature


Temperature indicated by Fahrenheit thermometer and Fahrenheit/Celsius readout.

Shift Inhibits
A brief description of the shift inhibit and the associated value.

ATD Wire information


• ATD Wire # - The wire circuit number of the programmed function.
• State – On/Off

l. The Strip Chart

l–1. Displaying the Strip Chart


The Strip Chart is a graph that tracks, over time, changes in selected data as the changes occur. The data-against-
time data stream is continuous regardless of the Strip Chart mode selected.

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To display the Strip Chart:


1. Select the Diagnostic drop-down menu or click the F3–Diagnostic button, or press the F3 key.
2. Select Strip Chart—the Select the Data to Graph on the Strip Chart window displays.

3. Select up to eight Diagnostic Data types from the left-hand column.


4. Choose a color for the trace of the data selected or allow the default color.

NOTE: Contrasting colors are easier to see on the strip chart.


5. Click OK.
The selected data types appear in the Strip Chart window.

1000/2000/2400 Series™ Strip Chart

l–2. Data Trace Identification


The selected data is assigned a color on the graph. The name of the data and its corresponding color is displayed
in the upper-right corner of the Strip Chart display.

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l–3. X-axis Scaling


The passage of time in seconds is indicated on the X-axis, horizontal bottom of the graph. As time passes, data
lines on the graph move to the right. The Strip Chart displays 10 seconds of data at a time. If playing back recorded
data, the VCR Control window displays the Total File Time and the Current File Time, in minutes. Total File Time is
the total length of the recording. Current File Time is the time elapsed since you started the playback.

l–4. Y-axis Scaling


The Y-axis, vertical left side of the Strip Chart, displays a range of values based upon the data selected for display.
If you select data having different types of measurements such as input rpm and engine cooling temperature, a
divisor, preceded by a slash (/), displays next to the data that requires calculation to determine the correct value.
For example: input speed and engine cooling temperature. RPM is displayed on the Y-axis, from 0 to 4000. To
determine the engine cooling temperature, divide the value of the engine cooling temperature trace by 15.7. An
easier method is to use the Strip Chart Cursor mode, which calculates the adjustment and displays the correct
value.

l–5. Strip Chart Modes


Several data display modes are selectable from the tool bar in the upper left portion of the Strip Chart window.
These modes, or commands, allow you to control the data display on the Strip Chart. To change to a particular
mode, simply click the desired mode icon. When a mode other than Plot is selected, the data display at that time is
frozen; but the data-against-time stream continues in the background. When Plot is re-selected, the data-against-
time stream is re-entered at the time Plot was re-selected.
The control modes are:

Plot
Plot is the default Strip Chart mode, where data lines move from left to right across the Strip Chart graph.

Pause
Pauses the plot. Data continues to be collected, but not displayed in the graph. Click the PLOT button to resume
normal plotting.

Zoom Out All Axes


Each click on the Zoom Out All Axes button increases the values displayed to the left of the graph, which increases
the area displayed and provides a less detailed display than the standard plot mode. Click the PLOT button to
resume normal plotting.

Zoom In All Axes


Each click on the Zoom In All Axes button decreases the values displayed to the left of the graph, which decreases
the area displayed and provides a more detailed display than the standard plot mode. Click the PLOT button to
resume normal plotting.

Cursor
Cursor mode allows you to place a vertical line at any point in the graph. A widow containing the Y, vertical, value
of the selected trace displays next to the cursor. Use drag and drop to position the cursor line. The Y value is for
the data selected from the list relating a line color to data. The cursor line color is the same as the selected data
line.

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Print
Sends the Strip Chart data display to your printer.

Data Bus Traffic View


The data flowing between the TCM and Allison DOC™ for PC is viewable in the Data Bus Traffic View. The 1000/
2000/24000 data is on the J1850 bus. You can view Data Bus Messages in either decimal, base 10, or
hexadecimal, base 16, number systems. The data bus traffic can also be saved to a file for later retrieval.

To view Data Bus Traffic:

1. Select the Diagnostics drop-down menu.

2. Click on the Data Bus Viewer menu item—the Data Bus Traffic Viewer window displays.

Data Bus Messages


The numeric representations of the data flow on the data bus.

MID/SA
Message Identifier/Source Address code— the message type/source/destination.

Component ID
Manufacturer of a controller.

Model
A controller’s model number.

Software ID
Identifies the software used by the controller.

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Hexadecimal
Toggles the Data Bus Message display between decimal and hexadecimal number systems.

Pause/Continue Button
Pauses and continues the Data Bus Message display.

Clear Button
Clears all Data Bus Message data.

Save Button
Saves the data as displayed in Data Bus Viewer in a file named by data and time that is located in the Allison
DOC™ for PC Saved DataBusViewerFiles folder. Use Windows Explorer to navigate to the hard drive on which
Allison DOC™ for PC is located, then to the following path—…\Program Files\Allison Transmission\Allison DOC
for PC\Saved DataBusViewer Files. The saved data can be viewed with NotePad® or WordPad™.

Exit Button
Closes the Data Bus Traffic viewer.

10–3. CLUTCH TESTS

b. 1000/2000/2400 Series™ Clutch Test


The 1000/2000/2400 Series™ Clutch Test uses a software tool bar to command a particular range. Fourth and
Fifth range are inhibited if the engine speed is above 1400 rpm. When clutch test is enabled, a appears next to
the Clutch Test item in the Action Request menu.

Enable the 1000/2000/2400 Series™ Clutch Test by:

1. Selecting the Action Request drop-down menu.

2. Selecting Clutch Test—the Clutch Test Tool Bar displays with the current range highlighted.

To select a range from the Clutch Test Tool Bar, click on the desired range. When the shift or range change is
accomplished, the selected number is highlighted. A successful clutch test is indicated by a message display.

Disable the 1000/2000/2400 Series™ Clutch Test by:

1. Selecting the Action Request drop-down menu.

2. Selecting Clutch Test—the Clutch Test Tool Bar display and the Clutch Test in the Action Request menu
are removed.

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10–4. 1000/2000/2400 SERIES™ SOLENOID TEST


1000/2000/2400 Series™ Solenoid Test provides a means of troubleshooting a particular solenoid’s performance.
To enable the Solenoid Test function:
1. Select the Diagnostics drop-down menu.
2. Click on the Solenoid Test menu item—the Solenoid Data window displays.

To test a particular solenoid:


1. Select the solenoid from the Select a Solenoid To Test drop-down list
2. Click the TEST SOLENOID button—test data appears in the Solenoid Data window.

Sensor Name
The name of the device for which data is being reported

Value
The data being reported for each sensor—duty cycle for solenoids A, B, and F, On/Off state for solenoids C, D, and
E.
To disable the Solenoid Test function, click the CLOSE button.

10–6. 1000/2000/2400 SERIES™ RESET ADAPTIVE SHIFT PARAMETERS


Reset Adaptive Shift Parameters replaces all adaptive clutch control parameters with the factory calibration values
and invokes fast adaptive algorithms to adapt clutch control parameters.

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To reset Adaptive Shift Parameters:

1. Select the Action Request drop-down menu

2. Click on the Reset Fast Adaptive menu item—the Reset Fast Adapt window displays.

The Reset Fast Adapt window contains 10 tabs; one for each shift that can be reset to fast adaptive.

The following information displays in the Reset Fast Adapt window:

Item Name
The name of a parameter

Value
The numerical value of the parameter

UOM
Unit Of Measure for the parameter value—cc (cubic centimeter), kPa (kilopascal), sec (second)

The fast adaptive parameters are reset when you click on the RESET FAST ADAPTIVE button—the Rest Fast
Adaptive Successful window displays. Click the OK button.

Reset Fast Adaptive Garage


Resets N (Neutral) to D (Drive) or N (Neutral) to R (Reverse) shifts to fast adaptive.

10–9. 1000/2000/2400 SERIES™ THROTTLE CALIBRATION

Throttle Calibration re-initializes the values of throttle sensor input that indicates closed throttle and wide open
throttle. Reset throttle calibration if the throttle sensor experienced over-travel or under-travel outside of normal
operational limits and within failure limits.

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To reset open throttle calibration:

1. Select the Action Request drop-down menu.

2. Select Reset Open Throttle Calibration. The Throttle Action window displays.

3. Fully depress the throttle.

4. Click OK.

5. The Reset Open Throttle Calibration Successful window displays.

To reset closed throttle calibration:

1. Select the Action Request drop-down menu.

2. Select Reset Closed Throttle Calibration. The Throttle Action window displays.

3. DO NOT depress the n throttle.

4. Click OK.

5. The Reset Closed Throttle Calibration Successful window displays.

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10–11. ENGINEERING CALCULATIONS


The Engineering Calculations function allows you to calculate Converter Speed Ratio, Vehicle Speed, and
Acceleration in g’s.

Enter the required data and press the OK button. The calculated data is added to the transmission information
displayed in the Data Monitor and Custom Data Monitors windows.

10–12.RECORDING SNAPSHOTS
Snapshots record all data being tracked by the TCM, allowing you to save the data for playback. At start up the
Allison DOC™ for PC automatically begins receiving data. Data is not saved unless a save method is selected in
the Record Options window.
If no data bus traffic is detected for 6 seconds, Allison DOC™ for PC assumes the vehicle ignition has been turned
off, recording is halted, and the Ignition Off window displays.

• Click NO to not save the recording.


• Click YES to save the recording—the Save As window displays.
If you close Allison DOC™ for PC during a recording session the following window displays—

• Click SAVE to save the recording


• Click CANCEL to return to Allison DOC™ for PC

NOTE: Data is recorded in 30-minute blocks. If a session lasts more than 30 minutes, data recorded at
the beginning of the session is lost. This function is similar to adding a ball to a tube filled with
balls. The new ball pushes the oldest ball out of the end of the tube.
To record a snapshot:
1. Select the Snapshot drop-down menu, or click the F4–Snapshot button, or press the F4 key.

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2. Select Record.

3. Select Recording Options—the Record Options window displays.

NOTE: The Sub Code field is disabled for 1000/2000/2400 Series™ transmissions.

4. Select one of the following trigger conditions to start recording data:


• When this Trouble Code appears, remember this session. You must enter a Trouble Code or select one from the
drop-down list. If the Trouble Code entered occurs, the session is recorded.
• When any Trouble Code appears, remember this session. The session is recorded if any Trouble Code occurs.
• Remember this session. Recording begins immediately after you click OK.

5. Click OK.

a. F6–FIRE TRIGGER
F6 –FIRE TRIGGER is a feature that allows you to bookmark a position for future reference in the TCM data
recording. Bookmarks are assigned a sequential number in the order in which they were inserted into the playback
file. In addition to their bookmark number, bookmarks are associated with a time relative to the length of the
recording. To insert a bookmark while recording data either press the F6 keyboard key or click on the F6–FIRE
TRIGGER BUTTON.

NOTE: If a recording has not been started and a bookmark is inserted, recording starts immediately and
ignores all record options. Bookmark #1 and a time stamp are set to the beginning of the file.

NOTE: The FIRE TRIGGER button text changes to display the next Bookmark #.

Example:

Bookmark number 4 has been inserted in the recording.

10–13. STOPPING/SAVING PLAYBACK FILES

1. Press the F7—Stop Recording button or press the F7 key.

2. Select record.

3. Click YES.

The Save As window displays.

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4. Type a log file filename. Do not type a filename extension.


(Example – Alpha5, NOT alpha5.log).

NOTE: To save a recording in a folder other than the Logs folder, navigate to the desired folder before
clicking the SAVE button.
5. Click the button.

10–14. PLAYING BACK SNAPSHOTS


Snapshot playback provides data to any of the diagnostic views.
1. Select the Snapshot drop-down menu, or click the F4–Snapshot button, or press the F4 key.
2. Select Playback.
3. Select Open Playback File.

NOTE: Allison DOC™ for PC breaks any live connection to an TCM and the Open File window displays.
4. Navigate to the appropriate directory.
5. Select the playback file to be played (example – playback1).
6. Click OK—the Trouble Code window and the Playback VCR control window display.

Playback indicators and VCR controls are:


• Meter bar—the percentage of the playback file played.
• Total File Time—the length of the playback file in minutes and seconds
• Current File Time—the elapsed time in minutes and seconds since the beginning of the file, based on the cur-
rent location of the meter bar.
Using your mouse pointer, you may click and drag the meter bar to any point within the file and play the file from
that point. Other controls include:

• Open file—displays the Open File window

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• Rewind to beginning of file

• Play

• Stop

• Play at four times normal speed

• Loop—continuous play

• Jump to trigger—displays data starting at the trigger condition selected when the data was recorded.

• Jump to Bookmark—displays the bookmark window

• Email Playback as Attachment—displays the Compose E-mail window

NOTE: A playback file that is not loaded can also be e-mailed. Click on the e-mail menu item in the
snapshot menu.

If you have not configured your PC for sending Email, click the CONFIGURATION button. The Email Configuration
window displays.

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Contact your E-mail Administrator for the correct values to enter for your configuration.

11. REPROGRAMMING TCM


11–1. REPROGRAMMING THE TCM
NOTE: You must have obtained and entered the proper authorization code for reprogramming the TCM.
Select the Reprogram drop-down menu or the TCM Reprogramming tab from the Application Configuration
window.

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Reprogram TCM Window


1. Select the Reprogram drop-down menu or the TCM Reprogramming tab from the Application Con-
figuration window.

2. The Reprogram TCM window displays.

Reprogramming Status
During the reprogramming function, a red, flashing status line displays at the bottom of the reprogramming window.

a–6. TCM Calibrations in the Reprogram TCM Window

b. Wire Number
The wire circuit number of the programmed function described below the wire number.

Status
The enabled or disabled status of the function. Click on the Check Box to toggle between enable/disable.

Customer Modifiable Constraints


Based on the assigned Current Vocation Package (see Reprogramming Package Assignments), the associated
CMCs appear in display in the Reprogram TCM window. CMC information includes:
• Customer Modifiable Constants—a description of the CMC
• Value—the current assigned value of the CMC

Reprogram TCM
After all data has been entered or changed, click the REPROGRAM TCM button.

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Select One
Allison DOC™ for PC can save TCM configurations under a unique file name.
• To load a saved configuration, select the configuration from the drop down list and click LOAD.
• To save a configuration, be sure the correct data is entered. Type a unique configuration name and click SAVE.

12. REPORTS
The Allison DOC™ for PC Report function allows you to generate TCM information reports. At least one report
must be selected for printing to occur. If the translator device uses the printer port on your PC, you must save the
report and print it when the translation device is no longer connected to the printer port. One or all report sections
may be printed at the same time. One or all report sections may be saved then printed under a single file name.

12–1. PRINTING ALLISON DOC™ FOR PC REPORTS


1. Select the File drop-down menu, or click the F2–File button, or press the F2 key.
2. Select Print—the Print Report window displays.
3. Select any or all of the available Report Sections to print.
4. Click the PRINT button.

1000/2000/2400 Series™ Report Selection

• ATD I/O Wires


• Diagnostic Data
• Customer Modifiable Constants
• Trouble Codes
• Failure Records (1000/2000/2400 Series™)
• Adapt Shifts (1000/2000/2400 Series™)
• DTC Test (1000/2000/2400 Series™)
5. Select any or all of the available Report Sections to print.
6. Click the PRINT button.

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12–2. SAVING ALLISON DOC™ FOR PC REPORTS

1. Select the File drop-down menu

2. Select Print—the Print Report window displays.

3. Select any or all of the available Report Sections to save

4. Click the SAVE button—the Report Name Dialog Box displays.

5. Type a unique name for the report.

6. Click the OK button—the report(s) is saved under the name typed in the Report Name Dialog Box.

NOTE: You do not have to exit the Print Report window to display a report on the screen.

12–3. DISPLAYING A SAVED REPORT ON THE SCREEN

1. Select the File drop-down menu

2. Select Print—the Print Report window displays.

3. Select a report from the drop-down list of saved reports

4. Click the LOAD button—the selected report displays

12–4. PRINTING A SAVED REPORT

1. Select the File drop-down menu.

2. Select Print—the Print Report window displays.

3. Select a report from the drop-down list of saved reports.

4. To confirm that you have the correct report, click the LOAD button—the selected report displays.

5. Click the PRINT button.

12–5. REPORT EXAMPLES

The reports may be printed or saved as a file. Saved reports can be displayed on the screen. Examples of each
report, as displayed on the screen, are on the following pages. All reports are configured with calibration
information at the beginning of the report.

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Failure Records Report (1000/2000/2400 Series™)

Adapt Shift Report (1000/2000/2400 Series™)

DTC Test Report (1000/2000/2400 Series™)

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12–6. PRINTING SCREENS


The Print Screen function of Allison DOC™ for PC allows you to print the screen being displayed.
To print a screen:
Select Print Screen from the drop-down list above the primary status bar. The Allison DOC™ for PC screen being
displayed prints at the default printer.

12–7. EXITING ALLISON DOC™ FOR PC


There are three ways to Exit Allison DOC™ for PC:
1. Click the EXIT button in the top right corner of the Allison DOC™ for PC window, or, Click the
button and select Exit or select the File drop-down menu and select Exit—the Allison
DOC™ for PC program closes.

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NOTES

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APPENDIX N — INPUT/OUTPUT FUNCTIONS


The schematics which followThis
wereschematic
taken fromshows
the SalestheTech
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“1000 Series™, feature
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which differs fromrefer
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Sectioncould
6 of this manual.
result in damage to equipment or
WARNING! property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR
This schematic shows the intended use of the specified controls feature which
UNINTENDED USE OF THESE FEATURES.
has been validated in the configuration shown. Any miswiring or use of this
feature which differs from that shown could result in damage to equipment or
WARNING! property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR
UNINTENDED USE OF THESE FEATURES.

A. SECONDARY SHIFT SCHEDULE


USES: Provides for operator selection of primary or secondary shift schedules. Can be used for performance/
economy, loaded/empty, or other shift schedule combinations.

VARIABLES TO SPECIFY: None

VOCATIONS: No vocational restrictions

WIRE 110 (INPUT)

DASH SWITCH
J1-10
J1 (GRAY)

Open: PRIMARY
(usually “PERFORMANCE”)
WIRE 128 Closed: SECONDARY
J1-28
SIGNAL RETURN (usually “ECONOMY”)
OPTIONAL
VIW CONNECTOR(S)
TCM

NOTE: When the TCM is turned ON,


the active shift schedule is determined
J2 (RED)

by the current switch position.

NOTE: All items shown, except TCM, are customer furnished.

V05693.01

Figure N–1. Secondary Shift Schedule

Copyright© 2003 General Motors Corp. N–1


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX N — INPUT/OUTPUT FUNCTIONS


This schematic shows the intended use of the specified controls feature which
has been validated in the configuration shown. Any miswiring or use of this
feature which differs from that shown could result in damage to equipment or
WARNING! property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR
UNINTENDED USE OF THESE FEATURES.

C. PTO ENABLE
USES: Permits the PTO to be engaged only when calibration-defined conditions are met. Also automatically
disengages the PTO if specified speeds are exceeded.

VARIABLES TO SPECIFY: Maximum engine speed for engagement, maximum engine speed for allowable
operation, maximum output speed for engagement, maximum output speed for
allowable operation, and neutral lockup ON shift speed.

VOCATIONS: Various (with usage of PTO)

When the PTO is disengaged due to overspeed, it will be automatically


re-engaged at the “Max. Engine Speed for PTO Engagement” speed (a User
CAUTION: Specified Variable), which is typically set at a relatively low speed. The resultant
re-engagement shock could cause damage to a high-inertia PTO system.

OPTIONAL
VIW CONNECTOR(S) SWITCHED
J1 (GRAY)

POWER
J1-6
DASH
J1-19 PTO LIGHT
SWITCH
PTO
TCM WIRE 106 (INPUT) PRESSURE
SWITCH
NC
J2 (RED)

COM PTO
NO

Relay shown
WIRE 119 (OUTPUT) de-energized
NOTE: All items shown, except TCM, are customer furnished. V05694.01

Figure N–2. PTO Enable

N–2 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX N — INPUT/OUTPUT FUNCTIONS


This schematic shows the intended use of the specified controls feature which
has been validated in the configuration shown. Any miswiring or use of this
feature which differs from that shown could result in damage to equipment or
WARNING! property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR
UNINTENDED USE OF THESE FEATURES.

E. AUXILIARY FUNCTION RANGE INHIBIT


USES: Prevents inadvertent range selection when auxiliary equipment (e.g. wheelchair lift) is operating. May
also be used to prevent neutral-to-range shifts unless the brake pedal is depressed.

VARIABLES TO SPECIFY: None

VOCATIONS: Various. Not for use in emergency equipment.

Typical Uses: School bus — brake pedal input


Special service bus— wheelchair lift interlock
Motorhome — “Door Ajar” interlock

If this function is enabled in the shift calibration, the function MUST be


integrated into the vehicle wiring. If the function is available in the shift
WARNING! calibration but will not be used in the vehicle, it MUST be disabled in the
calibration.

OPTIONAL WIRE 111 (INPUT) WIRE 111 INPUT


VIW CONNECTOR(S) — OR —
J1 (GRAY)

Switch is open BRAKE Switch closes


J1-11 when auxiliary PRESSURE when brakes
equipment is SWITCH are applied
WIRE 128 operating
J1-28 WIRE 128
(SIGNAL RETURN)
SIGNAL RETURN
TCM
J2 (RED)

NOTE: TCMs with this function activated must have wire 111
permanently connected to wire 128 if the function is not being used.

NOTE: All items shown, except TCM, are customer furnished.

V05695.01

Figure N–3. Auxiliary Function Range Inhibit

Copyright© 2003 General Motors Corp. N–3


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX N — INPUT/OUTPUT FUNCTIONS


This schematic shows the intended use of the specified controls feature which
has been validated in the configuration shown. Any miswiring or use of this
feature which differs from that shown could result in damage to equipment or
WARNING! property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR
UNINTENDED USE OF THESE FEATURES.

H. EXHAUST BRAKE/PRESELECT REQUEST, PLUS EXHAUST BRAKE ENABLE


(STANDARD)
USES: Signals the TCM that the engine exhaust-type brake is active. By automatically preselecting a lower
transmission range when the brake is enabled, this function creates increased braking and/or maintains
engine water and transmission fluid flows at elevated levels. Also prevents engagement of the exhaust
brake if throttle > 0 or if the TCC is disengaged.

VARIABLES TO SPECIFY: Preselect range (standard value is third range)


“Lowered” or “Standard” preselect downshift schedule.

VOCATIONS: No vocational restrictions

NOTE: This switch is part of the engine brake system and


EXHAUST–TYPE ENGINE BRAKE provides an indication when the engine is at closed throttle.
OPTIONAL DASH SWITCH This switch, or an equivalent control feature, is REQUIRED
VIW CONNECTOR(S) SWITCHED for all installations.
J1 (GRAY)

POWER
WIRE 107 (INPUT)
J1-7 NOTE: The engine exhaust brake must provide a low engine
speed shutoff feature, set to disable the brake at a speed
slightly higher than idle speed.
WIRE 120 (OUTPUT)
J1-20

TCM ENGINE THROTTLE


SWITCH
NC
J2 (RED)

COM NO ENGINE
DASH BRAKE EXHAUST–TYPE
LIGHT ON BRAKE
Relay shown
de-energized
NOTE: All items shown, except TCM, are customer furnished.
V06485.01

Figure N–4. Exhaust Brake/Preselect Request, Plus Exhaust Brake Enable (Standard)

N–4 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX N — INPUT/OUTPUT FUNCTIONS

This schematic shows the intended use of the specified controls feature which
has been validated in the configuration shown. Any miswiring or use of this
feature which differs from that shown could result in damage to equipment or
WARNING! property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR
UNINTENDED USE OF THESE FEATURES.

H. EXHAUST BRAKE/PRESELECT REQUEST, PLUS EXHAUST BRAKE ENABLE


(OPTIONAL)
USES: Signals the TCM that the engine exhaust-type brake is active. By automatically preselecting a lower
transmission range when the brake is enabled, this function creates increased braking and/or maintains
engine water and transmission fluid flows at elevated levels. Also prevents engagement of the exhaust
brake if throttle > 0 or if the TCC is disengaged.

VARIABLES TO SPECIFY: Preselect range (standard value is third range)


“Lowered” or “Standard” preselect downshift schedule.

VOCATIONS: No vocational restrictions

SWITCHED
POWER NOTE: Maximum current must not exceed
NC engine manufacturers specification
WIRE 107 (INPUT)
J1 (GRAY)

J1-7
COM NO
ENGINE
J1-20 ECM
ENGINE
OPTIONAL Relay shown EXHAUST BRAKE
VIW CONNECTOR(S) de-energized DASH SWITCH
TCM NC

COM NO ENGINE
J2 (RED)

WIRE 120 (OUTPUT)


EXHAUST
DASH BRAKE BRAKE
NOTE: The exhaust brake must provide a low engine speed Relay shown LIGHT ON
shutoff feature, set to disable the brake at a speed slightly de-energized (OPTIONAL)
higher than idle rpm.
SWITCHED
NOTE: All items shown, except TCM, are customer furnished. POWER
V07486

Figure N–5. Exhaust Brake/Preselect Request, Plus Exhaust Brake Enable (Optional)

Copyright© 2003 General Motors Corp. N–5


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX N — INPUT/OUTPUT FUNCTIONS


This schematic shows the intended use of the specified controls feature which
has been validated in the configuration shown. Any miswiring or use of this
feature which differs from that shown could result in damage to equipment or
WARNING! property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR
UNINTENDED USE OF THESE FEATURES.

I. EXHAUST BRAKE/PRESELECT REQUEST, PLUS ENGINE BRAKE ENABLE


(SPECIAL)
USES: Signals the TCM that the engine exhaust-type brake is active. By automatically preselecting a lower
transmission range when the brake is enabled, this function creates increased braking and/or maintains
engine water and transmission fluid flows at elevated levels. Also prevents engagement of the exhaust
brake if throttle > 0 or if the TCC is disengaged.

VARIABLES TO SPECIFY: Preselect range (standard value is third range).


“Lowered” or “Standard” preselect downshift schedule.

VOCATIONS: No vocational restrictions

ENGINE BRAKE
OPTIONAL DASH SWITCH
VIW CONNECTOR(S) SWITCHED NOTE: This switch is part of the engine brake system and
provides an indication when the engine is at closed throttle.
J1 (GRAY)

POWER
WIRE 107 This switch, or an equivalent control feature, is recommended
J1-7 for all installations.
(INPUT)

WIRE 120
J1-20
(OUTPUT)
TCM ENGINE THROTTLE
SWITCH
NC
J2 (RED)

COM NO
ENGINE
DASH BRAKE
BRAKE
LIGHT ON
Relay shown
de-energized
NOTE: All items shown, except TCM, are customer furnished.
V06487.01

Figure N–6. Exhaust Brake/Preselect Request, Plus Engine Brake Enable (Special)

N–6 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX N — INPUT/OUTPUT FUNCTIONS


This schematic shows the intended use of the specified controls feature which
has been validated in the configuration shown. Any miswiring or use of this
feature which differs from that shown could result in damage to equipment or
WARNING! property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR
UNINTENDED USE OF THESE FEATURES.

L. AUTOMATIC NEUTRAL FOR PTO


USES: Provides a means to automatically command N (Neutral) when PTO is operated. Requires the operator
to re-select a range to shift out of N (Neutral). Frequently used in utility trucks or wrecker/recovery trucks.

VARIABLES TO SPECIFY: Maximum output speed for activating this function.


Range indicator = N (Neutral).

VOCATIONS: Various. Not for use in emergency equipment.

If this function is enabled in the shift calibration, the function MUST be


integrated into the vehicle wiring. If the function is available in the shift
WARNING! calibration but will not be used in the vehicle, it MUST be disabled in the
calibration.

SWITCHED
DASH POWER
SWITCH
AUTO NEUTRAL (INPUT) DASH
J1-8
J1 (GRAY)

WIRE 108 OR WIRE 111 LIGHT

PTO
RANGE INDICATOR PRESSURE
J1-21
WIRE 121 (OUTPUT) SWITCH
NC
OPTIONAL
TCM VIW CONNECTOR(S)
COM NO
J2 (RED)

Relay shown PTO


de-energized

NOTE: All items shown, except TCM, are customer furnished.

V07487.00.01.eps

Figure N–7. Automatic Neutral for PTO

Copyright© 2003 General Motors Corp. N–7


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX N — INPUT/OUTPUT FUNCTIONS


This schematic shows the intended use of the specified controls feature which
has been validated in the configuration shown. Any miswiring or use of this
feature which differs from that shown could result in damage to equipment or
WARNING! property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR
UNINTENDED USE OF THESE FEATURES.

V. REVERSE ENABLE
USES: This function provides for a separate instrument panel-mounted switch which must be pressed
simultaneously with the R (Reverse) shift selector pushbutton to achieve reverse operation.

VARIABLES TO SPECIFY: None

VOCATIONS: European transit buses and tour buses.

If this function is enabled in the shift calibration, the function MUST be


integrated into the vehicle wiring. If the function is available in the shift
WARNING! calibration but will not be used in the vehicle, it MUST be disabled in the
calibration.

MOMENTARY
SWITCH
SWITCHED POWER
J1 (GRAY)

WIRE 106
J1–06
REVERSE ENABLE
TCM OPTIONAL
J2 (RED)

VEHICLE INTERFACE
WIRING CONNECTOR

V07488

Figure N–8. Reverse Enable

N–8 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX N — INPUT/OUTPUT FUNCTIONS


This schematic shows the intended use of the specified controls feature which
has been validated in the configuration shown. Any miswiring or use of this
feature which differs from that shown could result in damage to equipment or
WARNING! property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR
UNINTENDED USE OF THESE FEATURES.

AH. KICKDOWN
USES: Permits both “Economy” and “Performance” shift schedules to be used in the same operating mode.
Typically used in stop-and-go duty cycles with an emphasis on fuel economy.

VARIABLES TO SPECIFY: None

VOCATIONS: No vocational restrictions

CLOSED THROTTLE
OPTIONAL
VIW CONNECTOR(S) ENGINE
FULL THROTTLE OPERATING
J1-9 ECONOMY SHIFT POINTS RANGE
J1 (GRAY)

J1-28 THROTTLE FULL THROTTLE


PEDAL KICKDOWN SHIFT POINTS
Pedal movement beyond
this point must not change
MOMENTARY engine fuel setting or
TCM SWITCH transmission throttle position

WIRE 109
J2 (RED)

(INPUT) NOTE: “Full throttle economy shift points” position on the pedal should
coincide with full stroke of the Allison throttle position sensor (if used) and/or
“full fuel” setting of the engine control. Thus, pedal movement beyond
WIRE 128 “full throttle economy shift points” must not change fuel setting of the engine
(SIGNAL RETURN) or the throttle position signal to the transmission control system.
NOTE: All items shown, except TCM, are customer furnished.
V05702.01

Figure N–9. Kickdown

Copyright© 2003 General Motors Corp. N–9


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX N — INPUT/OUTPUT FUNCTIONS


This schematic shows the intended use of the specified controls feature which
has been validated in the configuration shown. Any miswiring or use of this
feature which differs from that shown could result in damage to equipment or
WARNING! property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR
UNINTENDED USE OF THESE FEATURES.

AM. REFUSE PACKER STEP SWITCH


USES: This signal can be used to denote the presence of personnel who are riding on a rear platform of the
vehicle (refuse packer).

VARIABLES TO SPECIFY: None

VOCATIONS: Refuse packer.

If this function is enabled in the shift calibration, the function MUST be


integrated into the vehicle wiring. If the function is available in the shift
WARNING! calibration but will not be used in the vehicle, it MUST be disabled in the
calibration.

MOMENTARY
SWITCH
Function is activated when
SWITCHED switch is depressed.
J1 (GRAY)

POWER Function is de-activated when


switch is released.
WIRE 108
REFUSE PACKER Switch opens to indicate
STEP SWITCH presence of personnel on step.
J1–08
TCM
OPTIONAL SWITCH OPENS
VIW CONNECTOR(S) TO INDICATE NOTE: Transmission will shift according to preselect
PRESENCE OF downshift schedule when function is activated while
J2 (RED)

PERSONNEL above 1st range.


ON STEP
If function is activated while in Reverse, transmission
will shift to Neutral.

V07489

Figure N–10. Refuse Packer Step Switch

N–10 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX N — INPUT/OUTPUT FUNCTIONS


This schematic shows the intended use of the specified controls feature which
has been validated in the configuration shown. Any miswiring or use of this
feature which differs from that shown could result in damage to equipment or
WARNING! property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR
UNINTENDED USE OF THESE FEATURES.

AR. OVERDRIVE DISABLE


USES: Can be used in conjunction with a 5–3–2–1 selector configuration to permit hold selection of all forward
ranges. This feature has no effect on 4-speed configurations.

VARIABLES TO SPECIFY: None

VOCATIONS: No vocational restrictions

SWITCHED LIGHTED CLOSED: Overdrive (5th)


POWER DASH is disabled
SWITCH
OPEN: Normal operation
J1 (GRAY)

OVERDRIVE DISABLE
J1–12
WIRE 112 (INPUT)

SIGNAL RETURN
J1–28
WIRE 128
TCM OPTIONAL
VIW CONNECTOR(S)
J2 (RED)

NOTE: All items shown, except TCM, are customer furnished.

V07490

Figure N–11. Overdrive Disable

Copyright© 2003 General Motors Corp. N–11


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX N — INPUT/OUTPUT FUNCTIONS


This schematic shows the intended use of the specified controls feature which
has been validated in the configuration shown. Any miswiring or use of this
feature which differs from that shown could result in damage to equipment or
WARNING! property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR
UNINTENDED USE OF THESE FEATURES.

B. SUMP TEMPERATURE INDICATOR


USES: Provides a means to turn on a dash indicator or other alarm when transmission sump temperature has
exceeded specified limits.

VARIABLES TO SPECIFY: None

VOCATIONS: No vocational restrictions

SWITCHED
POWER
J1 (GRAY)

WIRE 124 (OUTPUT) TRANSMISSION


J1-24 TEMP

OPTIONAL
VIW CONNECTOR(S)
TCM
If current in lamp circuit exceeds NC
0.5 amp, ground lamp through TRANS
a relay TEMP
COM
J2 (RED)

NO
SWITCHED
POWER
WIRE 124

NOTE: All items shown, except TCM, are customer furnished.


V05703.01

Figure N–12. Sump Temperature Indicator

N–12 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX N — INPUT/OUTPUT FUNCTIONS


This schematic shows the intended use of the specified controls feature which
has been validated in the configuration shown. Any miswiring or use of this
feature which differs from that shown could result in damage to equipment or
WARNING! property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR
UNINTENDED USE OF THESE FEATURES.

C. RANGE INDICATOR
USES: May be used in the control system of an auxiliary vehicle system to permit its operation only when the
transmission is engaged in specified gear range(s), including Neutral.

NOTE: P (Park) can be an indicated range for a 1000 SeriesTM or 2400 SeriesTM transmission (park pawl-
equipped models). For a 2000 SeriesTM or 2000MH Series transmission, which does not have a
park pawl, the “P” position can be used to indicate a second NEUTRAL position.

NOTE: This feature is not suitable for activating a customer-furnished park brake in the second
NEUTRAL position (2000 SeriesTM and 2000MH Series models), since the indicator is active only
when the engine is running.
VARIABLES TO SPECIFY: Range or ranges to be indicated.

VOCATIONS: No vocational restrictions

SWITCHED
POWER
J1 (GRAY)

WIRE 121 (OUTPUT)


J1-21
NC
OPTIONAL
VIW CONNECTOR(S) COM NO
TCM
Relay shown
de-energized
AUXILIARY
J2 (RED)

VEHICLE
SYSTEM
NOTE: This signal should not be used to automatically
apply the park brake or service brakes when the
transmission is shifted to N (Neutral).
NOTE: All items shown, except TCM, are customer furnished.
V05704.01

Figure N–13. Range Indicator

Copyright© 2003 General Motors Corp. N–13


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX N — INPUT/OUTPUT FUNCTIONS


This schematic shows the intended use of the specified controls feature which
has been validated in the configuration shown. Any miswiring or use of this
feature which differs from that shown could result in damage to equipment or
WARNING! property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR
UNINTENDED USE OF THESE FEATURES.

D. OUTPUT SPEED INDICATOR


USES: To indicate reaching a minimum or maximum operating speed to assist in the indication of and/or control
of the vehicle or auxiliary equipment. Frequently used to alert the operator that output speed has
exceeded a specified value.

VARIABLES TO SPECIFY: Output speed to turn indicator ON and to turn indicator OFF (ON value must be
higher than the OFF value).

VOCATIONS: No vocational restrictions

SWITCHED
POWER
NC
J1 (GRAY)

COM NO
WIRE 122 (OUTPUT)
J1-22
TRANSMISSION
OPTIONAL Relay shown OR VEHICLE
OVERSPEED
VIW CONNECTOR(S) de-energized INDICATOR
TCM
J2 (RED)

NOTE: All items shown, except TCM, are customer furnished.


V05705.01

Figure N–14. Output Speed Indicator

N–14 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX P — FLUID CHECK PROCEDURE

For vehicles containing 1000 and 2400 models, each time you park the vehicle or
leave the operator’s station with the engine running, do the following.
• Bring the vehicle to a complete stop using the service brake.
• Ensure that the engine is at low idle rpm.
• Put the transmission in P (Park).
• Engage the P (Park) range by slowly releasing the service brake.
WARNING!
• Apply the emergency brake and/or parking brake, if present, and make sure it
is properly engaged.
• If the operator’s station will be unoccupied with the engine running, chock the
wheels and take any other steps necessary to keep the vehicle from moving.
If this procedure is not followed, the vehicle can move suddenly and you or others
could be injured.

For vehicles containing 2000 models without auto-apply parking brakes, each time
you park the vehicle or leave the operator’s station with the engine running, do the
following.
• Bring the vehicle to a complete stop using the service brake.
• Ensure that the engine is at low idle rpm.
• Put the transmission in N (Neutral).
WARNING!
• Apply the emergency brake and/or parking brake and make sure they are
properly engaged.
• If the operator’s station will be unoccupied with the engine running, chock the
wheels and take any other steps necessary to keep the vehicle from moving.
If this procedure is not followed, the vehicle can move suddenly and you or others
could be injured.

For vehicles containing 2000 models with auto-apply parking brakes, each time you
park the vehicle or leave the operator’s station with the engine running, do the
following.
• Bring the vehicle to a complete stop using the service brake.
• Ensure that the engine is at low idle rpm.
• Put the transmission in PB (Auto-Apply Parking Brake). Make sure that the
WARNING! parking brake is properly engaged.
• Apply the emergency brake, if present, and make sure it is properly engaged.
• If the operator’s station will be unoccupied with the engine running, chock the
wheels and take any other steps necessary to keep the vehicle from moving.
If this procedure is not followed, the vehicle can move suddenly and you or others
could be injured.

Copyright© 2003 General Motors Corp. P–1


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX P — FLUID CHECK PROCEDURE

NOTE: To ensure accurate fluid level checks, be sure that the fill tube and dipstick meet Allison
Transmission specifications. Requirements for the standard oil pan are shown in Figure P–1
and requirements for the shallow oil pan are shown in Figure P–2.

When checking a long dipstick calibration:

• Be sure the dipstick contacts the oil pan surface as shown in Figures P–1 and P–2.
• Take measurements from the end of the dipstick.

When checking a short dipstick calibration:

• Remove the oil pan.


• Take measurements from the oil pan splitline.

TRANSMISSION 5.0 mm TRANSMISSION 5.0 mm


CENTERLINE (0.20 in) CENTERLINE (0.20 in)

Fill tube to be Fill tube to be


98.9 mm straight in all 98.9 mm straight in all
(3.89 in) vertical planes (3.89 in) vertical planes
for this distance for this distance

72.6 mm 72.6 mm
10.0 mm (2.86 in) 10.0 mm (2.86 in)
(0.39 in) (0.39 in)
30.0 mm 30.0 mm
(1.18 in) HOT RUN (1.18 in) HOT RUN
OIL PAN OIL PAN
SPLIT LINE SPLIT LINE
(Ref. only) TYPICAL TYPICAL
COLD CHECK COLD CHECK
BAND BAND

101.9 mm
(4.01 in)

Dipstick must
contact oil pan

LONG FILL TUBE AND DIPSTICK* SHORT FILL TUBE AND DIPSTICK
*Check measurements from end of dipstick
V05803

Figure P–1. Fill Tube And Dipstick Requirements (Standard Oil Pan)

P–2 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX P — FLUID CHECK PROCEDURE

TRANSMISSION 5.0 mm TRANSMISSION 5.0 mm


CENTERLINE (0.20 in) CENTERLINE (0.20 in)

Fill tube to be Fill tube to be


98.9 mm straight in all 98.9 mm straight in all
(3.89 in) vertical planes (3.89 in) vertical planes
for this distance for this distance

72.6 mm 72.6 mm
10.0 mm (2.86 in) 10.0 mm (2.86 in)
(0.39 in) (0.39 in)
30.0 mm 30.0 mm
(1.18 in) HOT RUN (1.18 in) HOT RUN
OIL PAN OIL PAN
SPLIT LINE SPLIT LINE
(Ref. only) TYPICAL TYPICAL
COLD CHECK COLD CHECK
BAND BAND

88.5 mm
(3.48 in)
Dipstick must
contact oil pan

LONG FILL TUBE AND DIPSTICK* SHORT FILL TUBE AND DIPSTICK
*Check measurements from end of dipstick
V05804

Figure P–2. Fill Tube And Dipstick Requirements (Shallow Oil Pan)

A. Manual Fluid Check Procedure


Clean all dirt from around the end of the fluid fill tube before removing the dipstick. Do not allow dirt or
foreign matter to enter the transmission. Dirt or foreign matter in the hydraulic system may cause
undue wear of transmission parts, make valves stick, and clog passages. Check the fluid level using
the following procedure and report any abnormal fluid levels to your maintenance persons.

B. Cold Check Procedure


The purpose of the cold check is to determine if the transmission has enough fluid to be operated
safely until a hot check can be made.

The fluid level rises as fluid temperature increases. DO NOT fill above the “COLD
CAUTION: CHECK” band if the transmission fluid is below normal operating temperatures.

• Park vehicles containing 1000 and 2400 models as follows:


— Bring the vehicle to a complete stop on a level surface using the service brake.
— Ensure that the engine is at low idle rpm.
— Put the transmission in P (Park).
— Engage the P (Park) range by slowly releasing the service brake.
— Apply the emergency brake and/or parking brake, if present, and make sure it is properly
engaged.

Copyright© 2003 General Motors Corp. P–3


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX P — FLUID CHECK PROCEDURE

• Park vehicles containing 2000 models with auto-apply parking brakes as follows:
— Bring the vehicle to a complete stop on a level surface using the service brake.
— Ensure that the engine is at low idle rpm.
— Put the transmission in PB (Auto-Apply Parking Brake). Make sure that the parking brake is
properly engaged.
— Apply the emergency brake, if present, and make sure it is properly engaged.
• Park vehicles containing 2000 models without auto-apply parking brakes as follows:
— Bring the vehicle to a complete stop on a level surface using the service brake.
— Ensure that the engine is at low idle rpm.
— Put the transmission in N (Neutral).
— Apply the emergency brake and/or parking brake and make sure they are properly engaged.
• Chock the wheels and take any other steps necessary to keep the vehicle from moving.

• Run the engine for at least one minute. Apply the service brakes and shift to D (Drive), then to
N (Neutral), and then shift to R (Reverse) to fill the hydraulic system. Finally, shift to P (Park)
or PB (Auto-Apply Parking Brake), if available, or N (Neutral) and allow the engine to idle
(500–800 rpm). Slowly release the service brakes.
• With the engine running, remove the dipstick from the tube and wipe the dipstick clean.

• Insert the dipstick into the tube and remove. Check the fluid level reading. Repeat the check
procedure to verify the reading.
• If the fluid level is within the “COLD CHECK” band, the transmission may be operated until the fluid
is hot enough to perform a “HOT RUN” check. If the fluid level is not within the “COLD CHECK”
band, add or drain as necessary to bring it to the middle of the “COLD CHECK” band.
• Perform a hot check at the first opportunity after the normal operating sump temperature of
71ºC–93ºC (160ºF–200ºF) is reached.

C. Hot Check Procedure

The fluid must be hot to ensure an accurate check. The fluid level rises as
CAUTION: temperature increases.

• Operate the transmission in D (Drive) range until normal operating temperature is reached:
— sump temperature 71ºC–93ºC (160ºF–200ºF)
— converter-out temperature 82ºC–104ºC (180ºF–220ºF)
— If a transmission temperature gauge is not present, check fluid level when the engine water
temperature gauge has stabilized and the transmission has been operated under load for at
least one hour.
• Park vehicles containing 1000 and 2400 models as follows:
— Bring the vehicle to a complete stop on a level surface using the service brake.
— Ensure that the engine is at low idle rpm.
— Put the transmission in P (Park).
— Engage the P (Park) range by slowly releasing the service brake.
— Apply the emergency brake and/or parking brake, if present, and make sure it is properly
engaged.

P–4 Copyright© 2003 General Motors Corp.


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX P — FLUID CHECK PROCEDURE

• Park vehicles containing 2000 models with auto-apply parking brakes as follows:
— Bring the vehicle to a complete stop on a level surface using the service brake.
— Ensure that the engine is at low idle rpm.
— Put the transmission in PB (Auto-Apply Parking Brake). Make sure that the parking brake is
properly engaged.
— Apply the emergency brake, if present, and make sure it is properly engaged.
• Park vehicles containing 2000 models without auto-apply parking brakes as follows:
— Bring the vehicle to a complete stop on a level surface using the service brake.
— Ensure that the engine is at low idle rpm.
— Put the transmission in N (Neutral).
— Apply the emergency brake and/or parking brake and make sure they are properly engaged.
• Chock the wheels and take any other steps necessary to keep the vehicle from moving.

• With the engine running, remove the dipstick from the tube and wipe the dipstick clean.

• Insert the dipstick into the tube and remove. Check fluid level reading. Repeat the check procedure
to verify the reading.

NOTE: Safe operating level is within the “HOT RUN” band on the dipstick. See Figures P–1 and P–2. The
width of the “HOT RUN” band represents approximately 1.0 liter (1.06 quart) of fluid at normal
operating sump temperature.

• If the fluid level is not within the “HOT RUN” band, add or drain as necessary to bring the fluid level
to within the “HOT RUN” band.

D. Consistency of Readings
Always check the fluid level at least twice using the procedure described above. Consistency
(repeatable readings) is important to maintaining proper fluid level. If inconsistent readings persist,
check the transmission breather to be sure it is clean and unclogged. If readings are still inconsistent,
contact your nearest Allison distributor or dealer.

Copyright© 2003 General Motors Corp. P–5


ALLISON 1000/2000/2400 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

APPENDIX P — FLUID CHECK PROCEDURE

NOTES

P–6 Copyright© 2003 General Motors Corp.

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