PCS 4LHD Application Manual Download Page 79

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Ph: 804.227.3023

10511 Old Ridge Rd. Ashland, VA 23005

4LHD/4LHDX Application Manual

Powertrain Control Solutions

REV 1.1

3.2 End-of-Line Inspection Procedures

Several items must be inspected prior to operating the vehicle and a test drive must be performed prior to delivering the

vehicle to the end-user. Data from the inspections outlined below must be retained during the transmission warranty period

and available for PCS review if a warranty claim is made on a transmission. PCS encourages vehicle manufacturers to

implement a rigorous quality inspection prior to customer delivery, but requires the minimum items specified in this section

to be inspected and documented. Improper installation will result in transmission damage that is not covered under

warranty. The critical items required include:

•

Fastener selection, installation, and torque

•

Position Lever

•

TCM firmware and calibration

•

Transmission fluid type and level

•

Throttle position

•

Engine RPM

•

Vehicle speed

•

Diagnostic codes

3.2.1 Pre-Start Checks

Fastener Torque

Prior to starting the vehicle for the first time, inspect all mounting bolts, torque converter bolts, flywheel bolts, and

all other driveline hardware to ensure it is present and torqued to the proper value.

Position Lever Check

Move the shift lever through all the ranges and verify that the transmission shift arm is centered in the detent for

each position. This may require disconnecting the cable at the transmission for each position to ensure the arm

is in the detent. Improper shift cable adjustment will result in premature transmission failure.

3.2.2 Stationary Engine-Off Checks

Firmware

Turn the ignition on (do not start the engine) and connect to the TCM with the PCS TCM Diagnostic Software.

Verify the firmware version is the current, recommended version on the PCS website referenced below. Perform

a firmware upgrade if necessary. Record the firmware version.

https://www.powertraincontrolsolutions.com/latest/firmware/

Calibration

PCS Transmission Control Modules are shipped with a base calibration that limits the transmission to first gear.

Every vehicle model must have a PCS validated calibration to install at this point during vehicle assembly. Verify

the proper calibration is installed or program now if necessary.

Position Lever Verification

Move the shift lever through the ranges and verify the actual shift lever position matches the position shown in the

software. This is also a good time to verify any applicable lights illuminate in the proper gear positions.

Throttle Position Sensor

Verify the throttle position reading is zero at when the pedal is not pressed, and 100% when fully depressed. For

a detailed description of TPS installation/assembly requirements reference Section 2.6.

Summary of Contents for 4LHD

Page 1: ...Ph 1 804 227 3023 www powertraincontrolsolutions com PCS 4LHD 4LHDX APPLICATION GUIDE ...

Page 2: ...on of the interface systems This manual is divided into three sections Section 1 Transmission Specifications and Attributes Includes guidelines that describe the transmission s internal features external features performance limitations and functionality options Section 2 Transmission to Vehicle Interfaces Defines the transmission integration subsystem characteristics options limitations and integ...

Page 3: ...res and Specifcations 12 Section 1 4 1 Abuse Protection 12 Section 1 4 2 Neutral Idle 12 Section 1 4 3 Electronic Range 12 Section 1 4 4 Inching Mode 12 Section 1 5 Electrical Specifications 13 18 Section 1 5 1 Solenoids 13 16 Section 1 5 2 Internal Wiring 17 18 Section 2 Transmission to Vehicle Interfaces 19 69 Section 2 1 Transmission Input 19 30 Section 2 1 1 Torque Converters 19 23 Section 2 1...

Page 4: ...e Position Sensor 68 69 Section 3 Production Line Procedures 70 73 Section 3 1 Assembly Procedures 70 71 Section 3 1 1 Storage Requirements 70 Section 3 1 2 Handling Requirements 70 Section 3 1 3 Assembly Requirements 71 Section 3 2 End of Line Inspection Procedures 72 73 Section 3 2 1 Pre Start Checks 72 Section 3 2 2 Stationary Engine Off Checks 72 Section 3 2 3 Stationary Engine Running Checks ...

Page 5: ...SECTION 1 TRANSMISSION SPECIFICATION AND ATTRIBUTES ...

Page 6: ...OVERRUN CLUTCH FORWARD CLUTCH FORWARD SPRAG CL ASSEMBLY 3 4 CLUTCH INPUT PLANETARY GEARSET LO AND REVERSE CLUTCH TORQUE CONVERTER ASSEMBLY STATOR ROLLER CLUTCH PUMP ASSEMBLY LO ROLLER CLUTCH ASSEMBLY REACTION PLANETARY GEARSET TURBINE SHAFT 2 4 BAND ASSEMBLY INSIDE DETENT LEVER MANUAL SHAFT CONTROL VALVE ASSEMBLY PARKING LOCK ACTUATOR ASSEMBLY OUTPUT SHAFT PARKING PAWL SPEED SENSOR SHIFT SOLENOID ...

Page 7: ...ission I D Nameplate Locations Rev Sheet 86 24214609 4 4 1 VIN The following procedure is recommended for VIN operation Typical locations are shown in Figure 4 4 1 1 1 Scan bar code on transmission 2 Place etcher on transmission in designsted GMPT approved VIN number area or use hand stamp and imprint VIN number into transmission in designated GMPT approved area Figure 4 4 1 1 Case Drawing No 1 Lo...

Page 8: ...g Right Side View Rev Sheet 24 24214609 FIGURE 2 4 6 1 2 2 Piece Transmission Case with Small Bell Housing 245mm 258mm Right Side View TRANSMISSION CASE FLARE OR QUICK CONNECT AIR BREATHER VENT FROM COOLER TO COOLER ENGINE FACE FILL TUBE HOLE VEHICLE MOUNTING PAD SPEED SENSOR HEAT SHIELD LOCATION S ATTACHMENT TRANSMISSION CONTROL CONNECTOR TRANSMISSION OIL PAN Figure 1 1 2 2 PCS 4LHD 4LHDX with GM...

Page 9: ...nstalled GM 2WD 1 8 kg 4 0 lbs GM 4WD 2 4 kg 5 3 lbs PCS Parking Brake 10 2 kg 22 5 lbs C6 Replacement 4 3 kg 10 1 lbs Accessory Mass As Installed Transmission Harness 0 7 kg 1 6 lbs Dipstick Kit 0 4 kg 0 9 lbs Heat Shield Kit 0 4 kg 0 9 lbs Controller TCM 0 3 kg 0 7 lbs TCU Bracket Kit 0 5 kg 1 1 lbs Overflow Vent Kit 0 2 kg 0 5 lbs Flexplate Kit 1 8 kg 4 0 lbs Flywheel Adapter 8 8 kg 19 4 lbs Th...

Page 10: ...189 0 271 9 630 7 807 0 580 7 266 3 A Bellhousing Length B Engine Face to Manual Shaft Distance C Engine Face to Vehicle Mount Distance C Engine Face to Vehicle Mount Distance D Overall Length Engine Face to Rear Face of Extension E Length of Case Dimension F Length of Extension Housing Rev Sheet 32 24214609 B A E C F TRANSMISSION ASM TWO PIECE CASE 2WD D A BELL HOUSING LENGTH B ENGINE FACE TO MAN...

Page 11: ...REV 1 1 1 2 3 Center of Gravity Figure 1 2 3 1 4LHD 4LHDX with 2WD Extension Housing Figure 1 2 3 2 4LHD 4LHDX with 4WD Extension Housing Object Weight X Y Z 83 9 kg 185 00 lb 253 mm 9 96 in 3 mm 12 in 17 mm 67 in Object Weight X Y Z 85 28 kg 188 00 lb 251 mm 9 90 in 10 mm 40 in 18 mm 70 in ...

Page 12: ...s dependent on transmission model Reference SAE Engine Coordinate System or figures found in Section 1 2 3 1 Referred to the input shaft of the transmission without torque converter transfer case or parking brake 1 2 5 Gross Vehicle Weight Rotational Inertia 1st gear 0 0547 kg m2 2nd gear 0 039616 kg m2 3rd gear 0 02553 kg m2 4th gear 0 06692 kg m2 GVW 3 900 kg 8 600 lb maximum Rotational Inertia ...

Page 13: ...340 Nm 250 lb ft 300 mm 542 Nm 400 lb ft Torque Converter Capacity Stall Power 258 mm 79 1 kW 106 hp 300 mm 124 6 kW 167 hp NOTE Values 690 kPa 100 psi increase limit by 0 75 kW 14 kPa 1 hp psi not to exceed 1020 kPa 150 psi Torque Converter Capacity Turbine Torque 258 mm 632 Nm 392 lb ft 300 mm 943 Nm 696 lb ft NOTE Must verify adequate spline engagement Reference Section 2 1 1 Calculated engine ...

Page 14: ...operating temperatures Maximum Output Speed Maximum output speed is 7 200 RPM Maximum Vehicle Speed Maximum vehicle speed is dependent on final drive ratio torque converter ratio and engine torque curve profile Powertrain Control Solutions must be consulted for application specific maximum speeds 1 3 3 Acceleration Limitations The 4LHD 4LHDX automatic transmission has been tested for longitudinal ...

Page 15: ...hat shift cable systems are also sensitive to heat and should be routed to avoid extreme temperatures Temperatures shall be monitored during testing to ensure appropriate temperature levels A thermal packaging study is recommended to verify all underbody temperatures Component Skin Temperature Limits The following maximum temperatures are based on released component materials These temperatures mu...

Page 16: ...loded View 1 3 5 Grade Limitations Maximum Grade for Hydraulic Operation This transmission is validated to operate on longitudinal and lateral slopes of up to 30 16 7 degree grade without detrimental effect on the operation of the hydraulic system at normal working temperature Consult with Powertrain Control Solutions if the proposed application exceeds these values Maximum Grade for Park System T...

Page 17: ...tion can be reduced especially for vehicles that spend a lot of time idling in gear With the forward gears disengaged the reduced brake force required to hold the vehicle especially in high gear reduction drivelines can significantly improve the drivability of the vehicle from the operator s perspective 1 4 3 Electronic Range Option This allows you to eliminate the shift cable and shift the transm...

Page 18: ...es 2 Manual Second First gear is electronically prevented under normal operating conditions 3 Solenoid state will be opposite shown during abuse protection Shift Solenoids The two identical shift solenoids are two port on off solenoids normally on that are used to control the shift change events The shift solenoid coil resistance should be 20 40 ohms at 20 0 5 0 C The shift solenoid current flow s...

Page 19: ... transmission fluid temperature e Current Flow fined as the percent of time current is coil during each cycle The number of a specified amount of time usually ed frequency Typically the operation led pulse width modulated solenoid is cycle and frequency C solenoid valve on a positive duty of 292 5 Hz cycles per second A s a greater current flow through the ive side of the PC solenoid valve CM cont...

Page 20: ...eed Sensor TISS contains an AC coupled Hall effect chip that switches in response to changing differential magnetic fields created by rotating ferrous targets and requires a constant supply voltage between 4 0 and 26 5 volts to operate The signal is induced by a 15 tooth spline on the turbine shaft a k a input shaft 38 TEMPERATURE SENSOR 50 30 10 10 30 50 70 90 110 130 150 110 100 90 80 70 60 50 4...

Page 21: ... Use the alignment key to ensure proper installation Reference Figure 1 5 2 1 The pass thru connector envinromental temperature shall not exceed 40 to 135 C at any time Proper shielding is required Reference Section 1 3 4 for temperature details NEGATIVE TERMINAL POSITIVE TERMINAL SPEED SENSOR CONNECTORS FIGURE 2 6 8 1 3 Speed Sensor Connector 2 6 8 2 Shift Solenoids The shift solenoids are two po...

Page 22: ...lectrical Connections Two connections must be made to the transmission to interface with the TCM The connections are for the transmission control connector and the output speed sensor Figures 1 5 2 1 and 1 5 2 2 shows the internal system schematic CAV Function A Shift SOL A B Shift SOL B C Line Pressure D Line Pressure E Switched 12V F IMS A G IMS C H IMS B J IMS P K Turbine Speed L Trans Temp Sen...

Page 23: ...TRANSMISSION E A T E A E A B T R R B T R B S S S A B SHIFT SOLENOID B TCC ENABLE SOLENOID ON OFF P1 OUTPUT SPEED SENSOR TURBINE SPEED SENSOR S2 B P U U U TCC CONTROL PWM SOLENOID FORWARD CLUTCH SOLENOID REVERSE CLUTCH SOLENOID VEHICLE CONNECTOR D M G H J N K V D M G H J N K V J N K V C C L L F F D M G H C L F PRESSURE TEMP SENSOR Internal Mode Switch CONTROL SOLENOID S1 A C ...

Page 24: ...SECTION 2 TRANSMISSION TO VEHICLE INTERFACES ...

Page 25: ... Section 2 2 4 A spring damper smooths out torsional variation when the converter clutch is locked The correct choice of components will result in a package that provides an optimum level of fuel economy performance and driveability We offer two torque converters 258mm and 300mm The 258mm torque converter is used in SAE4 SAE5 applications while the 300mm torque converter is used in SAE3 and GM 3 0...

Page 26: ...converter cover A thread adhesive should be used to ensure durability Figure 2 1 1 2 Torque Converter Pilot Arrangement Rev Sheet 79 24214609 4 2 4 Flexplate to Converter Connection Converter piloting is provided by a counterbore in the end of the engine crankshaft shown in Figure 4 2 4 1 Axial movement of the converter is contained within this floating pilot to ensure that thrust loads are not tr...

Page 27: ...mage To measure the Torque Converter Pull Out 1 Align and install the bellhousing transmission assembly to the engine Before tightening the bellhousing fasteners completely check to be sure converter rotates freely 2 Once the bellhousing fasteners are torqued to specification push the torque converter back into the transmission as far as possible 3 Using feeler gauges or calipers measure the gap b...

Page 28: ... A A ENGINE BLOCK A A CONVERTER PILOT Ø20 94 0 02mm Ø 247 65mm M10 x 1 5 6H THD THRU LUG 3 HOLES Figure 2 1 1 5 258 mm Torque Converter Attachment Features Figure 2 1 1 4 300 mm Torque Converter Attachment Features Rev Sheet 83 24214609 A A 300 mm CONVERTER LUG TO REAR FACE OF ENGINE 21 667mm 1 181 ENGINE OFF CONVERTER PILOT Ø43 234 281 0mm M10 x 1 5 6H THD THRU 3 HOLES SECTION A A 016 015 mm Figu...

Page 29: ...Page 23 Ph 804 227 3023 10511 Old Ridge Rd Ashland VA 23005 4LHD 4LHDX Application Manual REV 1 1 Figure 2 1 1 6 C6 Torque Converter Attachment Features ...

Page 30: ...land VA 23005 Powertrain Control Solutions REV 1 1 2 1 2 Flexplate PCS uses a universal flexplate for our GM and SAE applications while the C6 converter is designed for the stock C6 flexplate Figure 2 1 2 1 GM Flexplate Figure 2 1 2 2 C6 Flexplate ...

Page 31: ... can be measured by the distance between the torque converter pad and the flexplate referenced in Figure 2 1 1 3 This measurement only works if the torque converter has been gently pushed into the transmission pump as far as possible which should already be the case for proper installation referenced in section 3 1 3 If the torque converter is removed from the transmission pump for any reason rein...

Page 32: ...Contact PCS for an updated list Figures 2 1 4 1 to 2 1 4 5 show these bellhousing configurations Dimensions are for reference only Reference section 3 1 for a discussion of assembly considerations that are critical to the alignment of the transmission to the engine These bellhousings have been factory installed to 51 lb ft 70 N m removing them without the instruction permission of PCS will damage ...

Page 33: ...Page 27 Ph 804 227 3023 10511 Old Ridge Rd Ashland VA 23005 4LHD 4LHDX Application Manual REV 1 1 Figure 2 1 4 2 PCS SAE3 Bellhousing Front View ...

Page 34: ...Page 28 Ph 804 227 3023 10511 Old Ridge Rd Ashland VA 23005 Powertrain Control Solutions REV 1 1 Figure 2 1 4 3 PCS SAE4 Bellhousing Front View ...

Page 35: ...Page 29 Ph 804 227 3023 10511 Old Ridge Rd Ashland VA 23005 4LHD 4LHDX Application Manual REV 1 1 Figure 2 1 4 4 PCS SAE5 Bellhousing Adapter Front View ...

Page 36: ...Page 30 Ph 804 227 3023 10511 Old Ridge Rd Ashland VA 23005 Powertrain Control Solutions REV 1 1 Figure 2 1 4 5 PCS C6 Bellhousing Front View ...

Page 37: ...housing to fill with fluid which can cause permanent damage Contact PCS in the case of applications requiring dry extension housings 2 2 2 Output Shaft Requirements Propshaft Alignment and Torsional Vibrations The presence of universal joints in the propshaft will induce torsional vibrations in the driveline due to the angles at which the driveshafts operate This can have a detrimental effect on c...

Page 38: ...t but must also Avoid loading the internal components Allow for frame twist Absorb driveline torque To damp driveline shock forces Not exceed 200 lbs on transmission mount GM 2WD Extension Housing Used in rear wheel drive applications this extension housing does not have a parking brake incorporated When installed properly the journal of the slip yoke provides a seal for the rear of the transmissi...

Page 39: ...000 mm Max Effective Tooth Thickness 1 821 mm Pressure Angle 30 0 Min Actual Tooth Thickness 1 719 mm Pitch Diameter Reference 28 575 mm Max Actual Tooth Thickness 1 795 mm Base Diameter Reference 24 747 mm Measure Over Pins Min 31 173 mm Max 31 051 mm Major Diameter 29 822 39 845 mm Pin Diameter Reference 1 778 mm Minor Diameter 27 00 27 20 mm Spline Length 115 5 mm Figure 2 2 3 1 GM 2WD Extensio...

Page 40: ...2 3 3 is the PCS approved two speed electronic shifting transfer case 2Hi 4Hi Neutral and 4Lo are controlled via an external PCS Transfer Case Module The rear output shaft takes a GM 32 tooth female yoke while the front output shaft takes a GM 32 tooth make yoke Reference the PCS OEM Parts Catalog for part numbers Figure 2 2 3 2 GM 4WD Extension Housing ...

Page 41: ...Page 35 Ph 804 227 3023 10511 Old Ridge Rd Ashland VA 23005 4LHD 4LHDX Application Manual REV 1 1 Figure 2 2 3 3 GM 4WD Transfer Case ...

Page 42: ...ides a mechanical brake and also has an optional hydraulic brake that can be used for certain applications It also can be electronically controlled with the Parking Brake Module The caliper can be mounted in several different clocking orientations and is available with a left hand cable exit or a right hand cable exit Figure 2 2 3 5 PCS Parking Brake Dimensions Figure 2 2 3 4 PCS Parking Brake Exp...

Page 43: ...ed to take a standard driveshaft flange yoke dimensions shown in Figure 2 2 3 8 A common example shown in figure 2 2 3 7 is the Spicer 3 2 159 This is a parking brake only not an emergency brake Max vehicle holding weight is dependant on final gear ratio and tire size Contact PCS for application engineering BORE FOR MALE FLANGE Figure 2 2 3 7 Example Flange Figure 2 2 3 8 Flange Yoke Bolt Circle ...

Page 44: ...cations as the old Ford C6 w drum parking brake option Shown in Figures 2 2 3 9 to 2 2 3 10 This utilizes the original brake housing drum driveshaft yoke and other hardware to correctly seal and operate Same as the original our output shaft is an SAE10B spline Reference SAE Standard J499 for full spline detail Figure 2 2 3 9 PCS 4LHD 4LHDX with C6 Bellhousing and C6 Output ...

Page 45: ...Page 39 Ph 804 227 3023 10511 Old Ridge Rd Ashland VA 23005 4LHD 4LHDX Application Manual REV 1 1 Figure 2 2 3 10 PCS C6 Extension Housing ...

Page 46: ...m Overview Automatic Transmission Fluid Automatic transmission fluid ATF is a complex lubricant that consists of a base oil and an additive package The additive package is designed to impart several desirable performance characteristics above and beyond those that the base oil could do alone The performance of ATF s are driven by the needs of the product and must provide excellent fluidity values ...

Page 47: ...ust all be rated for a minimum of 300 psi Temperature Requirements The cooler lines cooler and fittings shall be capable of withstanding fluid temperatures of 177 C 350 F Figure 2 3 3 1 Cooler Line Connection Rev Sheet 62 24214609 3 2 Thermal Requirements 3 2 1 Cooling Transmission fluid is heated primarily by the pumping action that occurs within the torque converter Heat load varies depending on...

Page 48: ...oler lines and fittings 2 Loose assemble the lines to the transmission and hand start nuts Torque as specified 28 lb ft 38 N m Over torquing could distress the established thread lock of the connector in the transmission case 3 Assure hoses pipes are not kinked crossed twisted or grounded to any unspecified vehicle components Due care must be taken to prevent intentional movement of the cooler lin...

Page 49: ...op of the fill tube must be arranged so that any fluid expelled from the fill under extreme adverse conditions can not fall on surfaces hot enough e g exhaust system turbo charger etc to cause ignition of the fluid Powertrain Control Solutions Engineering will specify nominal indicator marking positions These will have been derived from the transmission s functional fluid level limits which are di...

Page 50: ... environmental or vehicle contaminants Remotely attached breathers are required new designs must be provided by the vehicle manufacturer to be reviewed with Powertrain Control Solutions Engineering PCS overflow vent kits serve this purpose and are available for purchase Reference the PCS OEM Parts Catalog for part numbers Overflow Vent Kit Installation The following procedure should be applied whe...

Page 51: ...ncorrect automatic transmission fluid may damage the vehicle Before checking the fluid level perform the following 1 Start the engine and park the vehicle on a level surface Keep the engine running 2 Apply the parking brake and place the shift lever in PARK P or NEUTRAL N 3 Depress the brake pedal and move the shift lever through each gear range if available pausing for about 3seconds in each rang...

Page 52: ...ithin range 1 Start the engine and locate the transmission dipstick at the rear of the engine compartment on the passenger side of the vehicle 2 Flip the handle up and then pull out the dipstick and wipe the dipstick end with a clean rag or paper towel 3 Install the dipstick by pushing it back in the dipstick tube all the way wait three seconds and then pull it back out NOTE Always check the fluid...

Page 53: ...he transmission for leaks 8 If the fluid level is in the acceptable range push the dipstick back into the dipstick tube all the way and then flip the handle down to lock the dipstick in place 9 If applicable and if the vehicle is equipped reset the transmission oil life monitor only if the fluid was changed How to Add Fluid Add fluid only after checking the transmission fluid while it is hot A col...

Page 54: ...lts from the front and sides of the pan only WARNING When the transmission is at operating temperatures take necessary precautions when removing the pan to avoid being burned by draining fluid Figure 2 3 8 1 2 3 8 Fluid Change The useful life of the transmission depends on the time at temperature of the ATF which is a function of the transmission duty cycle cooling system efficiency and local ambi...

Page 55: ...il pan and gasket Reference Figure 2 3 8 3 Figure 2 3 8 2 5 Loosen the rear oil pan bolts approximately 4turns 6 Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain Reference Figure 2 3 8 1 7 Remove the remaining oil pan bolts Reference Figure 2 3 8 2 Figure 2 3 8 3 ...

Page 56: ...n with a twisting motion in order to remove the filter Reference Figure 2 3 8 4 10 If the filter is going to be replaced remove the filter seal The filter seal may be stuck in the pump if necessary carefully use pliers or another suitable tool to remove the seal Reference Figure 2 3 8 5 11 Discard the seal Figure 2 3 8 4 Figure 2 3 8 5 ...

Page 57: ...oil pan and a new gasket Reference Figure 2 3 8 7 1 Coat the new filter seal with automatic transmission fluid 2 Install the new filter seal into the transmission case Tap the seal into place using a suitable size socket Reference Figure 2 3 8 6 3 Install the new filter into the case Figure 2 3 8 6 Figure 2 3 8 7 ...

Page 58: ...ved reinstall the exhaust heat shield 7 Lower the vehicle 8 Fill the transmission to the proper level with DEXRON VI transmission fluid Refer to Section 2 3 6 for fluid capacity 9 Check the COLD fluid level reading for initial fill only 10 Inspect the oil pan gasket for leaks 11 Test drive vehicle and verify proper transmission operation 12 Check fluid level when transmission is at operating tempe...

Page 59: ...vehicle manufacturer must make provisions to provide all the linkage and controls up to the transmission manual shaft Sections 2 4 1 2 4 2 describe how to design this linkage For an electronic shift reference Section 2 4 3 Figure 2 4 1 Typical Shift System Figure 2 4 2 Shift System with NSBU Switch FIGURE 3 4 2 Typical Shift System with NSBU Switch TRANSMISSION SHIFT LEVER SHIFT CABLE REACTION BRA...

Page 60: ...ver required to be compatible with coating on manual shaft Figure 2 4 1 1 Manual Shaft Dimension Rev Sheet 69 24214609 3 4 2 Manual Shaft Lever Interface The shift lever which is to be supplied by the vehicle assembly division must conform to the following specification Stock Thickness 4 3 to 4 7 mm 0 169 to 0 185 in Hardness Surface file hard Rc 59 min Case depth 0 12 to 0 25 mm 0 005 to 0 010 in...

Page 61: ...ation The adjustment of the shift cable or linkage must be performed with the selector system in its final routed position the vehicle resting on its wheels and the transmission in Neutral This adjusts out positional tolerances between the transmission and the shifter mechanism After the cable or linkage is properly adjusted the indicator may be installed and adjusted Adjustment of the indicator m...

Page 62: ... transmission shift lever The transmission detent centering torque is then determined by detaching the shift cable linkage removing the neutral start switch and again rotating the manual shaft nut The system drag as seen by the transmission is equal to the total system torque minus the detent centering torque The detent centering torque must be greater than the system drag For shifter systems whic...

Page 63: ...Lost system motion consists of system lash and component deflection Figure 2 4 2 3 Minimum Park Gate Position Rev Sheet 72 24214609 FIGURE 3 4 4 1 1 Minimum Park Gate Position 3 4 4 Transmission Range Selection System Kinematic Relationship Requirements The transmission Park system is designed for park engagement with the transmission detent roller located in the Park valley of the detent lever Th...

Page 64: ...nt Position With Lost System Motion Rev Sheet 73 24214609 FIGURE 3 4 4 2 1 Park Position Without Lost System Motion 3 4 4 2 Kinematic Requirements Under minimum stack conditions and neglecting lost system motion the kinematic relationship between the detent lever and the range selection lever is to ensure that the detent roller is in the Park valley when the range selection lever is in the minimum...

Page 65: ...and PCS TCM can eliminate the shift cable This allows for electronic shifting of the transmission with the push of a button or movement of an electronic lever In this application the transmission manual shaft must be engaged in neutral at all times Figure 2 3 4 1 represents one of many position switch options available Reference the PCS OEM Parts Catalog for other available options ...

Page 66: ...ing Temp Range 40 C 85 C 40 F 185 F 0 95 relative humidity Operating Volt Range 3V 32V Solenoid Load 2A 12 8V with arc suppression Measurements Ø 65 02 mm x 220 47mm L Ø 2 56 in x 8 68 in L Features IP67 turn signals are built to complement the shifter or can be mounted as stand alone Shifter Pin TCU Pin TCU Channel Description 1 2 7 Digital 6 Reverse 3 29 Digital 9 Gear Selection 4 5 6 10 Digital...

Page 67: ...s is critical to prevent pin damage For other TCMs reference their respective PCS TCM manuals TCM Installation TCM mounting location definition mounting bracket design sourcing validation and vehicle assembly process are all the responsibility of the customer If the vehicle will be subjected to electrical welding procedures e g during body building assembly process the harness and TCM must be elec...

Page 68: ...dy state operation control algorithms optimize operation to increase vehicle fuel economy while protecting transmission durability The TCM will operate the line pressure control solenoid to ensure smooth ratio transitions and to maximize fuel economy Torque Converter Clutch Control The Torque Converter Clutch is used to eliminate slip across the transmission torque converter In some applications a...

Page 69: ...ta Interface The TCM is accessed via a serial data interface and a laptop The Serial Data interface device is provided by PCS with each TCM Two typical vehicle service tool interfaces are 2 X CAN 2 0b 1x RS 232 1 x J1850 All PCS TCMs are based on the PCS proprietary real time operating system which contains the functionality to control nearly any automatic transmission with PCS controls and includ...

Page 70: ... feature The single line is either open or grounded Due to the Fault detection hardware of the TCM output circuitry an incandescent bulb is require LEDs can potentially illuminate falsely Position Transmission Range The position indication is from three discrete inputs from an Internal Mode Switch mounted inside the transmission on the shift lever The following external inputs are optional Shift p...

Page 71: ... output speed signal is a frequency input that is provided by a magnetic pickup or a conditioned signal source The magnetic pickup is a variable reluctance sensor that generates an AC sine wave induced by the 40 rotating teeth of the target rotor The sensor has a minimum output of 0 5 volts peak to peak when loaded at 60 RPM 40 Hz and a maximum output of 200 volts peak to peak loaded at a speed of...

Page 72: ...ble USB Use TCM4180 Cable TCM2600 Low Side Drive Only TCM2800 Programmable High or Low Side Drive PWM Outputs 5 6 7 8 9 1 2 3 4 11 12 13 14 51 52 53 54 40 TCM2600 Low Side Drive Only TCM2800 Programmable High or Low Side Drive Programmable Dither Current Measurement OBDII Diagnostics PCS Tuning Interface Data Logging Interface Speedometer Output Analog Inputs 0 5V 45 46 47 48 49 50 1 2 3 4 5 5V 1k...

Page 73: ...harness on the vehicle transmission avoid all high temperature heat sources in the engine compartment Assure the connection of all harnesses by using the PUSH CLICK VERIFY method Avoid twisting of the harness when securing the harness in clips Secure the clips to transmission studs where appropriate Insure that the proper amperage fuses are used in the correct locations Failure to do this will cau...

Page 74: ...from the pedal or throttle linkage When the sensor is connected to the TCM the signal should measure less than 0 2V Position 2 IDLE POSITION The sensor arm should be off of the minimum stop such that the reported voltage is between 0 5V and 1 5V Position 3 FULL THROTTLE POSITION The sensor arm should not contact the maximum stop The reported voltage in this position should be 3 5V to 4 5V Position...

Page 75: ... the engine or pedal the sensor arm returns to the minimum stop and the voltage on the TCM software monitor screen is below 0 2V Code 22 becomes active after three seconds 5 When the pedal is pressed the sensor arm moves accordingly There is no movement or slop such that the pedal or engine throttle blade can move without seeing a voltage change on the TCM software monitor screen 6 The sensor move...

Page 76: ...SECTION 3 PRODUCTION LINE PROCEDURES ...

Page 77: ...opriate shipping racks by approved lifting hooks The lifting hooks should be designed to allow the following 1 Lift the transmission by at least two lift points 2 Employ one counter balance arm to ensure that the transmission is lifted straight up from the rack and it does not swing or tilt 3 Lift hook must include a safety latch to prevent the transmission from sliding off the hook during lifting...

Page 78: ...at the 3 and 9 o clock positions Then install remaining bolts in a crossing pattern to ensure proper fit Install the appropriate transmission to engine fasteners per the vehicle assembly instructions Assure any fastening sequence and torque values are followed Transmission to Engine Fasteners and Installation Torque It is preferred that a single part number fastener be used at all of the transmiss...

Page 79: ...ough all the ranges and verify that the transmission shift arm is centered in the detent for each position This may require disconnecting the cable at the transmission for each position to ensure the arm is in the detent Improper shift cable adjustment will result in premature transmission failure 3 2 2 Stationary Engine Off Checks Firmware Turn the ignition on do not start the engine and connect ...

Page 80: ...t Drive Vehicle Speed Move the vehicle and verify that the vehicle speed operates properly Shifting A test drive should be performed to check proper transmission operation in all gears This includes but is not limited to shift quality gear range and abuse protection if equipped Operate the vehicle until the transmission is at operating temperature 3 2 5 Post Drive Check Diagnostic Code Verificatio...

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