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Workhorse ALLISON 1000MH, Service Manual

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WORKHORSE CUSTOM CHASSIS

Service Manual

Automatic Transmission – Allison

2007 W Series

 © 2006 Workhorse Custom Chassis — All Rights Reserved

SECTION

7.2

PAGE

3

2007 W Series Chassis

WSM082106

Defi nitions and Abbreviations ................................. 50
Transmission Abbreviations ................................... 52
Transmission Identifi cation Information .................. 53
Transmission General Description ......................... 54
Transmission Component and System 
  Description ........................................................... 55
Transmission Indicators and Messages ................. 58
Electronic Component Description ......................... 59
Electronic Controlled Shifter (ECS) System ........... 92

DIAGNOSTIC INFORMATION AND PROCEDURES ..... 95

Diagnostic Starting Point - Automatic 
  Transmission ........................................................ 95
Scan Tool Data List ................................................ 95
Scan Tool Data Defi nitions ..................................... 99
Diagnostic Trouble Code (DTC) Type Defi nitions . 103
Diagnostic Trouble Code (DTC) List/Type ............ 104
DTC P0218 .......................................................... 106
DTC P0561 .......................................................... 110
DTC P0562 .......................................................... 114
DTC P0563 .......................................................... 117
DTC P0602 .......................................................... 120
DTC P0613 .......................................................... 123
DTC P0634 .......................................................... 126
DTC P0658 .......................................................... 129
DTC P0659 .......................................................... 133
DTC P0700 .......................................................... 137
DTC P0701 .......................................................... 139
DTC P0703 .......................................................... 142
DTC P0706 .......................................................... 146
DTC P0708 .......................................................... 150
DTC P0711 ........................................................... 155
DTC P0712 .......................................................... 160
DTC P0713 .......................................................... 164
DTC P0716 .......................................................... 169

DTC P0717 .......................................................... 173
DTC P0721 .......................................................... 177
DTC P0722 .......................................................... 181
DTC P0726 .......................................................... 185
DTC P0727 .......................................................... 189
DTC P0729 .......................................................... 193
DTC P0731 .......................................................... 196
DTC P0732 .......................................................... 200
DTC P0733 .......................................................... 203
DTC P0734 .......................................................... 206
DTC P0735 .......................................................... 209
DTC P0736 .......................................................... 212
DTC P0741 .......................................................... 216
DTC P0742 .......................................................... 219
DTC P0751 .......................................................... 222
DTC P0752 .......................................................... 227
DTC P0756 .......................................................... 232
DTC P0757 .......................................................... 237
DTC P0761 .......................................................... 242
DTC P0762 .......................................................... 247
DTC P0776 .......................................................... 252
DTC P0777 .......................................................... 256
DTC P0826 .......................................................... 260
DTC P0827 .......................................................... 264
DTC P0828 .......................................................... 268
DTC P0842 .......................................................... 272
DTC P0843 .......................................................... 277
DTC P0847 .......................................................... 282
DTC P0848 .......................................................... 287
DTC P0851 or 0852 ............................................. 292
DTC P0872 .......................................................... 294
DTC P0873 .......................................................... 299
DTC P0873 .......................................................... 304
DTC P0877 .......................................................... 309

Summary of Contents for ALLISON 1000MH

Page 1: ...tom Chassis All Rights Reserved WORKHORSE CUSTOM CHASSIS Service Manual WSM082106 2007 AUTOMATIC TRANSMISSION ALLISON 1000MH 2100MH LCT1000 REMOTE SHIFTER PRND321 9999 9mi T1 gear1 4 TRANSMISSION GEAR...

Page 2: ...ing Oil Pump Cover Assembly 27 Oil Pump Assembly Disassembled View 28 Oil Pump Cover Assembly Disassembled View 28 Oil Pump Cover Oil Pump Assembly and Associated Parts Disassembled View 29 1 2 3 4 4...

Page 3: ...ons 99 Diagnostic Trouble Code DTC Type De nitions 103 Diagnostic Trouble Code DTC List Type 104 DTC P0218 106 DTC P0561 110 DTC P0562 114 DTC P0563 117 DTC P0602 120 DTC P0613 123 DTC P0634 126 DTC P...

Page 4: ...odes 448 Clutch Test 449 FastLearn Procedure 450 Limp Home Mode 452 Road Test 454 Torque Converter Diagnosis 459 Flexplate Torque Converter Vibration Test 8 1L 463 Noise and Vibration Analysis 465 Flu...

Page 5: ...Transmission Control Module Replacement 483 Transmission Fluid Filter Adapter Replacement 484 Transmission Fluid Cooler Hose Pipe Connector Replacement 486 Automatic Transmission Fluid and Filter Repl...

Page 6: ...Main Housing Bolt 12 N m 108 lb in Wire Harness Vent Tube Bracket to Transmission Nut 18 N m 13 lb ft Yoke Assembly to Output Shaft Bolt 123 N m 91 lb ft SPECIFICATIONS FASTENER TIGHTENING SPECIFICATI...

Page 7: ...n Initial Fill Refill Liters Quarts Liters Quarts Allison 1000 12 12 7 7 7 4 TRANSMISSION GENERAL SPECIFICATIONS Torque Converter Clutch Pressure Control Solenoid TCC PCS Speci cations Sump Temperatur...

Page 8: ...51 155338 40 40 95826 100735 105644 35 31 68952 72315 75679 30 22 50153 52480 54807 25 13 36854 38478 40103 20 4 27345 28488 29631 15 5 20476 21286 22097 10 14 15467 16045 16624 5 23 11781 12197 12612...

Page 9: ...3 110 230 129 7 133 0 136 4 115 239 112 6 115 6 118 7 120 248 98 17 100 9 103 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...

Page 10: ...PSM LOGIC Range Pressure Switch 1 N O Pressure Switch 2 N O Pressure Switch 3 N O Pressure Switch 4 N C Switch Status Scan Tool Status Switch Status Scan Tool Status Switch Status Scan Tool Status Swi...

Page 11: ...es SOLENOID AND CLUTCH CHART NORMAL MODE Solenoid and Clutch Chart Normal Mode Range Status Logic State Clutch to Line Pressure Control Solenoids Shift Solenoids TCC Sol PCS1 PCS2 SS1 SS2 SS3 Steady S...

Page 12: ...utch Trimming Off De energized 2 6 Clutch Trimming On OFF OFF OFF OFF Steady State 3 1 2 3 4 Clutch De energized 3rd 5th and Reverse Clutch Applied De energized 4 5 6 Clutch Exhausted ON OFF OFF OFF U...

Page 13: ...Steady State 1 1 2 3 4 Clutch De energized Low and Reverse Clutch Applied De energized 2 6 Clutch Exhausted OFF ON OFF OFF Upshift 1 2 1 2 3 4 Clutch Energized Low and Reverse Clutch Trimming Off Ene...

Page 14: ...verse Clutch Trimming Off Energized 2 6 Clutch Trimming On OFF OFF ON ON Downshift 6 5 4 5 6 Clutch De energized 3rd 5th and Reverse Clutch Trimming On De energized 2 6 Clutch Trimming Off OFF OFF ON...

Page 15: ...OFF ON OFF OFF OFF OFF Fourth Clutch A Overrun Clutch A A A A A A A Overdrive Roller Clutch H H H H H H OR A A A A A A A Forward Clutch A A A A A A A A A A A Direct Clutch A A A A Front Band A A Inter...

Page 16: ...ch Not Applied 700 380 kPa 101 200 PSI 1 515 1 795 kPa 220 260 PSI Forward Lockup Torque Converter Clutch Applied N A 1 000 1 170 kPa 145 170 PSI Reverse 700 1 380 kPa 101 200 PSI 1 515 1 795 kPa 220...

Page 17: ...Reserved SECTION 7 2 PAGE 17 2007 W Series Chassis WSM082106 J 21369 F Torque Converter Leak Test Fixture J 24204 2 Bar and Stud Assembly J 24420 B Universal Puller J 24446 Rear Bearing Installer J 2...

Page 18: ...Chassis All Rights Reserved WSM082106 J 39200 Digital Multimeter DMM J 43763 Torque Converter Leak Test Plug J 43764 Torque Converter End Play Gage J 43765 Stator Shaft Installer Remover J 43767 Tone...

Page 19: ...9 2007 W Series Chassis WSM082106 J 43772 Torque Converter Seal Installer J 43773 Valve Spring Compressor J 43774 Stator Shaft Bushing Installer J 43775 Oil Pump Cover Needle Bearing Installer J 43778...

Page 20: ...ll Rights Reserved WSM082106 J 43782 Rear Seal Installer J 43785 Intermediate Bushing Remover Installer J 43791 Output Turbine Shaft Bushing Installer J 43797 Output Carrier Bearing Race Installer J 4...

Page 21: ...PAGE 21 2007 W Series Chassis WSM082106 J 44525 Clutch Backing Plate Selector J 44526 Output Turbine Shaft Bushing Remover J 44528 Output Carrier Bearing Race Remover J 44529 Stator Shaft Bushing Rem...

Page 22: ...que Converter Lifting Handles J 47339 1 Piston Return Spring Compressor J 47339 2 Seal Area Protector COMPONENT LOCATOR 1 Turbine Sensor Harness Connector 2 Power Take Off PTO Connector 3 Output Speed...

Page 23: ...Y Pin Wire Color Circuit No Function Pin Wire Color Circuit No Function A L GN 1222 Shift Solenoid 1 SS1 Low A D GN 1222 Shift Solenoid 1 SS1 Low B YE BK 1223 Shift Solenoid 2 SS2 Low B L GN 1223 Shif...

Page 24: ...2762 Transmission Fluid Temperature TFT Sensor H BK 2762 Transmission Fluid Temperature TFT Sensor Low J BN 418 Torque Converter Clutch Pressure Control Solenoid TCC PCS Low J PK 418 Torque Converter...

Page 25: ...cription 20 Way M Micro Pack 100 Series GY Pin Wire Color Circuit No Function Pin Wire Color Circuit No Function R OG BK 1786 Transmission Park Neutral Signal R PU 1786 Transmission Park Neutral Signa...

Page 26: ...SS Sensor TORQUE CONVERTER CLUTCH CONVERTER HOUSING ASSEMBLY DISASSEMBLED VIEW 1 Torque Converter 2 Torque Converter Housing 3 Line Pressure Test Hole Plug 4 Line Pressure Test Hole Plug O ring 5 Tran...

Page 27: ...t Sun Gear Thrust Bearing 5 Internal Retaining Ring 6 3rd 5th and Reverse Clutch Backing Plate 7 3rd 5th and Reverse Clutch Fiber Plate 4 8 3rd 5th and Reverse Clutch Steel Plate 3 9 3rd 5th and Rever...

Page 28: ...Seal 3 Torque Converter Oil Seal 4 Oil Pump Bushing 5 Oil Pump Body 6 Oil Pump Driven Gear 7 Oil Pump Drive Gear 8 Locating Pin 9 Oil Pump Wear Plate OIL PUMP COVER ASSEMBLY DISASSEMBLED VIEW 1 Oil Pu...

Page 29: ...4 Clutch Backfill Valve 18 1 2 3 4 Clutch Backfill Valve Spring 19 Retaining Clip 20 Pressure Regulator Valve 21 Pressure Regulator Valve Spring 22 Pressure Regulator Valve Stop 23 Pressure Regulator...

Page 30: ...3 4 Clutch Piston Inner Seal 22 1 2 3 4 Clutch Piston Outer Seal 23 1 2 3 4 Clutch Piston 24 1 2 3 4 Clutch Piston Return Spring Assembly 25 1 2 3 4 Clutch Balance Piston 26 1 2 3 4 Clutch Hub Intern...

Page 31: ...smission Oil Pan Gasket 75 Transmission Oil Pan Magnet 76 Transmission Oil Pan 77 Transmission Oil Pan Drain Plug O ring 78 Transmission Oil Pan Drain Plug 79 Transmission Oil Pan Bolt M8 x 1 25 x 20...

Page 32: ...dy Locating Pin 22 Detent Lever IMS Bolt 23 Connector Shipping Cover 24 Control Valve Body Assembly 25 Control Valve Body Bolt M6 x 1 0 x 50 Flanged Head 15 26 Manual Shift Shaft Detent Spring 27 Manu...

Page 33: ...EW 1 Input Carrier and Ring Gear Assembly 2 Input Carrier Thrust Bearing 3 Intermediate Carrier and Ring Gear Assembly 4 Intermediate Carrier Thrust Bearing 5 Main Shaft 6 Intermediate Sun Gear 7 Inte...

Page 34: ...arrier and Ring Gear Assembly 2 Intermediate Carrier Internal Retaining Ring 3 Intermediate Carrier Assembly 4 Output Carrier and Low and Reverse Clutch Ring Gear INPUT CARRIER ASSEMBLY DISASSEMBLED V...

Page 35: ...ermediate Carrier Thrust Washer 4 5 Intermediate Carrier Roller Bearing Assembly 8 6 Intermediate Carrier Pinion Gear 4 7 Intermediate Carrier Thrust Washer 4 8 Intermediate Carrier Spindle 4 OUTPUT C...

Page 36: ...ler Bearing Assembly 8 5 Output Carrier Pinon Gear 4 6 Output Carrier Thrust Washer 4 7 Output Carrier Planetary Spindle 4 8 Output Carrier Bearing Race LOW AND REVERSE CLUTCH PISTON HOUSING DISASSEMB...

Page 37: ...ton 3 Low and Reverse Clutch Outer Piston Seal 4 Low and Reverse Clutch Inner Piston Seal 5 Internal Retaining Ring 6 Output Carrier Support Bearing 7 Output Speed Sensor Reluctor Wheel 8 Low and Reve...

Page 38: ...ontrol Valve Body Assembly 2 Shift Valve Body Assembly 3 Separator Plate 4 Main Valve Body Assembly 5 Transmission Fluid Pressure TFP Switch 6 Main Valve Body Assembly Bolt M6 x 10 x 50 Flanged Head 2...

Page 39: ...Retaining Clip 3 Shift Solenoid 2 SS2 Shift Plug 4 SS2 Shift Spring 5 SS2 Shift Valve 6 Retaining Clip 7 SS3 Shift Plug 8 SS3 Shift Spring 9 SS3 Shift Valve 10 Retaining Clip 11 SS1 Shift Spring 12 S...

Page 40: ...elief Valve 8 Main Valve Body 9 Locating Pin 4 10 Locating Pin 11 Pressure Control Solenoid 1 PCS1 Spring 12 PCS1 Valve 13 PCS1 Spring 14 Trim Gain Valve 15 PCS1 16 PCS1 O Ring 17 PCS2 Spring 18 PCS2...

Page 41: ...Cover Assembly Needle Bearing 5 Turbine Shaft Bushing 6 1 2 3 4 Clutch Drive Hub Thrust Bearing 7 4 5 6 Clutch Hub Thrust Bearing 8 Input Carrier Thrust Bearing 9 Intermediate Carrier Bushing 10 Inte...

Page 42: ...alance Piston 13 Turbine Speed Sensor O Ring 14 3rd 5th and Reverse Clutch Piston Seal Assembly 15 2 6 Clutch Piston Seal Assembly 16 Low and Reverse Clutch Piston Outer Seal 17 Low and Reverse Clutch...

Page 43: ...t Information OEM 15326727 Service Description 2 Way F SRS Faston NA Pin Wire Color Circuit No Function 1 RD 150 Actuator Supply Voltage 1 HSD1 2 D BU 1525 Pressure Control Solenoid 1 PCS1 Low Pressur...

Page 44: ...o Function A OG 1224 Fluid Pressure Switch 1 PS1 Signal B WH 1225 Fluid Pressure Switch 2 PS2 Signal C GY 1226 Fluid Pressure Switch 3 PS3 Signal D BN 901 Fluid Pressure Switch 4 PS4 Signal E TN 1227...

Page 45: ...ation OEM 12146094 Service Description 2 Way F Metri Pack 150 2 Series P2S GY Pin Wire Color Circuit No Function A RD BK 250 Actuator Supply Voltage 2 HSD2 B YE BK 1528 Shift Solenoid 2 SS2 Low Shift...

Page 46: ...or Circuit No Function 1 RD 150 Actuator Supply Voltage 1 HSD1 2 PK 1531 Torque Converter Clutch Pressure Control Solenoid TCC PCS Low Transmission Internal Mode Switch Connector Part Information OEM...

Page 47: ...Metri Pack 150 2 Series SLD BK Pin Wire Color Circuit No Function A RD BK 1230 Automatic Transmission Input Speed Sensor AT ISS Signal High B D BU WH 1231 Automatic Transmission Input Speed Sensor AT...

Page 48: ...GY 773 Transmission Range Switch Signal C 15 16 Not Used 17 PK 1224 Fluid Pressure Switch Signal 1 18 YE 400 Vehicle Speed Sensor VSS Signal High 19 Not Used 20 L BU 1984 Transmission Turbine Speed Sw...

Page 49: ...Return 59 RD BK 1280 Automatic Transmission Input Speed Sensor AT ISS Signal High 60 PU WH 821 Vehicle Speed Sensor VSS Signal High 61 62 Not Used 63 PK 1020 Ignition 0 Voltage 64 65 Not Used 66 D BU...

Page 50: ...owledge of this powertrain If you perform diagnostic procedures with powertrain If you perform diagnostic procedures with out this basic knowledge you may incorrectly diagnose out this basic knowledge...

Page 51: ...seconds as during a manual downshift or WOT detent downshift may also be de ned as Late or Extended Double Bump Two bumps felt during a clutch apply Early Shift occurs at lower speed than expected oft...

Page 52: ...Converter Noise A whine usually noticed when the vehicle is stopped and the transmission is in D DRIVE or R REVERSE Thermostatic Fan Noise A normal noise that occurs while climbing a grade under load...

Page 53: ...WD Four Wheel Drive TRANSMISSION IDENTIFICATION INFORMATION 1 Nameplate 1 Model Series 2 Engineering Group Number 3 Transmission Identi cation Number 4 Engineering Feature Con guration Number 5 Serial...

Page 54: ...h modulated PWM signal 6 Measure the resistance of the sensor 7 Inspect for shorts to other circuits within the harness or transmission connector 8 Inspect to ensure there is no conductive material in...

Page 55: ...itional engine vibration control Gear Sets The planetary gear train includes 3 constant mesh planetary gear sets containing high helix gears By the engagement of the clutches in various combinations t...

Page 56: ...n A plug is installed in the unused location Park Pawl All 1000 Series transmissions have a park pawl The internal parking pawl is engaged by selection of the PARK position on the shift selector Power...

Page 57: ...on The transmission control module TCM produces excellent shift quality by applying closed loop control that constantly adjusts shift characteristics for changes in operating conditions These adjustme...

Page 58: ...shift High Output Speed Direction Change Shifts REVERSE to DRIVE DRIVE to REVERSE and NEUTRAL to REVERSE shifts initiated above 300 RPM output speed are inhibited to NEUTRAL Low Automatic Transmission...

Page 59: ...al function such as anti lock brakes or power take off is also an input to the TCM The TCM processes this data to determine proper shift points to monitor the current range to perform ratio tests and...

Page 60: ...sion operating range Speed sensor information is also used to control the timing of clutch apply pressures resulting in the best possible shift quality Hydraulic conditions are detected by comparing t...

Page 61: ...SE is selected in order to move the vehicle backward N NEUTRAL NEUTRAL may be used when starting the engine and for stationary operations The TCM disables the starter switch if a range other than NEUT...

Page 62: ...ince the valve states stroked or unstroked are critical to providing the correct transmission range each shift valve has a pressure switch located in the PSM which provides feedback to the computer re...

Page 63: ...so that electrical current is stopped at the switch When uid pressure is routed to the switch it moves the diaphragm and upper contact so that the contact element touches both the positive and ground...

Page 64: ...t shift valve 1 shift valve 2 and shift valve 3 are stroked Normally closed PCS1 blocks the exhaust of the PCS1 signal pressure raising the signal pressure PCS1 signal pressure strokes pressure contro...

Page 65: ...d to shift valve 2 In the de stroked position shift valve 2 routes uid to the 3rd 5th and reverse clutch All other clutches are exhausted so the transmission remains in Neutral N When shift valve 3 is...

Page 66: ...WORKHORSE CUSTOM CHASSIS Service Manual 2007 W Series SECTION 7 2 PAGE 66 Automatic Transmission Allison 2007 W Series Chassis 2006 Workhorse Custom Chassis All Rights Reserved WSM082106 Neutral...

Page 67: ...timed to prevent SS3 from becoming latched down allowing both valves to de stroke PCS2 is also de energized exhausting PCS2 signal pressure allowing the pressure control valve 2 to de stroke which ex...

Page 68: ...h the TCC valve to the bottom of shift valve 2 de stroking the valve and opening the path for main pressure to feed the low and reverse clutch keeping the clutch applied PCS1 control pressure is then...

Page 69: ...WORKHORSE CUSTOM CHASSIS Service Manual Automatic Transmission Allison 2007 W Series 2006 Workhorse Custom Chassis All Rights Reserved SECTION 7 2 PAGE 69 2007 W Series Chassis WSM082106 First Range...

Page 70: ...shift valve 2 and the PCS1 now exhausts through exhaust back ll keeping the low and reverse clutch released The 3rd 5th and reverse clutch has an exhaust path through shift valve 2 to the pressure con...

Page 71: ...with subsequent third range operation moving the manual selector valve to reverse will cut off main pressure to the 1 2 3 4 clutch exhausting the 1 2 3 4 clutch The manual selector directs main press...

Page 72: ...WORKHORSE CUSTOM CHASSIS Service Manual 2007 W Series SECTION 7 2 PAGE 72 Automatic Transmission Allison 2007 W Series Chassis 2006 Workhorse Custom Chassis All Rights Reserved WSM082106 Second Range...

Page 73: ...ng PCS1 signal and PCS1 pressures The PCS1 pressure is directed through shift valve 2 to the 3rd 5th and reverse clutch The TCM reduces current to PCS1 which controls the rate at which the pressure co...

Page 74: ...C valve to de stroke exhausting pressure from the top of the converter ow valve The converter ow valve de strokes redirecting main overage to converter in and converter out to the cooler The TCC is no...

Page 75: ...WORKHORSE CUSTOM CHASSIS Service Manual Automatic Transmission Allison 2007 W Series 2006 Workhorse Custom Chassis All Rights Reserved SECTION 7 2 PAGE 75 2007 W Series Chassis WSM082106 Third Range...

Page 76: ...the top of shift valve 3 stroking the valve In the stroked position main pressure is redirected through shift valve 2 and the manual selector valve to the 4 5 6 clutch keeping the 4 5 6 clutch applie...

Page 77: ...k ll releasing the 4 5 6 clutch The 3rd 5th and reverse clutch remains applied With only one clutch applied the transmission goes to neutral If electrical power is interrupted while the transmission i...

Page 78: ...WORKHORSE CUSTOM CHASSIS Service Manual 2007 W Series SECTION 7 2 PAGE 78 Automatic Transmission Allison 2007 W Series Chassis 2006 Workhorse Custom Chassis All Rights Reserved WSM082106 Fourth Range...

Page 79: ...sure switch 2 are turned OFF providing feedback that shift valve 1 and shift valve 2 are in the de stroked position and pressure switch 3 remains ON providing feedback that shift valve 3 is in the str...

Page 80: ...electrical power is interrupted while the transmission is in fth range fth range converter operation and the manual selector valve is moved to Reverse R the 4 5 6 clutch exhausts through the manual s...

Page 81: ...WORKHORSE CUSTOM CHASSIS Service Manual Automatic Transmission Allison 2007 W Series 2006 Workhorse Custom Chassis All Rights Reserved SECTION 7 2 PAGE 81 2007 W Series Chassis WSM082106 Fifth Range...

Page 82: ...on of the 4 5 6 clutch and the 2 6 clutch produces sixth range operation Pressure switch 1 and pressure switch 2 remain open OFF providing feedback that shift valve 1 and shift valve 2 remain in the d...

Page 83: ...clutch remains applied With only one clutch applied the transmission shifts to neutral If electrical power is interrupted while the transmission is in sixth range causing fth range converter operatio...

Page 84: ...WORKHORSE CUSTOM CHASSIS Service Manual 2007 W Series SECTION 7 2 PAGE 84 Automatic Transmission Allison 2007 W Series Chassis 2006 Workhorse Custom Chassis All Rights Reserved WSM082106 Sixth Range...

Page 85: ...ssure increases at a higher gain rate PCS2 pressure ows through shift valve 1 to shift valve 3 and on to apply the 3rd 5th and reverse clutch When the shift to reverse is complete PCS2 fully energizes...

Page 86: ...Series Chassis 2006 Workhorse Custom Chassis All Rights Reserved WSM082106 transmission remains in neutral If electrical power is interrupted with the transmission operating in reverse range resultin...

Page 87: ...WORKHORSE CUSTOM CHASSIS Service Manual Automatic Transmission Allison 2007 W Series 2006 Workhorse Custom Chassis All Rights Reserved SECTION 7 2 PAGE 87 2007 W Series Chassis WSM082106 Reverse Range...

Page 88: ...sure is directed through shift valve 3 to shift valve 2 Because shift valve 2 stays stroked due to the latching effect of pressure on two different diameter lands main pressure is blocked from reachin...

Page 89: ...ORSE CUSTOM CHASSIS Service Manual Automatic Transmission Allison 2007 W Series 2006 Workhorse Custom Chassis All Rights Reserved SECTION 7 2 PAGE 89 2007 W Series Chassis WSM082106 Reverse Range Limp...

Page 90: ...ignal pressure signal remains control main The signal pressure on top of pressure control valve 1 produces maximum PCS1 pressure which is routed through shift valve 2 to the 3rd 5th and reverse clutch...

Page 91: ...HORSE CUSTOM CHASSIS Service Manual Automatic Transmission Allison 2007 W Series 2006 Workhorse Custom Chassis All Rights Reserved SECTION 7 2 PAGE 91 2007 W Series Chassis WSM082106 Third Range Limp...

Page 92: ...ar the vehicle operator The shift selector is a self contained electronic control that contains the push button system Interface Control Module and Actuator Control Module The push button pad provides...

Page 93: ...fting to P will engage Park and turn off the system Pressing the R button shifts the transmission into Reverse Pressing the N button shifts the transmission to Neutral Neutral can be used to start the...

Page 94: ...identi ed by the label above it and may vary from vehicle to vehicle A light will illuminate in the corner of the button when the MODE is on This function is optional Service If the SERVICE display i...

Page 95: ...f the condition described by the customer is normal or if a malfunction exists If it is determined that a malfunction exists identify the concern by referring to Symptoms Automatic Transmission The Sy...

Page 96: ...ll 7 F5 PSI Varies 3 2 TAP Cell 8 F5 PSI Varies 3 2 TAP Cell 9 F5 PSI Varies 3 2 TAV Cell 1 F5 CM caret 3 Varies 3 2 TAV Cell 2 F5 CM caret 3 Varies 3 4 Adapt Status Cell 0 F6 Fast Slow Varies Scan To...

Page 97: ...ries 4WD Low F0 Enabled Disabled Disabled Cold Shift Pattern F2 Disabled Enabled Disabled Current Gear F0 F1 F2 F3 0 7 0 Driver Demanded Engine Torque F0 F2 F4 F5 F6 F7 F8 N m lb ft 0 Driver Reverse A...

Page 98: ...F7 F8 RPM Varies Normal Shift Pattern F2 Enabled Disabled Enabled PC Sol A Actual Current F0 F3 Amps Varies PC Sol A Ref Current F0 F3 Amps Varies PC Sol B Actual Current F0 F3 Amps Varies PC Sol B Re...

Page 99: ...arameter Data List Units Displayed Typical Data Value Data List Legend F0 Trans Data F1 TCC Data F2 Shift Data F3 PC Solenoid Data F4 1 2 Adapt Data F5 2 3 Adapt Data F6 3 4 Adapt Data F7 4 5 Adapt Da...

Page 100: ...00 to 8 00 1 This parameter is the actual gear ratio of the current commanded gear In the current gear of R D4 D3 D2 D1 it is calculated by dividing the input speed by the output speed In the current...

Page 101: ...ted Displays Enabled or Disabled This parameter indicates the status of the brake switch Enabled indicates that the brake pedal is not depressed Disabled indicates that the brake pedal is depressed Sh...

Page 102: ...Displays 4 080 to 4 079 RPM This parameter is the difference between transmission input speed and engine speed A negative value indicates the engine speed is less than the input speed deceleration A...

Page 103: ...ressed as RPM In commanded gears 1 2 3 and 4 the turbine speed equals the input speed 4WD Low Displays Enabled or Disabled This parameter is the signal state of the four wheel drive low circuit Enable...

Page 104: ...pe D Type X This DTC is available in the control module software but has been disabled or turned off In this case the diagnostic does not run DTCs are not stored and the MIL does not illuminate Type X...

Page 105: ...A DTC P0761 A DTC P0762 A DTC P0776 A DTC P0777 A DTC P0826 B DTC P0827 B DTC P0828 B DTC P0842 A DTC P0843 A DTC P0847 A DTC P0848 A DTC P0872 A DTC P0873 A DTC P0877 A DTC P0878 A DTC P0880 C DTC Co...

Page 106: ...ch manifold PSM assembly is mounted to the valve body If the transmission control module TCM detects a high TFT for an extended period of time then DTC P0218 sets DTC P0218 is a type C DTC DTC Descrip...

Page 107: ...g etc The TFT should rise steadily during warm up cycles 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...

Page 108: ...rame and Failure Records The Clear Info function will erase the data erase the data 3 Record the DTC Freeze Frame and Failure Records 4 Clear the DTC 5 Perform the Transmission Fluid Checking Procedur...

Page 109: ...on Go to Step 6 Go to Symptoms Automatic Transmission 6 Perform the following procedure in order to verify the repair 1 Clear the DTC 2 Using the scan tool monitor the TFT 3 Start the engine 4 The TFT...

Page 110: ...en the DTC Sets The TCM does not illuminate the malfunction indicator lamp MIL The transmission fails to hydraulic default DTC P0561 is stored in TCM history The TCM inhibits torque converter clutch T...

Page 111: ...e Custom Chassis All Rights Reserved SECTION 7 2 PAGE 111 2007 W Series Chassis WSM082106 Test Description The number below refers to the step number on the diagnostic table 3 This step observes batte...

Page 112: ...ion will erase the data 3 Record the DTC Freeze Frame and Failure Records 4 Clear the DTC 5 Start the engine and observe the charge indicator on the instru ment panel cluster IPC Does the charge indic...

Page 113: ...and Wiring Repairs Did you find and correct the condition Go to Step 10 Go to Diagnostic Aids 9 IMPORTANT In most cases the TCM is not at fault Investigate thor In most cases the TCM is not at fault...

Page 114: ...ts at 20 C 68 F Action Taken When the DTC Sets The TCM does not illuminate the malfunction indicator lamp MIL The transmission fails to hydraulic default DTC P0562 is stored in TCM history The TCM inh...

Page 115: ...ds for refer record the Freeze Frame and Failure Records for refer ence The Clear Info function will erase the data ence The Clear Info function will erase the data 3 Record the DTC Freeze Frame and F...

Page 116: ...No 6 Perform the following procedure in order to verify the repair 1 Clear the DTC 2 Using the scan tool monitor TCM voltage 3 Select Specific DTC 4 Enter DTC P0562 Has the test run and passed Go to...

Page 117: ...uminate the malfunction indicator lamp MIL The transmission fails to hydraulic default DTC P0563 is stored in TCM history The TCM inhibits torque converter clutch TCC engagement The TCM freezes shift...

Page 118: ...the Freeze Frame and Failure Records for refer ence The Clear Info function will erase the data ence The Clear Info function will erase the data 3 Record the DTC Freeze Frame and Failure Records 4 Cl...

Page 119: ...No 6 Perform the following procedure in order to verify the repair 1 Clear the DTC 2 Using the scan tool monitor TCM voltage 3 Select Specific DTC 4 Enter DTC P0564 Has the test run and passed Go to...

Page 120: ...e TCM Not Programmed Conditions for Running the DTC The components are powered and ignition voltage is greater than 9 0 volts and less than 18 volts This test will run before any TCM function Conditio...

Page 121: ...ds The Clear Info function will Freeze Frame and Failure Records The Clear Info function will erase the data erase the data 3 Record the DTC Failure Records 4 Clear the DTC 5 Turn OFF the ignition for...

Page 122: ...the following procedure in order to verify the repair 1 Clear the DTC 2 Turn OFF the ignition for 30 seconds 3 Turn ON the ignition 4 Select Specific DTC 5 Enter DTC P0602 Has the test run and passed...

Page 123: ...DTC The components are powered and ignition voltage is greater than 9 0 volts and less than 18 volts This test is run during the entire ignition cycle Conditions for Setting the DTC DTC P0613 sets if...

Page 124: ...e Freeze Frame and Failure Records for refer ence The Clear Info function will erase the data ence The Clear Info function will erase the data 3 Record the DTC Freeze Frame and Failure Records 4 Clear...

Page 125: ...No 6 Perform the following procedure in order to verify the repair 1 Clear the DTC 2 Using the scan tool monitor TCM voltage 3 Select Specific DTC 4 Enter DTC P0563 Has the test run and passed Go to...

Page 126: ...than 200 RPM and less than 7 500 RPM for greater than 10 seconds Conditions for Setting the DTC DTC P0634 sets if the TCM internal temperature is greater than or equal to 140 C 284 F for 10 seconds wi...

Page 127: ...ase the data 3 Record the DTC Freeze Frame and Failure Records 4 Clear the DTC 5 Using the scan tool drive the vehicle and monitor TCM internal temperature Did DTC P0634 return Go to Step 3 Go to Diag...

Page 128: ...07 W Series Chassis 2006 Workhorse Custom Chassis All Rights Reserved WSM082106 DTC P0634 Step Action Yes No 6 With the scan tool observe the stored information capture info and DTC Info Does the scan...

Page 129: ...n When the DTC Sets The TCM illuminates the malfunction indicator lamp MIL If the failure occurs while in a forward range a shift to 1st 3rd or 5th range is made While diagnostic response is active if...

Page 130: ...to Before clearing the DTC use the scan tool in order to record the Freeze Frame and Failure Records for refer record the Freeze Frame and Failure Records for refer ence The Clear Info function will...

Page 131: ...ve the connectors to PCS1 MAIN MOD and TCC sole noids 4 Using the DMM measure the supply voltage of each solenoid connector Is the voltage within the specified value at each solenoid connector B Go to...

Page 132: ...the TCM is not at fault Investigate thor oughly before replacing the TCM oughly before replacing the TCM Replace the TCM Refer to Control Module References for replacement setup and programming Did yo...

Page 133: ...ommanding HSD1 ON Action Taken When the DTC Sets The TCM illuminates the malfunction indicator lamp MIL If the failure occurs while in a forward range a shift to 1st 3rd or 5th range is made While dia...

Page 134: ...2007 W Series SECTION 7 2 PAGE 134 Automatic Transmission Allison 2007 W Series Chassis 2006 Workhorse Custom Chassis All Rights Reserved WSM082106 equipment for a change You may have to drive the veh...

Page 135: ...he DTC Freeze Frame and Failure Records 4 Clear the DTC 5 Using the scan tool measure ignition voltage Is the voltage within the specified range 9 18 V Go to Step 3 Go to DTC P0562 for low voltage or...

Page 136: ...Did you find and correct the condition Go to Step 10 7 Replace the AT internal wiring harness Refer to Wiring Harness Replacement Did you complete the replacement Go to Step 10 8 IMPORTANT In most cas...

Page 137: ...DTC P0700 Transmission Control Module TCM Requested MIL Illumination Conditions for Running the DTC The engine is running Conditions for Setting the DTC The ECM receives a serial data message from th...

Page 138: ...fore clearing the DTCs use the scan tool in order to record the Freeze Frame and Failure Records The Clear Info function will erase the data DTC P0700 is set by the ECM DTC P0700 allows a technician t...

Page 139: ...ter than 500 RPM for 6 seconds or 400 RPM for 15 seconds Forward or REVERSE range is selected Action Taken When the DTC Sets The TCM does not illuminate the malfunction indicator lamp MIL DTC P0701 is...

Page 140: ...scan tool in order to record the Before clearing the DTCs use the scan tool in order to record the Freeze Frame and Failure Records The Clear Info function will Freeze Frame and Failure Records The C...

Page 141: ...the following conditions Stuck or sticking lube regulator valve Stuck or sticking main regulator valve Loose or damaged suction lter Defective suction lter seal Did you find the reason for a no line...

Page 142: ...ke is OFF DTC P0703 is stored in TCM history The TCM inhibits torque converter clutch TCC engagement The TCM inhibits grade braking Conditions for Clearing the DTC A scan tool can clear the code from...

Page 143: ...ng the DTC use the scan tool in order to Before clearing the DTC use the scan tool in order to record the Freeze Frame and Failure Records for refer record the Freeze Frame and Failure Records for ref...

Page 144: ...o Diagnostic Aids Go to Step 4 4 Using the DMM measure voltage at terminal C of the stop lamp switch and ground Refer to Automatic Transmission Controls Schematics Is voltage within the specified valu...

Page 145: ...re in order to verify the repair 1 Clear the DTC 2 Using the scan tool monitor the brake switch 3 Operate the vehicle under the Conditions for Setting the DTC 4 Select Specific DTC 5 Enter DTC P0703 H...

Page 146: ...volts and less than 18 volts Engine speed is less than 350 RPM Conditions for Setting the DTC DTC P0706 sets when the TCM detects an invalid IMS range input at engine start up NEUTRAL or PARK is not...

Page 147: ...eference The the Freeze Frame and Failure Records for reference The Clear Info function will erase the data Clear Info function will erase the data 3 Record the DTC Freeze Frame and Failure Records 4...

Page 148: ...rounded and HIGH when open Go to Step 6 Go to Step 7 6 1 Turn the ignition OFF 2 Connect the transmission AT inline 20 way connector 3 Remove the transmission oil pan Refer to Oil Pan Replacement 4 Re...

Page 149: ...eplace the TCM Refer to Control Module References for replacement setup and programming Did you complete the replacement Go to Step 11 11 Perform the following procedure in order to verify the repair...

Page 150: ...ndition and parity error occurring over consecutive ignition cycles Action Taken When the DTC Sets While diagnostic response is active one of the following conditions can occur The TCM illuminates the...

Page 151: ...ated response DTC P0722 can also set Test Description The numbers below refer to step numbers on the diagnostic table 4 This step tests TCM input response 5 This step tests the integrity of the engine...

Page 152: ...eeze Frame and Failure Records 4 Clear the DTC 5 With the scan tool monitor IMS A B C P status while moving the shift selector through each range Refer to Transmission Internal Mode Switch Logic Does...

Page 153: ...rounded and HIGH when open Go to Step 6 Go to Step 7 6 1 Turn the ignition OFF 2 Connect the transmission AT inline 20 way connector 3 Remove the transmission oil pan Refer to Oil Pan Replacement 4 Re...

Page 154: ...eplace the TCM Refer to Control Module References for replacement setup and programming Did you complete the replacement Go to Step 11 11 Perform the following procedure in order to verify the repair...

Page 155: ...erformance Conditions for Running the DTC DTC P0712 P0713 P0716 P0717 P0721 and P0722 are not active The components are powered and ignition voltage is greater than 9 0 volts and less than 18 volts En...

Page 156: ...acked 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 watchin...

Page 157: ...can tool in order to record Before clearing the DTC use the scan tool in order to record the Freeze Frame and Failure Records for reference The the Freeze Frame and Failure Records for reference The C...

Page 158: ...tance at terminals G and H of the J 44152 Refer to Automatic Transmission Inline Harness Connector End View Is the resistance within the specified value 3 490 ohms 20 C 68 F 177 9 ohms 100 C 212 F Go...

Page 159: ...er to Control Module References for replacement setup and programming Did you complete the replacement Go to Step 12 12 Perform the following procedure in order to verify the repair 1 Clear the DTC 2...

Page 160: ...Fluid Temperature TFT Sensor Circuit Low Input Conditions for Running the DTC DTC P0711 and P0713 are not active The components are powered and ignition voltage is greater than 9 0 volts and less tha...

Page 161: ...has set Follow the diagnostic table for DTC P0712 before proceeding to the diagnostics for DTC P0218 Test Description The numbers below refer to step numbers on the diagnostic table 4 This step tests...

Page 162: ...4 1 Turn the ignition OFF 2 Disconnect the 80 way connector at the TCM 3 Install the J 39700 breakout box the J 47275 breakout box adapter and the J 47275 1 magnetic overlay 4 Turn ON the ignition wi...

Page 163: ...ep 12 9 Replace the automatic transmission internal harness Refer to Wiring Harness Replacement Did you complete the replacement Go to Step 12 10 Replace the PSM Refer to Pressure Switch Manifold Repl...

Page 164: ...ecreases The TCM uses this information to control shift quality and torque converter clutch TCC apply DTC P0713 is a type B DTC DTC Descriptor This diagnostic procedure supports the following DTC DTC...

Page 165: ...l 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 wa...

Page 166: ...ol in order to Before clearing the DTC use the scan tool in order to record the Freeze Frame and Failure Records for refer record the Freeze Frame and Failure Records for refer ence The Clear Info fun...

Page 167: ...ls G and H of the J 44152 Refer to Automatic Transmission Inline Harness Connector End View Is the resistance within the specified value 3 490 ohms 20 C 68 F 177 9 ohms 100 C 212 F Go to Step 8 Go to...

Page 168: ...efer to Control Module References for replacement setup and programming Did you complete the replacement Go to Step 12 12 Perform the following procedure in order to verify the repair 1 Clear the DTC...

Page 169: ...elated elds Using 2 wire differential inputs at the TCM eliminates noise from other sources DTC P0716 is a type A DTC DTC Descriptor This diagnostic procedure supports the following DTC DTC P0716 Turb...

Page 170: ...ire 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 expe...

Page 171: ...4 Clear the DTC 5 Using the scan tool observe ignition voltage Is the voltage within the specified range 9 18 V Go to Step 3 Go to DTC P0562 for low voltage or DTC P0563 for high voltage 3 1 Turn the...

Page 172: ...fixed and if changed may cause improp er operation er operation Replace the turbine speed sensor Refer to Speed Sensor Replacement Did you complete the replacement Go to Step 7 7 Perform the following...

Page 173: ...oltage related elds Using 2 wire differential inputs at the TCM eliminates noise from other sources DTC P0717 is a type A DTC DTC Descriptor This diagnostic procedure supports the following DTC DTC P0...

Page 174: ...r 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...

Page 175: ...4 Clear the DTC 5 Using the scan tool observe ignition voltage Is the voltage within the specified range 9 18 V Go to Step 3 Go to DTC P0562 for low voltage or DTC P0563 for high voltage 3 1 Turn the...

Page 176: ...fixed and if changed may cause improp er operation er operation Replace the turbine speed sensor Refer to Speed Sensor Replacement Did you complete the replacement Go to Step 7 7 Perform the following...

Page 177: ...erential inputs at the TCM eliminates noise from other sources DTC P0721 is a type A DTC DTC Descriptor This diagnostic procedure supports the following DTC DTC P0721 Output Speed Sensor Circuit Perfo...

Page 178: ...ire 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 expe...

Page 179: ...cords 4 Clear the DTC 5 Using the scan tool observe ignition voltage Is the voltage within the specified range 9 18 V Go to Step 3 Go to DTC P0562 for low voltage or DTC P0563 for high voltage 3 1 Tur...

Page 180: ...tion is fixed and if changed may cause improper oper ation ation Replace the output speed sensor Refer to Speed Sensor Replacement Did you complete the replacement Go to Step 7 7 Perform the following...

Page 181: ...fferential inputs at the TCM eliminates noise from other sources DTC P0722 is a type A DTC DTC Descriptor This diagnostic procedure supports the following DTC DTC P0722 Output Speed Sensor Circuit No...

Page 182: ...r 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...

Page 183: ...ecords 4 Clear the DTC 5 Using the scan tool observe ignition voltage Is the voltage within the specified range 9 18 V Go to Step 3 Go to DTC P0562 for low voltage or DTC P0563 for high voltage 3 1 Tu...

Page 184: ...is fixed and if changed may cause improper operation operation Replace the output speed sensor Refer to Speed Sensor Replacement Did you complete the replacement Go to Step 7 7 Perform the following...

Page 185: ...shielded to protect from voltage related elds Using 2 wire differential inputs at the TCM eliminates noise from other sources DTC P0726 is a type B DTC DTC Descriptor This diagnostic procedure support...

Page 186: ...and select the speed sensor indicated by the code If the signal is erratic investigate and eliminate the following Intermittent wiring connection Excessive vibration such as driveline or engine torsio...

Page 187: ...hin the specified range 9 18 V Go to Step 3 Go to DTC P0562 for low voltage or DTC P0563 for high voltage 3 1 Turn the ignition OFF 2 Disconnect the 80 way connector at the TCM 3 Install the J 39700 b...

Page 188: ...fixed and if changed may cause improp er operation er operation Replace the engine speed sensor Refer to Speed Sensor Replacement Did you complete the replacement Go to Step 7 7 Perform the following...

Page 189: ...pairs to cancel magnetically induced elds The cable is also shielded to protect from voltage related elds Using 2 wire differential inputs at the TCM eliminates noise from other sources DTC P0727 is a...

Page 190: ...e speed sensor indicated by the code If the signal is erratic investigate and eliminate the following Intermittent wiring connection Excessive vibration such as driveline or engine torsionals Irregula...

Page 191: ...ds 4 Clear the DTC 5 Using the scan tool observe ignition voltage Is the voltage within the specified range 9 18 V Go to Step 3 Go to DTC P0562 for low voltage or DTC P0563 for high voltage 3 1 Turn t...

Page 192: ...fixed and if changed may cause improp er operation er operation Replace the turbine speed sensor Refer to Speed Sensor Replacement Did you complete the replacement Go to Step 7 7 Perform the followin...

Page 193: ...dicator lamp MIL The transmission defaults to 4th range while diagnostic response is active If the shift selector is moved to NEUTRAL the transmission will shift to NEUTRAL If the shift selector is mo...

Page 194: ...orrect Go to Step 3 Go to Transmission Fluid Checking Procedure 3 1 Install the scan tool 2 Turn ON the ignition with the engine OFF IMPORTANT Before clearing the DTC use the scan tool in order to rec...

Page 195: ...cessive material found in the pan Go to Step 7 Go to Step 8 7 Remove the transmission for overhaul or replacement Refer to Transmission Replacement Did you complete the replacement Go to Step 10 8 Ins...

Page 196: ...powered and ignition voltage is greater than 9 0 volts and less than 18 volts Output speed exceeds 200 RPM 1st range is selected and attained Conditions for Setting the DTC DTC P0731 sets when the ca...

Page 197: ...icle in order to experience a condition Test Description The numbers below refer to the step numbers on the diagnostic table 3 This step tests ignition voltage 5 This step tests speed sensor readings...

Page 198: ...to Step 4 Go to DTC P0562 for low voltage or DTC P0563 for high voltage 4 1 Start the engine 2 Using the scan tool observe the gear ratio Is the correct 1st range ratio shown 3 10 1 Go to Step 5 Go to...

Page 199: ...ure control solenoid 3 PCS3 Refer to Control Valve Solenoid Replacement Did you complete the replacement Go to Step 11 11 Perform the following procedure in order to verify the repair 1 Clear the DTC...

Page 200: ...function indicator lamp MIL The transmission defaults to 3rd range while diagnostic response is active If the shift selector is moved to NEUTRAL the transmission will shift to NEUTRAL If the shift sel...

Page 201: ...efore clearing the DTC use the scan tool in order to Before clearing the DTC use the scan tool in order to record the Freeze Frame and Failure Records for reference record the Freeze Frame and Failure...

Page 202: ...Go to Step 10 8 Inspect for a stuck or sticking pressure control valve Refer to Control Valve Body Cleaning and Inspection Did you find and correct the condition Go to Step 10 Go to Step 9 9 Replace p...

Page 203: ...ction indicator lamp MIL The transmission defaults to 4th range while diagnostic response is active If the shift selector is moved to NEUTRAL the transmission will shift to NEUTRAL If the shift select...

Page 204: ...ne OFF IMPORTANT Before clearing the DTC use the scan tool in order to record Before clearing the DTC use the scan tool in order to record the Freeze Frame and Failure Records for reference The Clear...

Page 205: ...Go to Step 10 8 Inspect for a stuck or sticking pressure control valve Refer to Control Valve Body Cleaning and Inspection Did you find and correct a condition Go to Step 10 Go to Step 9 9 Replace pr...

Page 206: ...ndicator lamp MIL The transmission defaults to 5th range while diagnostic response is active If the shift selector is moved to NEUTRAL the transmission will shift to NEUTRAL If the shift selector is m...

Page 207: ...orrect Go to Step 3 Go to Transmission Fluid Checking Procedure 3 1 Install the scan tool 2 Turn ON the ignition with the engine OFF IMPORTANT Before clearing the DTC use the scan tool in order to rec...

Page 208: ...ul or replacement Refer to Transmission Replacement Did you complete the replacement Go to Step 10 8 Inspect for a stuck or sticking pressure control valve Refer to Control Valve Body Cleaning and Ins...

Page 209: ...dicator lamp MIL The transmission defaults to 4th range while diagnostic response is active If the shift selector is moved to NEUTRAL the transmission will shift to NEUTRAL If the shift selector is mo...

Page 210: ...orrect Go to Step 3 Go to Transmission Fluid Checking Procedure 3 1 Install the scan tool 2 Turn ON the ignition with the engine OFF IMPORTANT Before clearing the DTC use the scan tool in order to rec...

Page 211: ...ul or replacement Refer to Transmission Replacement Did you complete the replacement Go to Step 10 8 Inspect for a stuck or sticking pressure control valve Refer to Control Valve Body Cleaning and Ins...

Page 212: ...o steady state detected by the TCM differs from the known REVERSE range ratio Action Taken When the DTC Sets The TCM illuminates the malfunction indicator lamp MIL The transmission will lock in NEUTRA...

Page 213: ...re clearing the DTC use the scan tool in order to record the Freeze Frame and Failure Records for reference The the Freeze Frame and Failure Records for reference The Clear Info function will erase th...

Page 214: ...gine speed to 1 000 RPM Did turbine speed remain at zero Go to Diagnostic Aids Go to Step 7 7 1 Remove the transmission oil pan Refer to Automatic Transmission Fluid Filter Replacement 2 Inspect for c...

Page 215: ...der to verify the repair 1 Clear the DTC 2 Start the engine 3 Using the scan tool monitor REVERSE gear ratio and operate the vehi cle under normal operating conditions 4 Select Specific DTC 5 Enter DT...

Page 216: ...rd range The torque converter clutch TCC is enabled Conditions for Setting the DTC DTC P0741 sets when the TCM detects one of the following conditions A TCC slip value greater than 80 RPM for 15 secon...

Page 217: ...learing the DTC use the scan tool in order to record the Before clearing the DTC use the scan tool in order to record the Freeze Frame and Failure Records for reference The Clear Info Freeze Frame and...

Page 218: ...he TCC valve bore Clogged converter relief passage Did you find and repair a condition Go to Step 5 5 Perform the following procedure in order to verify the repair 1 Clear the DTC 2 Start the engine 3...

Page 219: ...the TCM detects TCC slip speed values indicating a stuck on or locked condition for 2 5 seconds Action Taken When the DTC Sets The TCM illuminates the malfunction indicator lamp MIL during the second...

Page 220: ...the test equipment for a change You may have to drive the vehicle in order to experience a condition Test Description The numbers below refer to the step numbers on the diagnostic table 2 This step te...

Page 221: ...rd the DTC Freeze Frame and Failure Records 4 Clear the DTC 5 Start the engine 6 Apply the vehicle brakes and select DRIVE Did the engine stall Go to Step 3 Go to Diagnostic Aids 3 1 Remove the transm...

Page 222: ...essure switches The pressure switch 1 PS1 monitors shift solenoid valve 1 SS1 positioning and relays it to the transmission control module TCM When PS1 is in the open state SS1 should be in the destro...

Page 223: ...ompletes 40 warm up cycles without failure Diagnostic Aids Inspect the wiring for poor electrical connections at the TCM Inspect for the following conditions A bent terminal A backed out terminal A da...

Page 224: ...urn ON the ignition with the engine OFF IMPORTANT Before clearing the DTC use the scan tool in order to record the Before clearing the DTC use the scan tool in order to record the Freeze Frame and Fai...

Page 225: ...ess from the PSM and ground terminal A Does the scan tool indicate PS1 status is LOW when grounded and HIGH when open Go to Step 8 Go to Step 13 8 1 Remove the PSM from the control valve body and leav...

Page 226: ...lacing the TCM swap the TCM with a known good TCM Prior to replacing the TCM swap the TCM with a known good TCM In most cases the TCM is not at fault Investigate thoroughly before In most cases the TC...

Page 227: ...mains ON for 2 16 seconds depending on uid temperature Action Taken When the DTC Sets The TCM illuminates the malfunction indicator lamp MIL When in a forward range and shifting is completed the trans...

Page 228: ...he shift valve is stuck in the stroked state When DTC P0752 and P0842 are set in combination this may indicate a short to ground is present at the pressure switch circuit or the shift valve is stuck i...

Page 229: ...an tool in order to record the Before clearing the DTC use the scan tool in order to record the Freeze Frame and Failure Records for reference The Clear Info Freeze Frame and Failure Records for refer...

Page 230: ...and ground terminal A Does the scan tool indicate PS1 status is LOW when grounded and HIGH when open Go to Step 8 Go to Step 13 8 1 Remove the PSM from the control valve body and leave the internal h...

Page 231: ...eplacing the TCM swap the TCM with a known good TCM Prior to replacing the TCM swap the TCM with a known good TCM In most cases the TCM is not at fault Investigate thoroughly before In most cases the...

Page 232: ...d PS2 status remains OFF for 5 seconds depending on uid temperature Action Taken When the DTC Sets The TCM illuminates the malfunction indicator lamp MIL When in a forward range and shifting is comple...

Page 233: ...the shift valve is stuck in the destroked state When DTC P0756 and P0848 are set in combination this may indicate an open circuit condition is present at the pressure switch circuit or the shift valv...

Page 234: ...an tool in order to record the Before clearing the DTC use the scan tool in order to record the Freeze Frame and Failure Records for reference The Clear Info Freeze Frame and Failure Records for refer...

Page 235: ...ng harness from the PSM and ground terminal B Does the scan tool indicate PS2 status is LOW when grounded and HIGH when open Go to Step 8 Go to Step 13 8 1 Remove the PSM from the control valve body a...

Page 236: ...lacing the TCM swap the TCM with a known good TCM Prior to replacing the TCM swap the TCM with a known good TCM In most cases the TCM is not at fault Investigate thoroughly before In most cases the TC...

Page 237: ...mains ON for 2 16 seconds depending on uid temperature Action Taken When the DTC Sets The TCM illuminates the malfunction indicator lamp MIL When in a forward range and shifting is completed the trans...

Page 238: ...he shift valve is stuck in the stroked state When DTC P0757 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 i...

Page 239: ...an tool in order to record the Before clearing the DTC use the scan tool in order to record the Freeze Frame and Failure Records for reference The Clear Info Freeze Frame and Failure Records for refer...

Page 240: ...nd terminal B Does the scan tool indicate PS2 status is LOW when grounded and HIGH when open Go to Step 8 Go to Step 13 8 1 Remove the PSM from the control valve body and leave the internal harness co...

Page 241: ...lacing the TCM swap the TCM with a known good TCM Prior to replacing the TCM swap the TCM with a known good TCM In most cases the TCM is not at fault Investigate thoroughly before In most cases the TC...

Page 242: ...OFF for 5 seconds depending on uid temperature Action Taken When the DTC Sets The TCM illuminates the malfunction indicator lamp MIL When in a forward range and shifting is completed the transmission...

Page 243: ...valve is stuck in the destroked state When DTC P0761 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...

Page 244: ...an tool in order to record the Before clearing the DTC use the scan tool in order to record the Freeze Frame and Failure Records for reference The Clear Info Freeze Frame and Failure Records for refer...

Page 245: ...ess from the PSM and ground terminal C Does the scan tool indicate PS3 status is LOW when grounded and HIGH when open Go to Step 8 Go to Step 13 8 1 Remove the PSM from the control valve body and leav...

Page 246: ...lacing the TCM swap the TCM with a known good TCM Prior to replacing the TCM swap the TCM with a known good TCM In most cases the TCM is not at fault Investigate thoroughly before In most cases the TC...

Page 247: ...mains ON for 2 16 seconds depending on uid temperature Action Taken When the DTC Sets The TCM illuminates the malfunction indicator lamp MIL When in a forward range and shifting is completed the trans...

Page 248: ...he shift valve is stuck in the stroked state When DTC P0762 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 i...

Page 249: ...r to record the Freeze Frame and Failure Records for reference The Clear Info Freeze Frame and Failure Records for reference The Clear Info function will erase the data function will erase the data 3...

Page 250: ...d HIGH when open Go to Step 8 Go to Step 13 8 1 Remove the PSM from the control valve body and leave the internal harness connected Refer to Pressure Switch Manifold Replacement 2 Provide a ground con...

Page 251: ...lacing the TCM swap the TCM with a known good TCM Prior to replacing the TCM swap the TCM with a known good TCM In most cases the TCM is not at fault Investigate thoroughly before In most cases the TC...

Page 252: ...eater than 125 RPM The transmission is at normal operating temperature Conditions for Setting the DTC DTC P0776 sets when the TCM detects an incorrect oncoming ratio during a forward range shift for a...

Page 253: ...Observe scan tool failure record data for previous or current range information when the DTC was set in order to determine the speci c shift when the DTC was set Refer to Solenoid and Clutch Chart to...

Page 254: ...and Failure Records for reference The Clear Info function will erase the data Clear Info function will erase the data 3 Record the DTC Freeze Frame and Failure Records 4 Clear the DTC 5 Using the scan...

Page 255: ...nsmission Replacement Did you complete the repair or replacement Go to Step 11 9 Inspect for a stuck or sticking PCS2 valve Refer to Control Valve Body Cleaning and Inspection Did you find and correct...

Page 256: ...d less than 18 volts Output speed is greater than 200 RPM Turbine speed is greater than 200 RPM Conditions for Setting the DTC DTC P0777 sets when the TCM detects the off going clutch controlled by PC...

Page 257: ...rve scan tool failure record data for previous or current range information when the DTC was set to determine the speci c shift when the DTC was set Refer to the Solenoid and Clutch Chart to determine...

Page 258: ...me and Failure Records for reference The Clear Info function will erase the data Clear Info function will erase the data 3 Record the DTC Freeze Frame and Failure Records 4 Clear the DTC 5 Using the s...

Page 259: ...nsmission Replacement Did you complete the repair or replacement Go to Step 11 9 Inspect for a stuck or sticking PCS2 valve Refer to Control Valve Body Cleaning and Inspection Did you find and correct...

Page 260: ...ft request is commanded Conditions for Setting the DTC DTC P0826 sets when the transmission control module TCM detects an open condition in the TAP up down shift switch circuit for greater than 6 seco...

Page 261: ...clearing the DTC use the scan tool in order to record the Freeze Frame and Failure Records for reference The the Freeze Frame and Failure Records for reference The Clear Info function will erase the...

Page 262: ...to Step 7 Go to Step 9 6 IMPORTANT The condition that affects this circuit may exist in other con The condition that affects this circuit may exist in other con necting branches of the circuit Refer...

Page 263: ...ault Investigate thoroughly before replacing the TCM before replacing the TCM Replace the TCM Refer to Control Module References for replacement setup and programming Did you complete the replacement...

Page 264: ...request is commanded Conditions for Setting the DTC DTC P0827 sets when the transmission control module TCM detects a short to ground condition in the TAP up down shift switch circuit for greater than...

Page 265: ...clearing the DTC use the scan tool in order to record the Freeze Frame and Failure Records for reference The the Freeze Frame and Failure Records for reference The Clear Info function will erase the...

Page 266: ...o Step 9 6 IMPORTANT The condition that affects this circuit may exist in other con The condition that affects this circuit may exist in other con necting branches of the circuit Refer to Power Distri...

Page 267: ...ault Investigate thoroughly before replacing the TCM before replacing the TCM Replace the TCM Refer to Control Module References for replacement setup and programming Did you complete the replacement...

Page 268: ...request is commanded Conditions for Setting the DTC DTC P0828 sets when the transmission control module TCM detects a short to ground condition in the TAP up down shift switch circuit for greater tha...

Page 269: ...clearing the DTC use the scan tool in order to record the Freeze Frame and Failure Records for reference The the Freeze Frame and Failure Records for reference The Clear Info function will erase the...

Page 270: ...ep 9 6 IMPORTANT The condition that affects this circuit may exist in other con The condition that affects this circuit may exist in other con necting branches of the circuit Refer to Power Distributi...

Page 271: ...ault Investigate thoroughly before replacing the TCM before replacing the TCM Replace the TCM Refer to Control Module References for replacement setup and programming Did you complete the replacement...

Page 272: ...as been commanded OFF Action Taken When the DTC Sets The TCM illuminates the malfunction indicator lamp MIL When in a forward range the transmission will fail to another forward range unless the trans...

Page 273: ...k in the stroked state Test Description The numbers below refer to the step numbers on the diagnostic table 5 This step tests the TCM response function 6 This step tests the transmission wiring harnes...

Page 274: ...ool indicate PS1 status is LOW Go to Diagnostic Aids Go to Step 5 5 1 Turn the ignition OFF 2 Disconnect the 80 way connector at the TCM 3 Install the J 39700 breakout box the J 47275 breakout box ada...

Page 275: ...on the PS1 membrane Does the scan tool indicate PS1 status is LOW when grounded and HIGH when open Go to Diagnostic Aids Go to Step 9 9 Replace the PSM Refer to Pressure Switch Manifold Replacement Di...

Page 276: ...m the following procedure in order to verify the repair 1 Clear the DTC 2 Start the engine 3 Using the scan tool monitor PS1 status 4 Select Specific DTC 5 Enter DTC P0842 Has the test run and passed...

Page 277: ...r 0 1 second Action Taken When the DTC Sets The TCM illuminates the malfunction indicator lamp MIL When in a forward range and shifting is completed the transmission will fail to another forward range...

Page 278: ...rcuit condition is present at the pressure switch circuit or the shift valve 1 is stuck in the destroked position This DTC may indicate that SS1 is mechanically defective This DTC can be caused by a l...

Page 279: ...an tool in order to record the Before clearing the DTC use the scan tool in order to record the Freeze Frame and Failure Records for reference The Clear Info Freeze Frame and Failure Records for refer...

Page 280: ...PSM and ground terminal A Does the scan tool indicate PS1 status is LOW when grounded and HIGH when open Go to Step 8 Go to Step 13 8 1 Remove the PSM from the control valve body and leave the interna...

Page 281: ...eplacing the TCM swap the TCM with a known good TCM Prior to replacing the TCM swap the TCM with a known good TCM In most cases the TCM is not at fault Investigate thoroughly before In most cases the...

Page 282: ...uid temperature Action Taken When the DTC Sets The TCM illuminates the malfunction indicator lamp MIL When in a forward range and shifting is completed the transmission will fail to another forward r...

Page 283: ...alve is stuck in the stroked state You may have to drive the vehicle in order to experience a condition This DTC may indicate that SS2 is mechanically defective or shift valve 2 is stuck in the stroke...

Page 284: ...an tool in order to record the Before clearing the DTC use the scan tool in order to record the Freeze Frame and Failure Records for reference The Clear Info Freeze Frame and Failure Records for refer...

Page 285: ...l B Does the scan tool indicate PS2 status is LOW when grounded and HIGH when open Go to Step 8 Go to Step 13 8 1 Remove the PSM from the control valve body and leave the internal harness connected Re...

Page 286: ...eplacing the TCM swap the TCM with a known good TCM Prior to replacing the TCM swap the TCM with a known good TCM In most cases the TCM is not at fault Investigate thoroughly before In most cases the...

Page 287: ...25 milliseconds Action Taken When the DTC Sets The TCM illuminates the malfunction indicator lamp MIL When in a forward range and shifting is completed the transmission will fail to another forward ra...

Page 288: ...6 and P0848 are set in combination this may indicate an open circuit is present at the pressure switch circuit or the shift valve is stuck in the destroked position This DTC can be caused by a loss of...

Page 289: ...an tool in order to record the Before clearing the DTC use the scan tool in order to record the Freeze Frame and Failure Records for reference The Clear Info Freeze Frame and Failure Records for refer...

Page 290: ...rnal wiring harness from the PSM and ground terminal B Does the scan tool indicate PS2 status is LOW when grounded and HIGH when open Go to Step 8 Go to Step 13 8 1 Remove the PSM from the control val...

Page 291: ...eplacing the TCM swap the TCM with a known good TCM Prior to replacing the TCM swap the TCM with a known good TCM In most cases the TCM is not at fault Investigate thoroughly before In most cases the...

Page 292: ...Parameter Normal Range In Gear Park Neutral Park Neutral Signal Park Neutral In Gear In Gear Circuit System Description The engine control module ECM powertrain control module PCM provides 12 volts t...

Page 293: ...MS and the P N Switch where no electrical fault is present Ensure the gear shift selector cable is properly adjusted and there are no service bulletins that address this concern before replacing parts...

Page 294: ...ircuit tests normal replace the ECM PCM 4 Install a fused jumper between the signal circuit and ground Verify the Park Neutral parameter displays Park Neutral If not the speci ed value test the signal...

Page 295: ...freezes shift adapts The TCM inhibits torque converter clutch TCC engagement Conditions for Clearing the DTC A scan tool can clear the code from TCM history The TCM automatically clears the DTC from T...

Page 296: ...urn ON the ignition with the engine OFF IMPORTANT Before clearing the DTC use the scan tool in order to record the Before clearing the DTC use the scan tool in order to record the Freeze Frame and Fai...

Page 297: ...lacement 3 Disconnect the AT internal wiring harness from the PSM and ground terminal C Does the scan tool indicate PS3 status is LOW when grounded and HIGH when open Go to Step 8 Go to Step 10 8 1 Re...

Page 298: ...t at fault Investigate thoroughly before replacing the TCM replacing the TCM Replace the TCM Refer to Control Module References for replacement setup and programming Did you complete the replacement G...

Page 299: ...after 0 1 second Action Taken When the DTC Sets The TCM illuminates the malfunction indicator lamp MIL When in a forward range and shifting is completed the transmission will fail to another forward r...

Page 300: ...n combination this may indicate an open circuit condition is present in PS3 This DTC may indicate that SS3 is mechanically defective This DTC can be caused by a loss of prime Test Description The numb...

Page 301: ...an tool in order to record the Before clearing the DTC use the scan tool in order to record the Freeze Frame and Failure Records for reference The Clear Info Freeze Frame and Failure Records for refer...

Page 302: ...C Does the scan tool indicate PS3 status is LOW when grounded and HIGH when open Go to Step 8 Go to Step 13 8 1 Remove the PSM from the control valve body and leave the internal harness connected Ref...

Page 303: ...replacing the TCM swap the TCM with a known good TCM Prior to replacing the TCM swap the TCM with a known good TCM In most cases the TCM is not at fault Investigate thoroughly before In most cases th...

Page 304: ...after 0 1 second Action Taken When the DTC Sets The TCM illuminates the malfunction indicator lamp MIL When in a forward range and shifting is completed the transmission will fail to another forward r...

Page 305: ...n combination this may indicate an open circuit condition is present in PS3 This DTC may indicate that SS3 is mechanically defective This DTC can be caused by a loss of prime Test Description The numb...

Page 306: ...an tool in order to record the Before clearing the DTC use the scan tool in order to record the Freeze Frame and Failure Records for reference The Clear Info Freeze Frame and Failure Records for refer...

Page 307: ...C Does the scan tool indicate PS3 status is LOW when grounded and HIGH when open Go to Step 8 Go to Step 13 8 1 Remove the PSM from the control valve body and leave the internal harness connected Ref...

Page 308: ...replacing the TCM swap the TCM with a known good TCM Prior to replacing the TCM swap the TCM with a known good TCM In most cases the TCM is not at fault Investigate thoroughly before In most cases th...

Page 309: ...C 32 F DTC P0708 and P0878 is not active Conditions for Setting the DTC DTC P0877 sets when P PARK N NEUTRAL or a forward range is selected and the PS4 state remains in the mechanically closed electr...

Page 310: ...sion wiring harness integrity 7 This step tests and evaluates the internal wiring harness 8 This step tests the PSM for a failed condition DTC P0877 Step Action Yes No Schematic Reference Automatic Tr...

Page 311: ...can tool indicate PS4 status is HIGH Go to Diagnostic Aids Go to Step 5 5 1 Turn the ignition OFF 2 Disconnect the 80 way connector at the TCM 3 Install the J 39700 breakout box the J 47275 breakout b...

Page 312: ...itch R membrane Does the scan tool indicate PS4 status is LOW when grounded and HIGH when open Go to Step 9 Go to Diagnostic Aids 9 Replace the PSM Refer to Pressure Switch Manifold Replacement Did yo...

Page 313: ...m the following procedure in order to verify the repair 1 Clear the DTC 2 Start the engine 3 Using the scan tool monitor PS4 status 4 Select Specific DTC 5 Enter DTC P0877 Has the test run and passed...

Page 314: ...0 C 32 F DTC P0708 and P0877 is not active Conditions for Setting the DTC DTC P0878 sets when P PARK N NEUTRAL or a forward range is selected and the PS4 state remains in the mechanically closed elect...

Page 315: ...sion wiring harness integrity 7 This step tests and evaluates the internal wiring harness 8 This step tests the PSM for a failed condition DTC P0878 Step Action Yes No Schematic Reference Automatic Tr...

Page 316: ...can tool indicate PS4 status is HIGH Go to Diagnostic Aids Go to Step 5 5 1 Turn the ignition OFF 2 Disconnect the 80 way connector at the TCM 3 Install the J 39700 breakout box the J 47275 breakout b...

Page 317: ...ncil push gently on pressure switch R membrane Does the scan tool indicate PS4 status is LOW when grounded and HIGH when open Go to Step 9 Go to Diagnostic Aids 9 Replace the PSM Refer to Pressure Swi...

Page 318: ...ssion control module TCM has lost battery positive voltage circuit supply voltage before it has nished saving information from that drive cycle This process is usually completed in less than 10 second...

Page 319: ...for poor electrical connections at the TCM Inspect 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 in...

Page 320: ...eeze Frame and Failure Records for reference The Clear Info function will erase the data Clear Info function will erase the data 3 Record the DTC Freeze Frame and Failure Records 4 Clear the DTC IMPOR...

Page 321: ...Go to Step 6 Go to Step 8 6 1 Turn the ignition ON with the engine OFF 2 Using the DMM measure the voltage between connector terminal 9 and terminal 10 3 Measure the voltage between connector termina...

Page 322: ...criptor This diagnostic procedure supports the following DTC DTC P0881 Transmission Control Module TCM Power Input Signal Performance Conditions for Running the DTC Engine speed is greater than 400 RP...

Page 323: ...icle in order to experience a condition Vehicle accessories imposing a large load on the battery circuit could also cause this DTC to set Loose or corroded battery cables could allow this DTC to set A...

Page 324: ...e DTC 5 Using the scan tool monitor TCM input voltage Is voltage within the specified value B Go to Diagnostic Aids Go to Step 3 3 1 Turn the ignition OFF 2 Disconnect the 80 way connector at the TCM...

Page 325: ...No 6 Perform the following procedure in order to verify the repair 1 Clear the DTC 2 Using the scan tool monitor TCM voltage 3 Select Specific DTC 4 Enter DTC P0881 Has the test run and passed Go to...

Page 326: ...luminate the malfunction indicator lamp MIL Hydraulic default is commanded Shift selector position and hydraulic state of logic valves determine range The TCM inhibits main modulation The TCM inhibits...

Page 327: ...eze Frame and Failure Records for reference The Clear Info function will erase the data Clear Info function will erase the data 3 Record the DTC Freeze Frame and Failure Records 4 Clear the DTC 5 Usin...

Page 328: ...No 6 Perform the following procedure in order to verify the repair 1 Clear the DTC 2 Using the scan tool monitor TCM voltage 3 Select Specific DTC 4 Enter DTC P0882 Has the test run and passed Go to...

Page 329: ...tion and hydraulic state of logic valves determine range The TCM inhibits main modulation The TCM inhibits torque converter clutch TCC engagement Conditions for Clearing the DTC A scan tool can clear...

Page 330: ...or reference The Clear Info function will erase the data Clear Info function will erase the data 3 Record the DTC Freeze Frame and Failure Records 4 Clear the DTC 5 Start the engine Start the engine 6...

Page 331: ...re control solenoid 1 PCS1 through a separate solid state device called high side driver 1 HSD1 The TCM uses a low side driver to switch MAIN MOD ON and OFF DTC P0960 is a type A DTC DTC Descriptor Th...

Page 332: ...r 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 condition DTC P0960 set in combinat...

Page 333: ...Info function will erase the data 3 Record the DTC Freeze Frame and Failure Records 4 Clear the DTC 5 Using the scan tool measure ignition voltage Is voltage within the specified value 9 18 V Go to S...

Page 334: ...ing harness at the solenoid MAIN MOD connector 3 Using the DMM measure the resistance of the MAIN MOD solenoid Is the solenoid resistance within the specified value 22 0 ohms at 20 C 68 F Go to Step 8...

Page 335: ...Perform the following procedure in order to verify the repair 1 Clear the DTC 2 Drive the vehicle under normal operating conditions 3 Select Specific DTC 4 Enter DTC P0960 Has the test run and passed...

Page 336: ...ng the DTC The components are powered and ignition voltage is greater than 9 0 volts and less than 18 volts TCM initialization is in process or engine speed is greater than 200 RPM and less than 7 500...

Page 337: ...ecord the DTC Freeze Frame and Failure Records 4 Clear the DTC 5 Using the scan tool measure ignition voltage Is voltage within the specified value 9 18 V Go to Step 3 Go to DTC P0562 for low voltage...

Page 338: ...lenoid connector 3 Using the DMM measure the resistance of the MAIN MOD solenoid Is the solenoid resistance within the specified value 22 0 ohms at 20 C 68 F Go to Step 8 Go to Step 9 7 Test the MAIN...

Page 339: ...Perform the following procedure in order to verify the repair 1 Clear the DTC 2 Drive the vehicle under normal operating conditions 3 Select Specific DTC 4 Enter DTC P0962 Has the test run and passed...

Page 340: ...r Running the DTC The components are powered and ignition voltage is greater than 9 0 volts and less than 18 volts TCM initialization is in process or engine speed is greater than 200 RPM and less tha...

Page 341: ...rds 4 Clear the DTC 5 Using the scan tool measure ignition voltage Is voltage within the specified value 9 18 V Go to Step 3 Go to DTC P0562 for low voltage or DTC P0563 for high voltage 3 1 Turn the...

Page 342: ...l Pan Replacement 3 Remove the AT internal wiring harness at the MAIN MOD connector 4 Using the DMM measure for voltage at terminal 2 of the MAIN MOD solenoid and ground Is the voltage greater than th...

Page 343: ...any 1 of the 5 clutches The transmission control module TCM provides voltage to the PCS2 shift solenoid 1 2 and 3 SS1 SS2 and SS3 through a separate solid state device called high side driver 2 HSD2...

Page 344: ...in TCM history Main modulation MAIN MOD is inhibited The TCM freezes shift adapts The TCM inhibits torque converter clutch TCC engagement Conditions for Clearing the DTC A scan tool can clear the code...

Page 345: ...Using the scan tool measure ignition voltage Is voltage within the specified value 9 18 V Go to Step 3 Go to DTC P0562 for low voltage or DTC P0563 for high voltage 3 1 Turn the ignition OFF 2 Discon...

Page 346: ...ind and correct the condition Go to Step 10 Go to Step 9 7 Replace the AT internal wiring harness Refer to Wiring Harness Replacement Did you complete the replacement Go to Step 10 8 Replace the PCS2...

Page 347: ...ontrol Solenoid 2 PCS2 Control Circuit Low B Conditions for Running the DTC The components are powered and ignition voltage is greater than 9 0 volts and less than 18 volts TCM initialization is in pr...

Page 348: ...iring for poor electrical connections at the TCM Inspect for the following conditions A bent terminal A backed out terminal A damaged terminal Poor terminal tension A chafed wire A broken wire inside...

Page 349: ...Freeze Frame and Failure Records 4 Clear the DTC 5 Using the scan tool measure ignition voltage Is voltage within the specified value 9 18 V Go to Step 3 Go to DTC P0562 for low voltage or DTC P0563...

Page 350: ...ve the AT internal wiring harness at the PCS2 connector 3 Using the DMM measure the resistance of the PCS2 Is the solenoid resistance within the specified value 5 05 ohms at 20 C 68 F Go to Step 8 Go...

Page 351: ...transmission control module TCM provides voltage to the PCS2 shift solenoid 1 2 and 3 SS1 SS2 and SS3 through a separate solid state device called high side driver 2 HSD2 The TCM regulates the amount...

Page 352: ...stored in TCM history Main modulation MAIN MOD is inhibited The TCM freezes shift adapts The TCM inhibits torque converter clutch TCC engagement Conditions for Clearing the DTC A scan tool can clear t...

Page 353: ...re Records 4 Clear the DTC 5 Using the scan tool measure ignition voltage Is voltage within the specified value 9 18 V Go to Step 3 Go to DTC P0562 for low voltage or DTC P0563 for high voltage 3 1 Tu...

Page 354: ...ove the transmission oil pan Refer to Oil Pan Replacement 3 Remove the AT internal wiring harness at the pressure control sole noid 1 PCS1 connector 4 Using the DMM measure for voltage at terminal 2 o...

Page 355: ...id command logic to move shift valve 1 to attain a particular range The TCM provides voltage to pressure control solenoid 2 PCS2 and shift solenoid 1 2 and 3 SS1 SS2 and SS3 through a separate solid s...

Page 356: ...earing the DTC A scan tool can clear the code from TCM history The TCM automatically clears the DTC from TCM history if the vehicle completes 40 warm up cycles without failure Diagnostic Aids Inspect...

Page 357: ...Clear Info function will erase the data 3 Record the DTC Freeze Frame and Failure Records 4 Clear the DTC 5 Test drive the vehicle while collecting a snapshot and verify that the code becomes active D...

Page 358: ...M measure the resistance of SS1 Is the solenoid resistance within the specified value 22 0 ohms at 20 C 68 F Go to Step 8 Go to Step 9 7 Test the SS1 circuit between the TCM and the AT inline 20 way c...

Page 359: ...oid command logic to move shift valve 1 to attain a particular range The TCM provides voltage to pressure control solenoid 2 PCS2 and shift solenoid 1 2 and 3 SS1 SS2 and SS3 through a separate solid...

Page 360: ...overspeeding or direction change the transmission will shift to NEUTRAL DTC P0973 is stored in TCM history Main modulation MAIN MOD is inhibited The TCM freezes shift adapts The TCM inhibits torque c...

Page 361: ...the data 3 Record the DTC Freeze Frame and Failure Records 4 Clear the DTC 5 Using the scan tool measure ignition voltage Is voltage within the specified value 9 18 V Go to Step 3 Go to DTC P0562 for...

Page 362: ...re the resistance of SS1 Is the solenoid resistance within the specified value 22 0 ohms at 20 C 68 F Go to Step 8 Go to Step 9 7 Test the SS1 circuit between the TCM and the AT inline 20 way connecto...

Page 363: ...attain a particular range The TCM provides voltage to pressure control solenoid 2 PCS2 and shift solenoid 1 2 and 3 SS1 SS2 and SS3 through a separate solid state device called high side driver 2 HSD2...

Page 364: ...mission will shift to NEUTRAL DTC P0974 is stored in TCM history Main modulation MAIN MOD is inhibited The TCM freezes shift adapts The TCM inhibits torque converter clutch TCC engagement Conditions f...

Page 365: ...ilure Records 4 Clear the DTC 5 Using the scan tool measure ignition voltage Is voltage within the specified value 9 18 V Go to Step 3 Go to DTC P0562 for low voltage or DTC P0563 for high voltage 3 1...

Page 366: ...0 way connector 2 Remove the transmission oil pan Refer to Oil Pan Replacement 3 Remove the AT internal wiring harness at the SS1 connector 4 Using the DMM measure for voltage at terminal B of SS1 and...

Page 367: ...id command logic to move shift valve 2 to attain a particular range The TCM provides voltage to pressure control solenoid 2 PCS2 and shift solenoid 1 2 and 3 SS1 SS2 and SS3 through a separate solid s...

Page 368: ...earing the DTC A scan tool can clear the code from TCM history The TCM automatically clears the DTC from TCM history if the vehicle completes 40 warm up cycles without failure Diagnostic Aids Inspect...

Page 369: ...e Clear Info function will erase the data 3 Record the DTC Freeze Frame and Failure Records 4 Clear the DTC 5 Test drive the vehicle while collecting a snapshot and verify that the code becomes active...

Page 370: ...M measure the resistance of SS2 Is the solenoid resistance within the specified value 22 0 ohms at 20 C 68 F Go to Step 8 Go to Step 9 7 Test the SS2 circuit between the TCM and the AT inline 20 way c...

Page 371: ...oid command logic to move shift valve 2 to attain a particular range The TCM provides voltage to pressure control solenoid 2 PCS2 and shift solenoid 1 2 and 3 SS1 SS2 and SS3 through a separate solid...

Page 372: ...overspeeding or direction change the transmission will shift to NEUTRAL DTC P0976 is stored in TCM history Main modulation MAIN MOD is inhibited The TCM freezes shift adapts The TCM inhibits torque c...

Page 373: ...the data 3 Record the DTC Freeze Frame and Failure Records 4 Clear the DTC 5 Using the scan tool measure ignition voltage Is voltage within the specified value 9 18 V Go to Step 3 Go to DTC P0562 for...

Page 374: ...measure the resistance of SS2 Is the solenoid resistance within the specified value 22 0 ohms at 20 C 68 F Go to Step 8 Go to Step 9 7 Test the SS2 circuit between the TCM and the AT inline 20 way con...

Page 375: ...oid command logic to move shift valve 2 to attain a particular range The TCM provides voltage to pressure control solenoid 2 PCS2 and shift solenoid 1 2 and 3 SS1 SS2 and SS3 through a separate solid...

Page 376: ...overspeeding or direction change the transmission will shift to NEUTRAL DTC P0977 is stored in TCM history Main modulation MAIN MOD is inhibited The TCM freezes shift adapts The TCM inhibits torque c...

Page 377: ...ailure Records 4 Clear the DTC 5 Using the scan tool measure ignition voltage Is voltage within the specified value 9 18 V Go to Step 3 Go to DTC P0562 for low voltage or DTC P0563 for high voltage 3...

Page 378: ...0 way connector 2 Remove the transmission oil pan Refer to Oil Pan Replacement 3 Remove the AT internal wiring harness at the SS2 connector 4 Using the DMM measure for voltage at terminal B of SS2 and...

Page 379: ...id command logic to move shift valve 3 to attain a particular range The TCM provides voltage to pressure control solenoid 2 PCS2 and shift solenoid 1 2 and 3 SS1 SS2 and SS3 through a separate solid s...

Page 380: ...OD is inhibited The TCM freezes shift adapts The TCM inhibits torque converter clutch TCC engagement Conditions for Clearing the DTC A scan tool can clear the code from TCM history The TCM automatical...

Page 381: ...he Clear Info function will erase the data 3 Record the DTC Freeze Frame and Failure Records 4 Clear the DTC 5 Test drive the vehicle while collecting a snapshot and verify that the code becomes activ...

Page 382: ...M measure the resistance of SS3 Is the solenoid resistance within the specified value 22 0 ohms at 20 C 68 F Go to Step 8 Go to Step 9 7 Test the SS3 circuit between the TCM and the AT inline 20 way c...

Page 383: ...oid command logic to move shift valve 3 to attain a particular range The TCM provides voltage to pressure control solenoid 2 PCS2 and shift solenoid 1 2 and 3 SS1 SS2 and SS3 through a separate solid...

Page 384: ...overspeeding or direction change the transmission will shift to NEUTRAL DTC P0979 is stored in TCM history Main modulation MAIN MOD is inhibited The TCM freezes shift adapts The TCM inhibits torque c...

Page 385: ...the data 3 Record the DTC Freeze Frame and Failure Records 4 Clear the DTC 5 Using the scan tool measure ignition voltage Is voltage within the specified value 9 18 V Go to Step 3 Go to DTC P0562 for...

Page 386: ...measure the resistance of SS3 Is the solenoid resistance within the specified value 22 0 ohms at 20 C 68 F Go to Step 8 Go to Step 9 7 Test the SS3 circuit between the TCM and the AT inline 20 way con...

Page 387: ...oid command logic to move shift valve 3 to attain a particular range The TCM provides voltage to pressure control solenoid 2 PCS2 and shift solenoid 1 2 and 3 SS1 SS2 and SS3 through a separate solid...

Page 388: ...overspeeding or direction change the transmission will shift to NEUTRAL DTC P0980 is stored in TCM history Main modulation MAIN MOD is inhibited The TCM freezes shift adapts The TCM inhibits torque c...

Page 389: ...ailure Records 4 Clear the DTC 5 Using the scan tool measure ignition voltage Is voltage within the specified value 9 18 V Go to Step 3 Go to DTC P0562 for low voltage or DTC P0563 for high voltage 3...

Page 390: ...0 way connector 2 Remove the transmission oil pan Refer to Oil Pan Replacement 3 Remove the AT internal wiring harness at the SS3 connector 4 Using the DMM measure for voltage at terminal B of SS3 and...

Page 391: ...s between the engine control module ECM and the transmission control module TCM DTC P1688 is a type B DTC DTC Descriptor This diagnostic procedure supports the following DTC DTC P1688 Unmanaged Engine...

Page 392: ...e wiring for poor electrical connections at the TCM Inspect for the following conditions A bent terminal A backed out terminal A damaged terminal Poor terminal tension A chafed wire A broken wire insi...

Page 393: ...Clear the DTC 5 Disconnect the 80 way connector at the TCM 6 Inspect terminal 22 for a pulled back unlocked terminal or visible terminal damage Did you find and correct a condition Go to Step 8 Go to...

Page 394: ...e the stored information capture info and DTC info Does the scan tool display any DTCs that you have not diagnosed Go to Diagnostic Trouble Code DTC List Vehicle System OK DTC P1779 Circuit Descriptio...

Page 395: ...lutch TCC engagement Conditions for Clearing the DTC A scan tool can clear the code from TCM history The TCM automatically clears the DTC from TCM history if the vehicle completes 40 warm up cycles wi...

Page 396: ...4 Turn the ignition OFF 5 Disconnect the 80 way connector at the TCM 6 Inspect the terminal 44 for a pulled back unlocked terminal or visible terminal damage Did you find and correct a condition Go t...

Page 397: ...p 8 8 Perform the following procedure in order to verify the repair 1 Select DTC 2 Select Clear Info 3 Operate the vehicle under the following conditions Vehicle at operating temperature Engine speed...

Page 398: ...hen the DTC Sets The TCM illuminates the malfunction indicator lamp MIL If the failure occurs while in a forward range a shift to 1st 3rd or 5th range is made While diagnostic response is active if th...

Page 399: ...TC use the scan tool in order to Before clearing the DTC use the scan tool in order to record the Freeze Frame and Failure Records for reference record the Freeze Frame and Failure Records for referen...

Page 400: ...S1 SS2 and SS3 4 Using the DMM measure the supply voltage of each solenoid con nector Is the voltage within the specified value at each solenoid terminal B Go to Step 6 Go to Step 8 6 Test the PCS2 an...

Page 401: ...r normal operating conditions 3 Select Speci c DTC 4 Enter DTC P2670 Has the test run and passed Go to Step 12 Go to Step 2 12 With the scan tool observe the stored information capture info and DTC In...

Page 402: ...If the shift selector is moved to a forward range or to REVERSE and the transmission is compromised by overspeeding or direction change the transmission will shift to NEUTRAL DTC P2671 is stored in T...

Page 403: ...l erase the data 3 Record the DTC Freeze Frame and Failure Records 4 Clear the DTC 5 Using the scan tool measure ignition voltage Is voltage within the specified value 9 18 V Go to Step 3 Go to DTC P0...

Page 404: ...e the AT internal wiring harness Refer to Wiring Harness Replacement Did you complete the replacement Go to Step 10 8 IMPORTANT In most cases the TCM is not at fault Investigate thorough In most cases...

Page 405: ...d is greater than 60 RPM Output speed is greater than 125 RPM The transmission is at normal operating temperature Conditions for Setting the DTC DTC P2723 sets when the TCM detects an incorrect on com...

Page 406: ...or obstruction in a speci c clutch apply circuit Observe scan tool failure record data for previous or current range information when the DTC was set in order to determine the speci c shift when the D...

Page 407: ...Freeze Frame and Failure Records for reference The Clear Info function will erase the data The Clear Info function will erase the data 3 Record the DTC Freeze Frame and Failure Records 4 Clear the DTC...

Page 408: ...replacement Refer to Transmission Replacement Did you complete the repair or replacement Go to Step 11 9 Inspect for a stuck or sticking pressure control valve 1 Refer to Control Valve Body Cleaning a...

Page 409: ...tput speed is greater than 200 RPM Turbine speed is greater than 200 RPM Conditions for Setting the DTC DTC P2724 sets when the TCM determines the off going clutch controlled by pressure control solen...

Page 410: ...pply circuit Observe scan tool failure record data for previous or current range information when the DTC was set in order to determine the speci c shift when the DTC was set Refer to the Solenoid and...

Page 411: ...Frame and Failure Records for reference The Clear Info function will erase the data Clear Info function will erase the data 3 Record the DTC Freeze Frame and Failure Records 4 Clear the DTC 5 Using th...

Page 412: ...e there signs of clutch failure Go to Step 8 Go to Step 9 8 Remove the transmission for overhaul or replacement Refer to Transmission Replacement Did you complete the repair or replacement Go to Step...

Page 413: ...ts the following DTC DTC P2727 Pressure Control Solenoid 1 PCS1 Control Circuit Open A Conditions for Running the DTC DTC P0658 and P0659 are not active The components are powered and ignition voltage...

Page 414: ...iring for poor electrical connections at the TCM Inspect for the following conditions A bent terminal A backed out terminal A damaged terminal Poor terminal tension A chafed wire A broken wire inside...

Page 415: ...t the TCM 3 Install the J 39700 breakout box the J 47275 breakout box adapter and the J 47275 1 magnetic overlay Do not reconnect the TCM 4 Using the DMM measure the resistance at terminals 11 and 55...

Page 416: ...nt Did you complete the replacement Go to Step 10 9 IMPORTANT In most cases the TCM is not at fault Investigate thorough In most cases the TCM is not at fault Investigate thorough ly before replacing...

Page 417: ...conds TCM initialization is in process Engine crank time is not extended Conditions for Setting the DTC DTC P2729 sets when the TCM detects a short to ground on the PCS1 circuit for greater than 2 sec...

Page 418: ...order to Before clearing the DTC use the scan tool in order to record the Freeze Frame and Failure Records for reference record the Freeze Frame and Failure Records for reference The Clear Info functi...

Page 419: ...als L and M of the J 44152 Refer to Automatic Transmission Inline Harness Connector End View Is the resistance within the specified value 5 05 ohms at 20 C 68 F Go to Step 7 Go to Step 6 6 1 Remove th...

Page 420: ...pture info and DTC Info Does the scan tool display any DTCs that you have not diagnosed Go to Diagnostic Trouble Code DTC List Vehicle System OK DTC P2730 Circuit Description The pressure control sole...

Page 421: ...l shift to REVERSE If the shift selector is moved to a forward range or to REVERSE and the transmission is compromised by overspeeding or direction change the transmission will shift to NEUTRAL DTC P2...

Page 422: ...ailure Records 4 Clear the DTC 5 Using the scan tool measure ignition voltage Is voltage within the specified value 9 18 V Go to Step 3 Go to DTC P0562 for low voltage or DTC P0563 for high voltage 3...

Page 423: ...ector 2 Remove the transmission oil pan Refer to Oil Pan Replacement 3 Remove the AT internal wiring harness at the PCS1 connector 4 Using the DMM measure for voltage at terminal 2 of the PCS1 and gro...

Page 424: ...TCM provides voltage to the main modulation MAIN MOD TCC and pressure control solenoid 1 PCS1 through a separate solid state device called high side driver 1 HSD1 The TCM regulates the amount of curr...

Page 425: ...The TCM inhibits REVERSE operation The TCM freezes shift adapts The TCM inhibits TCC engagement Conditions for Clearing the DTC A scan tool can clear the code from TCM history The TCM automatically c...

Page 426: ...sing the scan tool measure ignition voltage Is voltage within the specified value 9 18 V Go to Step 3 Go to DTC P0562 for low voltage or DTC P0563 for high voltage 3 1 Turn the ignition OFF 2 Disconne...

Page 427: ...u find and correct the condition Go to Step 10 Go to Step 9 7 Replace the AT internal wiring harness Refer to Wiring Harness Replacement Did you complete the replacement Go to Step 10 8 Replace the TC...

Page 428: ...ter Clutch TCC Pressure Control Solenoid PCS Control Circuit High Conditions for Running the DTC DTC P0716 P0717 P0721 and P0722 are not active The components are powered and ignition voltage is great...

Page 429: ...iring for poor electrical connections at the TCM Inspect for the following conditions A bent terminal A backed out terminal A damaged terminal Poor terminal tension A chafed wire A broken wire inside...

Page 430: ...e within the specified value 9 18 V Go to Step 3 Go to DTC P0562 for low voltage or DTC P0563 for high voltage 3 1 Turn the ignition OFF 2 Disconnect the 80 way connector at the TCM 3 Install the J 39...

Page 431: ...move the transmission oil pan Refer to Oil Pan Replacement 3 Remove the AT internal wiring harness at the TCC PCS connector 4 Using the DMM measure for voltage at terminal 2 of the TCC PCS and ground...

Page 432: ...ol module TCM provides voltage to the main modulation MAIN MOD TCC and pressure control solenoid 1 PCS1 through a separate solid state device called high side driver 1 HSD1 The TCM regulates the amoun...

Page 433: ...2764 is stored in TCM history The TCM inhibits MAIN MOD The TCM inhibits REVERSE operation The TCM freezes shift adapts The TCM inhibits TCC engagement Conditions for Clearing the DTC A scan tool can...

Page 434: ...l erase the data The Clear Info function will erase the data 3 Record the DTC Freeze Frame and Failure Records 4 Clear the DTC 5 Using the scan tool measure ignition voltage Is voltage within the spec...

Page 435: ...internal wiring harness at the TCC solenoid connec tor 3 Using the DMM measure the resistance of the TCC solenoid Is the solenoid resistance within the specified value 5 05 ohms at 20 C 68 F Go to St...

Page 436: ...ow range DTC P2771 is a type B DTC DTC Descriptor This diagnostic procedure supports the following DTC DTC P2771 4WD Low Switch Circuit Conditions for Running the DTC DTCs P0721 and P0722 are not acti...

Page 437: ...r 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...

Page 438: ...Failure Records 4 Clear the DTC 5 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...

Page 439: ...Go to Step 13 11 Inspect the short to ground in the brake switch signal circuit Refer to Circuit Testing and Wiring Repairs Did you find a condition Go to Step 12 Go to Step 15 12 Repair the open con...

Page 440: ...Info Does the scan tool display any DTCs that you have not diagnosed Go to Diagnostic Trouble Code DTC List Vehicle System OK SYMPTOMS AUTOMATIC TRANSMISSION The following table consists of six diagno...

Page 441: ...Contaminated Transmission Fluid Refer to Intermittent Buzzing Noise Noise and Vibration Diagnosis This category contains the following topics Noise drive gear nal drive whine growl rattle buzz poppin...

Page 442: ...Speed Diagnosis This category contains the following topic Inaccurate or inconsistent shift points Refer to Transmission Does Not Shift Properly Torque Converter Diagnosis This category contains the...

Page 443: ...oncerns detected These actions may appear to be transmission concerns Perform the Diagnostic System Check Vehicle in Vehicle DTC Information Did you perform the Diagnostic System Check Vehicle Go to S...

Page 444: ...ns No upshift or downshift Only one or two forward ranges No rst range second range third range fourth range or fth range Slipping Non rst range start Did the vehicle exhibit any of these shift patter...

Page 445: ...t one minute Apply the service brakes and shift to D DRIVE then to N NEUTRAL and then shift to R REVERSE in order to ll the hydraulic system 6 Ensure that the engine is at low idle RPM 500 800 RPM 7 W...

Page 446: ...vent assembly to be sure it is clean and unclogged If read assembly to be sure it is clean and unclogged If read ings are still inconsistent contact your nearest Allison ings are still inconsistent co...

Page 447: ...minute particles normally trapped in the oil lter indicate internal transmission damage When this occurs inspect the inside of the oil pan for excessive metal particles Refer to Oil Pan Replacement 3...

Page 448: ...h the brakes applied use the following scan tool settings to check pressures in FIRST through FIFTH gear ranges at 600 RPM The transmission will be in converter mode torque converter clutch not applie...

Page 449: ...Engine size i e G 8 1L V8 L18 Press ENTER 9 Select 6 Speed Automatic Press ENTER 10 Select F0 Diagnostic Trouble Codes DTC Press ENTER 11 Select F1 DTC s Transmission Press ENTER 12 Select F0 DTC Inf...

Page 450: ...ed While performing the clutch test at 600 RPM main pressure should drop momentarily then gain pressure again when each gear range is attained If main pressure remains low suspect damaged seal in that...

Page 451: ...5th and reverse clutch and 2 6 clutch apply release procedure FastLearn is able to characterize the pressure control solenoid 1 PCS1 and pressure control solenoid 2 PCS2 pressures corresponding to clu...

Page 452: ...ison transmission incorporates control logic that enables the transmission to revert to a limited total hydraulic operation The hydraulic system provides a Limp Home Mode allowing the operator to driv...

Page 453: ...uld engage THIRD range If REVERSE and THIRD range are available in Limp Home Mode an electrical failure may be indicated If only 1 of the 2 ranges or neither was obtainable this may indicate an intern...

Page 454: ...ore the road test ensure the following conditions are met The engine is performing properly Transmission uid level is correct Tire pressure is correct During the road test Perform the test only when t...

Page 455: ...t selector through the following ranges i PARK to REVERSE ii REVERSE to NEUTRAL iii NEUTRAL to DRIVE C Pause 2 to 3 seconds in each selector position IMPORTANT Harsh engagement may be caused by any of...

Page 456: ...rottle position of 10 percent 25 percent or 50 percent All throttle angles shown should be tested to cover the normal driving range 2 Monitor the following scan tool parameters Throttle angle Vehicle...

Page 457: ...fer to Torque Converter Diagnosis Procedure Lightly tap and release the brake pedal The TCC will release on most applications Part Throttle Detent Downshift 1 Place the shift selector in DRIVE 2 Accel...

Page 458: ...COND The engine slows the vehicle Manual 2 1 Downshift 1 Place the shift selector in DRIVE 2 Accelerate the vehicle until the 1 2 shift occurs 3 Go to 8 km h 5 mph above the 1 2 shift point 4 Release...

Page 459: ...he TCC variable bleed solenoid The converter ow valve and the TCC variable bleed solenoid are located inside the automatic transmission assembly Torque Converter Stator The torque converter stator ass...

Page 460: ...emergency brake and or parking brake if present and ensure it is properly engaged 6 If the vehicle will be unoccupied with the engine running chock the wheels and take any other steps necessary to kee...

Page 461: ...ation Coil Inspect for black discoloration on the bottom of the coil This indicates arcing while the engine is mis ring Fuel injector The lter may be plugged Vacuum leak The engine will not get the co...

Page 462: ...The converter is contaminated with engine coolant which contains antifreeze An internal failure occurs in the stator race Overheating produces heavy debris in the clutch You discover steel particles o...

Page 463: ...ds must be OFF unless instructed otherwise in these procedures If a tool or equipment could easily come in contact with a live exposed electrical terminal also disconnect the negative battery cable Fa...

Page 464: ...rrect tighten ing sequence and specifications when installing fasten ing sequence and specifications when installing fasten ers in order to avoid damage to parts and systems ers in order to avoid dama...

Page 465: ...to the vehicle or its compo nents 12 Connect the battery NOISE AND VIBRATION ANALYSIS A noise or vibration that is noticeable when the vehicle is in motion MAY NOT be the result of the transmission If...

Page 466: ...sary repairs POWDER METHOD 1 Thoroughly clean the suspected leak area with solvent 2 Apply an aerosol type powder such as foot powder to the suspected leak area 3 Operate the vehicle for 24 km 15 mi o...

Page 467: ...d is fully covered 4 Allow the epoxy cement to cure for 3 hours before starting the engine 5 Repeat the uid leak diagnosis procedures AUTOMATIC TRANSMISSION OIL COOLER FLUSHING AND FLOW TEST GM studie...

Page 468: ...the J 35944 A oil cooler components or transmission components The J 35944 22 ushing uid is environmentally safe yet powerful enough to cut through transmission uid to dislodge any contaminants from...

Page 469: ...tor 8 With the water supply valve 1 on the J 35944 A in the OFF position connect the water supply hose from the J 35944 A to the water supply at the faucet 9 Turn ON the water supply at the faucet INI...

Page 470: ...fluid is to be captured in a suitable container preferably with a lid with a lid 4 Flush the oil cooler and pipes with water and solution for 2 minutes During this ush attach the shop air supply 825...

Page 471: ...ct the discharge hose 5 to the cooler feed line Clip the discharge hose 5 to the empty oil drain container Start the engine with the transmission in PARK range and run for 5 seconds at 2 400 RPM A min...

Page 472: ...07 W Series SECTION 7 2 PAGE 472 Automatic Transmission Allison 2007 W Series Chassis 2006 Workhorse Custom Chassis All Rights Reserved WSM082106 4 Dispose of any waste water solution and transmission...

Page 473: ...s worn Inspect the 1 2 3 4 clutch plates and piston and rotating seals Replace rebuild as necessary Ranges 4 5 6 Only 4 5 6 clutch slipping leaks at rotating clutch seals leaks at piston seals 4 5 6 c...

Page 474: ...aminated with engine coolant or water Drain and replace fluid Locate and fix source of additional fluid Refer to Transmission Fluid Checking Procedure and Automatic Transmission Fluid Filter Replaceme...

Page 475: ...he transmission rear cover Refer to Seal Replacement Rear Propshaft Damaged or missing output bolt washer seal Replace the output bolt sealing washer Refer to Output Flange Yoke Replacement Damaged mi...

Page 476: ...assembly Replace the solenoids Refer to Control Valve Solenoid Replacement Main pressure regulator valve spring weak broken or missing Inspect the spring and replace if necessary Control module body l...

Page 477: ...rol module mounting bolts Inspect the lubrication valve and spring Inspect the converter housing to separator plate gasket Cooler lines restricted or leaking Inspect for kinks and leakage Reroute or r...

Page 478: ...d Replacement Erratic speed sensor signal Refer to the speed sensor DTCs Piston seals leaking or clutch plates slip ping in range involved Piston seals leaking or clutch plates slipping in range invol...

Page 479: ...ke controls Compare lugback vs static stall speed Incorrect torque converter Install the correct torque converter Refer to Torque Converter Replacement TRANSMISSION WILL NOT MAKE A SPECIFIC SHIFT Cond...

Page 480: ...ion Fluid Checking Procedure Faulty throttle signal from engine Correct the engine throttle signal Shift selector is not functioning properly Repair the shift selector Speed sensor or sensors not func...

Page 481: ...mperature sensor Replace the pressure switch manifold PSM or internal harness Refer to Pressure Switch Manifold Replacement or Wiring Harness Replacement Excessive cooler circuit pressure drop Inspect...

Page 482: ...speed sensor DTCs Loose speed sensor Tighten the speed sensor retaining bracket bolt Refer to Speed Sensor Replacement Degraded fluid Change the transmission fluid and filter Refer to Automatic Transm...

Page 483: ...skets prevent contaminant intrusion into the TCM The ignition must be OFF when disconnecting or reconnecting power to the TCM 1 Disconnect the negative battery cable Refer to Battery Negative Cable Di...

Page 484: ...er these condi tions it would take an unacceptably long time for the tions it would take an unacceptably long time for the adaptive values to converge to levels suitable for the adaptive values to con...

Page 485: ...nto the lter adapter 1 3 Lubricate the gasket 3 on the transmission external oil lter with transmission uid 4 Install by hand the transmission external oil lter 4 until the gasket on the lter touches...

Page 486: ...Procedure 1 Disconnect the hose from the transmission oil cooler pipe connector being replaced 2 Remove the transmission oil cooler pipe connectors 1 and 2 Installation Procedure NOTICE Refer to Faste...

Page 487: ...Use a standard strap type filter wrench to remove the Use a standard strap type filter wrench to remove the transmission external oil filter transmission external oil filter 3 Remove the lter 4 by rot...

Page 488: ...ive or Cycling the ignition clears the code and allows Drive or Reverse range to be attained Reverse range to be attained 7 Cycle the ignition until Drive or Reverse range is attained IMPORTANT Fluid...

Page 489: ...e plug 1 with the tang on the main housing 3 Install the ll tube plug 1 Press the plug into the seal 2 until the tab on the ll tube plug locks into place in the notch on the main housing 4 Install a N...

Page 490: ...ights Reserved WSM082106 TRANSMISSION FLUID COOLER HOSE PIPE REPLACEMENT Removal Procedure 1 Raise the vehicle Refer to Lifting and Jacking the Vehicle 2 Pull the plastic cap back from the quick conne...

Page 491: ...ies Chassis WSM082106 6 Pull on the open ends of the retaining ring in order to rotate the retaining ring around the quick connect tting until the retaining ring is out of the tting Discard the retain...

Page 492: ...omatic Transmission Allison 2007 W Series Chassis 2006 Workhorse Custom Chassis All Rights Reserved WSM082106 9 For vehicles without an auxiliary cooler remove the cooling lines from the radiator 10 F...

Page 493: ...o not reuse any of the existing oil lines or oil line ttings if there is excessive corrosion Do not reuse any of the existing retaining rings that were removed from the existing quick connect ttings A...

Page 494: ...007 W Series Chassis 2006 Workhorse Custom Chassis All Rights Reserved WSM082106 4 Rotate the retaining ring around the tting until the retaining ring is positioned with all three ears through the thr...

Page 495: ...WSM082106 6 Ensure that the three retaining ring ears are seen from inside the tting and that the retaining ring moves freely in the tting slots 7 Install the NEW retaining ring E clip into the remai...

Page 496: ...s 2006 Workhorse Custom Chassis All Rights Reserved WSM082106 10 Install the cooler lines to the vehicle 11 Do not use the plastic cap on the cooler line in order to install the cooler line into the t...

Page 497: ...SECTION 7 2 PAGE 497 2007 W Series Chassis WSM082106 13 Position snap the plastic cap onto the tting Do not manually depress the retaining ring when installing the plastic cap onto the quick connect...

Page 498: ...e quick connect tting A hidden yellow identi cation band indicates proper joint seating 17 Do not install the cooler line end into the tting incorrectly 18 If you cannot position the plastic cap again...

Page 499: ...W Series 2006 Workhorse Custom Chassis All Rights Reserved SECTION 7 2 PAGE 499 2007 W Series Chassis WSM082106 19 For vehicles without auxiliary cooling install the cooling lines to the radiator 20 F...

Page 500: ...ghts Reserved WSM082106 21 For vehicles with auxiliary cooling install the oil cooling lines to the auxiliary oil cooler 22 Install the cooling lines to the transmission 23 Install the cooling lines t...

Page 501: ...front heat shield bolts 2 3 Remove the front heat shield 1 4 Remove the side heat shield bolt 4 and nut 5 5 Remove the side heat shield 3 Installation Procedure NOTICE Refer to Fastener Notice in Caut...

Page 502: ...support the vehicle Refer to Lifting and Jacking the Vehicle 2 Support the transmission with a transmission jack 3 Remove the transmission mount to the transmission support retaining nut or nuts 4 Rai...

Page 503: ...hicle NOTICE Refer to Fastener Notice in Cautions and Notices Refer to Fastener Notice in Cautions and Notices 2 Install the transmission mount to the transmission or transfer case adapter mounting bo...

Page 504: ...l be at the settings that it learned for adaptive valves will be at the settings that it learned for the old transmission and will be in slow adaptive mode the old transmission and will be in slow ada...

Page 505: ...ort bracket bolts 11 Remove the transmission support bolts and nuts 12 Remove the transmission support 13 Remove the transmission mount bolts 1 14 Remove the transmission mount 15 Disconnect the shift...

Page 506: ...es Chassis 2006 Workhorse Custom Chassis All Rights Reserved WSM082106 19 Disconnect the transmission main electrical connector J 44257 may be used but is not required 20 Disconnect the park neutral p...

Page 507: ...n Allison 2007 W Series 2006 Workhorse Custom Chassis All Rights Reserved SECTION 7 2 PAGE 507 2007 W Series Chassis WSM082106 22 Remove the transmission heat shield bolt and nut 4 5 and shield 3 23 R...

Page 508: ...CTION 7 2 PAGE 508 Automatic Transmission Allison 2007 W Series Chassis 2006 Workhorse Custom Chassis All Rights Reserved WSM082106 24 Remove the transmission heat shield bolts 2 and shield 1 25 Remov...

Page 509: ...PAGE 509 2007 W Series Chassis WSM082106 26 Rotate the engine clockwise using the crankshaft bolt in order to access the torque converter bolts through the starter opening Have an assistant rotate th...

Page 510: ...ic Transmission Allison 2007 W Series Chassis 2006 Workhorse Custom Chassis All Rights Reserved WSM082106 29 Remove the fuel line bracket nut from the converter housing stud 30 Remove the wire harness...

Page 511: ...fety chain around the transmission Use care not to overlap any wiring fuel lines or other related components 32 Disconnect the transmission oil cooler lines 1 2 from the transmission 33 Plug the trans...

Page 512: ...ghts Reserved WSM082106 35 Remove the remaining converter housing bolts and studs 36 Separate the transmission from the engine 37 Install J 21366 to the converter housing in order to keep the torque c...

Page 513: ...to place while simultaneously installing the ll tube 3 Remove the J 21366 NOTICE Refer to Fastener Notice in Cautions and Notices Refer to Fastener Notice in Cautions and Notices IMPORTANT Do not inst...

Page 514: ...006 Workhorse Custom Chassis All Rights Reserved WSM082106 6 Position the wire harness vent tube bracket and install the wire harness vent tube bracket nut to the converter housing stud and tighten th...

Page 515: ...Series 2006 Workhorse Custom Chassis All Rights Reserved SECTION 7 2 PAGE 515 2007 W Series Chassis WSM082106 8 Install the transmission ll tube nuts to the converter housing studs and tighten the nu...

Page 516: ...torque converter bolts through the starter opening Have an assistant rotate the engine while aligning the bolts 11 If reusing the torque converter bolts clean the bolt threads and apply Loctite 242 GM...

Page 517: ...orse Custom Chassis All Rights Reserved SECTION 7 2 PAGE 517 2007 W Series Chassis WSM082106 14 Install the transmission heat shield 1 and bolts 2 and tighten the bolts to 17 N m 13 lb ft 15 Position...

Page 518: ...2007 W Series Chassis 2006 Workhorse Custom Chassis All Rights Reserved WSM082106 16 Install the transmission heat shield 3 and bolt nut 4 5 and tighten the bolt nut to 17 N m 13 lb ft 17 Install the...

Page 519: ...19 Disconnect the transmission main electrical connector 2 20 Connect the output speed sensor 3 electrical connector If the vehicle is equipped with 4WD the output speed sensor is located on the tran...

Page 520: ...tall the transmission mount 25 Install the transmission mount bolts 1 and tighten the bolts to 50 N m 37 lb ft 26 Install the transmission support 27 Install the transmission support bolts and nuts 28...

Page 521: ...image 34 Install the engine protection shield and bolts 35 Tighten the engine protection shield bolts to 20 N m 15 lb ft 36 Remove the plugs from the transmission oil cooler line ttings in the transm...

Page 522: ...ust be done in the proper order to prevent possible injury from unexpected movement of the tow or disabled vehicles NOTE Refer to the Allison service information for complete Refer to the Allison serv...

Page 523: ...o move it too fast This may result in moving past the NEUTRAL the 2 This may result in moving past the NEUTRAL the 2 detents position detents position The transmission MUST be in NEUTRAL for proper in...

Page 524: ...install the 2 rear cover bolts removed in step 2 7 For both the horizontally and vertically mounted actuators place the Round Spacer MT1246 supplied with Actuator between the actuator bracket and the...

Page 525: ...installed in step 7 12 Align the witness marks on the shift shaft adapter with the witness marks on the actuator housing For Horizontally mounted Actuators use the single groove witness mark on the Sh...

Page 526: ...e 3 screws to 5 lb ft System Checks CAUTION When performing the following system checks make sure that the vehicle s emer gency brake is set the wheels are chocked and foot pressure is maintained on t...

Page 527: ...DRIVE will indicate D1 through D6 depending on the vehicles speed or DD if CAN is not utilized for REVERSE the display will indicate RR Attempt to start the engine If the installation was done correc...

Page 528: ...tion of the actuator will move inward from the calibration position into the oper move inward from the calibration position into the oper ation position This is normal Back the cap nut off ation posit...

Page 529: ...the 2 detents position The transmission MUST be in NEUTRAL for proper calibration NEUTRAL for proper calibration 22 Remove the shift shaft adapter from the actuator 23 Place a 10 32 screw partially in...

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