Allison Transmission 1000 & 2000 Product Families Electronic Controls Troubleshooting Manual – PDF DOWNLOAD

Description

Allison Transmission 1000 & 2000 Product Families Electronic Controls Troubleshooting Manual – PDF DOWNLOAD

DESCRIPTION:

Allison Transmission 1000 & 2000 Product Families Electronic Controls Troubleshooting Manual – PDF DOWNLOAD

This manual provides troubleshooting information for Allison Transmission 1000 and 2000 Product
Families transmissions. Service Manual SM3191EN, Mechanics Tips MT3190EN, and Parts Catalog
PC3062EN may be used in conjunction with this manual.
This manual includes:
•Description of the electronic control system.
•Description of the electronic control system components.
•Description of diagnostic codes, system responses to faults, and troubleshooting.
•Wire, terminal, and connector repair information.

• Specific instructions for using many of the available or required service tools and equipment are not
  included in this manual. The service tool manufacturer will furnish instructions for using the tools or
  equipment.
• Additional information may be published from time to time in Service Information Letters (SIL) and will be
  included in future revisions of this and other manuals. Please use these SILs to obtain up-to-date
  information concerning Allison Transmission products.
• This publication is revised periodically to include improvements, new models, special tools, and
  procedures. A revision is indicated by a new date on the title page and rear cover. Check with your
• Allison Transmission service outlet for the currently applicable publication. Additional copies of this
  publication may be purchased from authorized Allison Transmission service outlets. Look in your
  telephone directory under the heading of Transmissions — Truck, Tractor, etc.

TABLE OF CONTENTS:

Allison Transmission 1000 & 2000 Product Families Electronic Controls Troubleshooting Manual – PDF DOWNLOAD

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
SAFETY INFORMATION
I
mportant Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Warnings, Cautions, and Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Trademarks Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Service Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
SECTION 1. GENERAL DESCRIPTION
1–1. TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
1–2. TRANSMISSION CONTROL MODULE (TCM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
1–3. SHIFT SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
A. Shift Selector Range Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
B. Manual Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
C. NSBU Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
1–4. THROTTLE POSITION SENSOR (TPS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
1–5. SPEED SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
A. Input (Engine) Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6
B. Turbine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6
C. Output Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6
1–6. CONTROL VALVE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
1–7. WIRING HARNESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
A. External Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
B. Internal Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
SECTION 2. DEFINITIONS AND ABBREVIATIONS
2–1. CHECK TRANS LIGHT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
2–2. SCAN TOOL INHIBITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
2–3. SCAN TOOL (Allison DOC™ For PC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
2–4. ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4
2–5. RANGE INHIBIT RESPONSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
SECTION 3. BASIC KNOWLEDGE
3–1. BASIC KNOWLEDGE REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3–2. USING THE TROUBLESHOOTING MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3–3. SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3–4. IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS . . . . . . . . . . . . 3–2
3–5. BASIC TROUBLESHOOTING INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
3–6. TCM REPLACEMENT PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6
3–7. RESETTING OF TCM PARAMETERS TO SUPPORT ENGINE UPDATE . . . . . . . . . . . . 3–7
3–8. RESETTING TCM AUTOSELECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7
TABLE OF CONTENTS
ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL
vi Copyright© 2004 General Motors Corp.
Page
SECTION 4. WIRE CHECK PROCEDURES
4–1. CHECKING OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND. . . . . 4–1
4–2. CHECKING AT TRANSMISSION CONNECTOR AND THE INTERNAL HARNESS
FOR OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND . . . . . . . . . . 4–2
SECTION 5. DIAGNOSTIC TROUBLE CODES (DTC)
5–1. DTC MEMORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
5–2. FAILURE RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
5–3. CODE READING AND DTC CLEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2
A. Clearing DTCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2
B. Clearing Active Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2
5–4. BEGINNING THE TROUBLESHOOTING PROCESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2
A. Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2
B. Solenoid Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
C. Wire/Terminal Numbering Scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
D. Available Diagnostic Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
5–5. DIAGNOSTIC TROUBLE CODES (DTCs — Includes Index) . . . . . . . . . . . . . . . . . . . . . . 5–6
SECTION 6. INPUT AND OUTPUT FUNCTIONS
6–1. SPECIAL INPUT AND OUTPUT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
A. Input Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
B. Output Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
SECTION 7. GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS
. . . . . . . . . . 7–1
APPENDICES
A. DIAGNOSING INTERMITTENT DTCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1
B. MAIN PRESSURE CHECK PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–1
C. SOLENOID AND CLUTCH TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C–1
D. WIRE/CONNECTOR TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–1
E. CONNECTOR REPAIR INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–1
F. THROTTLE POSITION SENSOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F–1
G. WELDING ON VEHICLE/VEHICLE INTERFACE MODULE. . . . . . . . . . . . . . . . . . . . . . . G–1
H. HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H–1
J. WIRING SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J–1
K. RESISTANCE vs. TEMPERATURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K–1
L. ELECTRONIC INTERFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L–1
M. DIAGNOSTIC TOOL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M–1
N. INPUT/OUTPUT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N–1
P. FLUID CHECK PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–1

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