Allison Transmission 3000 & 4000 Electronic Controls Troubleshooting Manual – PDF DOWNLOAD

Description

Allison Transmission 3000 & 4000 Electronic Controls Troubleshooting Manual – PDF DOWNLOAD

DESCRIPTION:

Allison Transmission 3000 & 4000 Electronic Controls Troubleshooting Manual – PDF DOWNLOAD

FOREWORD – How to use this Manual :

This manual provides troubleshooting information for Allison Transmission 1000 and 2000 Product Families
transmissions. Service Manual SM4006EN, Mechanics Tips MT4007EN, 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 3000 & 4000 Electronic Controls Troubleshooting Manual – PDF DOWNLOAD

TS2973EN……………………………………………………………………………………………………………………………………………………………………………… 2
FOREWORD—How to Use This Manual……………………………………………………………………………………………………………………………………………………… 3
IMPORTANT SAFETY NOTICE…………………………………………………………………………………………………………………………………………………………….. 4
WARNINGS, CAUTIONS, AND NOTES……………………………………………………………………………………………………………………………………………………….. 4
TRADEMARKS USED IN THIS MANUAL………………………………………………………………………………………………………………………………………………………. 5
SHIFT SELECTOR TERMS AND DISPLAY INDICATIONS………………………………………………………………………………………………………………………………………….. 5
Table of Contents………………………………………………………………………………………………………………………………………………………………….. 6
SECTION 1—GENERAL DESCRIPTION……………………………………………………………………………………………………………………………………………………….. 10
1–1. TRANSMISSION………………………………………………………………………………………………………………………………………………………………. 10
Figure 1–1. Electronic Control Unit Block Diagram………………………………………………………………………………………………………………………………. 10
Figure 1–2. WTEC III Electronic Control Components……………………………………………………………………………………………………………………………… 11
1–2. ELECTRONIC CONTROL UNIT (ECU)……………………………………………………………………………………………………………………………………………….. 12
Figure 1–3. Electronic Control Unit (ECU)……………………………………………………………………………………………………………………………………… 12
Figure 1–4. Pushbutton Shift Selectors………………………………………………………………………………………………………………………………………… 13
Figure 1–5. Typical Lever Shift Selector………………………………………………………………………………………………………………………………………. 13
1–4. THROTTLE POSITION SENSOR……………………………………………………………………………………………………………………………………………………. 14
Figure 1–6. Throttle Position Sensor (Without Mounting Brackets)…………………………………………………………………………………………………………………. 14
1–5. SPEED SENSORS……………………………………………………………………………………………………………………………………………………………… 14
Figure 1–7. Speed Sensors……………………………………………………………………………………………………………………………………………………. 15
1–6. CONTROL MODULE…………………………………………………………………………………………………………………………………………………………….. 15
Figure 1–8. WTEC III Control Modules………………………………………………………………………………………………………………………………………….. 16
1–7. WIRING HARNESSES…………………………………………………………………………………………………………………………………………………………… 17
Figure 1–9. WTEC III External Wiring Harnesses…………………………………………………………………………………………………………………………………. 18
Figure 1–10. WTEC III Internal Wiring Harness………………………………………………………………………………………………………………………………….. 19
1–8. VEHICLE INTERFACE MODULE……………………………………………………………………………………………………………………………………………………. 19
Figure 1–11. Vehicle Interface Module (VIM)……………………………………………………………………………………………………………………………………. 19
1–9. AUTODETECT FEATURE (V8, V8A, V9 SOFTWARE)…………………………………………………………………………………………………………………………………….. 20
1–10. AUTODETECT FEATURE (V9A, V9B, AND V9C SOFTWARE)………………………………………………………………………………………………………………………………. 21
1–11. TRANSID FEATURE…………………………………………………………………………………………………………………………………………………………… 22
Table 1–1. TransID 1 S/N Breakpoint…………………………………………………………………………………………………………………………………………… 23
Table 1–2. TransID 2 S/N Breakpoint…………………………………………………………………………………………………………………………………………… 24
Table 1–3. New Retarder Temperature Sensor S/N Breakpoint……………………………………………………………………………………………………………………….. 24
Table 1–4. Current Internal Harness Service Kit† P/N by TransID Version…………………………………………………………………………………………………………… 25
Table 1–5. ECU/TransID Compatibility………………………………………………………………………………………………………………………………………….. 25
Table 1–6. TID 3 S/N Break Point……………………………………………………………………………………………………………………………………………… 25
Compatibility between transmission and vehicle configuration…………………………………………………………………………………………………………………….. 26
Using New Replacement Transmissions (TID 3)……………………………………………………………………………………………………………………………………. 27
Rebuilding With Dynax Clutch Plates…………………………………………………………………………………………………………………………………………… 28
SECTION 2—DEFINITIONS AND ABBREVIATIONS………………………………………………………………………………………………………………………………………………. 30
2–1. CHECK TRANS LIGHT………………………………………………………………………………………………………………………………………………………….. 30
2–2. ALLISON TRANSMISSION DIAGNOSTIC TOOL…………………………………………………………………………………………………………………………………………. 30
2–3. ABBREVIATIONS……………………………………………………………………………………………………………………………………………………………… 32
SECTION 3—BASIC KNOWLEDGE…………………………………………………………………………………………………………………………………………………………… 36
3–1. BASIC KNOWLEDGE REQUIRED……………………………………………………………………………………………………………………………………………………. 36
3–2. USING THE TROUBLESHOOTING MANUAL…………………………………………………………………………………………………………………………………………….. 37
3–3. SYSTEM OVERVIEW……………………………………………………………………………………………………………………………………………………………. 37
3–4. IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS…………………………………………………………………………………………………………………………… 37
3–5. BEGINNING THE TROUBLESHOOTING PROCESS………………………………………………………………………………………………………………………………………… 38
SECTION 4—WIRE TESTING PROCEDURES……………………………………………………………………………………………………………………………………………………. 40
4–1. TESTING FOR OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND…………………………………………………………………………………………………………………… 40
Figure 4–1. Open Circuit…………………………………………………………………………………………………………………………………………………….. 41
Figure 4–2. Short Between Wires and to Ground………………………………………………………………………………………………………………………………….. 41
4–2. TESTING AT TRANSMISSION CONNECTOR AND THE INTERNAL HARNESS FOROPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND………………………………………………………………………. 42
Figure 4–3. Testing for Continuity……………………………………………………………………………………………………………………………………………. 42
Figure 4–4. Short Between Wires and to Ground………………………………………………………………………………………………………………………………….. 43
SECTION 5—OIL LEVEL SENSOR………………………………………………………………………………………………………………………………………………………….. 44
5–1. INTRODUCTION………………………………………………………………………………………………………………………………………………………………. 44
Figure 5–1. Oil Level Sensor…………………………………………………………………………………………………………………………………………………. 44
Figure 5–2. Current Oil Level Sensor Orientation……………………………………………………………………………………………………………………………….. 45
Table 5–1. Invalid for Display Codes………………………………………………………………………………………………………………………………………….. 47
Table 5–2………………………………………………………………………………………………………………………………………………………………….. 48
5–2. ELECTRONIC FLUID LEVEL CHECK (SHIFT SELECTOR)…………………………………………………………………………………………………………………………………. 46
5–3. ELECTRONIC FLUID LEVEL CHECK (Allison DOC™ For PC–Service Tool)…………………………………………………………………………………………………………………. 48
SECTION 6—DIAGNOSTIC CODES………………………………………………………………………………………………………………………………………………………….. 50
6–1. DIAGNOSTIC CODE MEMORY……………………………………………………………………………………………………………………………………………………… 50
Table 6–1. Code List………………………………………………………………………………………………………………………………………………………… 50
6–2. CODE READING AND CODE CLEARING………………………………………………………………………………………………………………………………………………. 50
6–3. DIAGNOSTIC CODE RESPONSE……………………………………………………………………………………………………………………………………………………. 52
6–4. SHIFT SELECTOR DISPLAYS RELATED TO ACTIVE CODES……………………………………………………………………………………………………………………………….. 53
6–5. DIAGNOSTIC CODE LIST AND DESCRIPTION…………………………………………………………………………………………………………………………………………. 53
Table 6–2. 3000 and 4000 Product Families Diagnostic Codes………………………………………………………………………………………………………………………. 53
TRANSMISSION COMPONENT WIRING DIAGRAMS AND DIAGNOSTICS……………………………………………………………………………………………………………………………… 64
6–6. DIAGNOSTIC CODE TROUBLESHOOTING……………………………………………………………………………………………………………………………………………… 65
Figure 6–1. Control Module Solenoid Location…………………………………………………………………………………………………………………………………… 66
CODE 13 XX—ECU INPUT VOLTAGE…………………………………………………………………………………………………………………………………………………….. 67
Table 6–3. Voltage Chart…………………………………………………………………………………………………………………………………………………….. 69
Figure 6–2. Code 13 Schematic Drawing…………………………………………………………………………………………………………………………………………. 67
CODE 14 XX—OIL LEVEL SENSOR (OLS)………………………………………………………………………………………………………………………………………………… 71
Figure 6–3. Code 14 Schematic Drawing…………………………………………………………………………………………………………………………………………. 71
CODE 21 XX—THROTTLE OR PWM FAULT…………………………………………………………………………………………………………………………………………………. 75
Figure 6–4. Code 21 Schematic Drawing…………………………………………………………………………………………………………………………………………. 75
CODE 22 XX—SPEED SENSOR/CIRCUITRY FAULT…………………………………………………………………………………………………………………………………………… 79
Figure 6–5. Code 22 Schematic Drawing…………………………………………………………………………………………………………………………………………. 79
CODE 23 XX—SHIFT SELECTOR……………………………………………………………………………………………………………………………………………………….. 83
Figure 6–6. Code 23 Schematic Drawing…………………………………………………………………………………………………………………………………………. 83
CODE 24 XX—SUMP FLUID TEMPERATURE………………………………………………………………………………………………………………………………………………… 85
Figure 6–7. Code 24 Schematic Drawing…………………………………………………………………………………………………………………………………………. 85
Figure 6–8. TransID 1 Temperature Sensor Chart…………………………………………………………………………………………………………………………………. 87
Table 6–4. Transmission Operation as a Function of Temperature…………………………………………………………………………………………………………………… 88
Table 6–5. External Hydraulic Circuit CharacteristicsBasic, PTO, 93°C (200°F) Sump Temperature………………………………………………………………………………………. 89
Table 6–6. External Hydraulic Circuit CharacteristicsBasic, PTO, 93°C (200°F) Sump Temperature………………………………………………………………………………………. 89
CODE 25 XX—OUTPUT SPEED SENSOR, DETECTED AT ZERO SPEED,X RANGE………………………………………………………………………………………………………………………. 91
Figure 6–9. Code 25 Schematic Drawing…………………………………………………………………………………………………………………………………………. 91
Table 6–2. Speed Sensor Temperature Resistance…………………………………………………………………………………………………………………………………. 93
CODE 26 XX—THROTTLE SOURCE/ENGINE COOLANT SOURCENOT DETECTED………………………………………………………………………………………………………………………… 94
CODE 32 XX—C3 PRESSURE SWITCH……………………………………………………………………………………………………………………………………………………. 95
Figure 6–10. Code 32 Schematic Drawing………………………………………………………………………………………………………………………………………… 95
CODE 33 XX—SUMP OIL TEMPERATURE SENSOR……………………………………………………………………………………………………………………………………………. 99
Figure 6–11. Code 33 Schematic Drawing………………………………………………………………………………………………………………………………………… 99
Figure 6–12. Temperature Sensor Chart (TID 1 and Earlier Sensors)…………………………………………………………………………………………………………………101
CODE 34 XX—CALIBRATION COMPATIBILITY OR CHECKSUM FAULT………………………………………………………………………………………………………………………………102
CODE 35 XX—POWER INTERRUPTION…………………………………………………………………………………………………………………………………………………….103
Figure 6–13. Code 35 Schematic Drawing…………………………………………………………………………………………………………………………………………103
CODE 36 XX—HARDWARE AND SOFTWARE NOT COMPATIBLE…………………………………………………………………………………………………………………………………….106
CODE 42 XX—SHORT-TO-BATTERY IN SOLENOID CIRCUIT…………………………………………………………………………………………………………………………………….107
Figure 6–14. Code 42 Schematic Drawing…………………………………………………………………………………………………………………………………………107
Figure 6–15. Solenoid Resistance vs. Temperature………………………………………………………………………………………………………………………………..109
CODE 44 XX—SHORT-TO-GROUND IN SOLENOID CIRCUIT……………………………………………………………………………………………………………………………………..111
Figure 6–16. Code 44 Schematic Drawing…………………………………………………………………………………………………………………………………………111
Figure 6–17. Solenoid Resistance vs. Temperature………………………………………………………………………………………………………………………………..113
CODE 45 XX—OPEN CONDITION IN SOLENOID CIRCUIT………………………………………………………………………………………………………………………………………115
Figure 6–18. Code 45 Schematic Drawing…………………………………………………………………………………………………………………………………………115
Figure 6–19. Solenoid Resistance vs. Temperature………………………………………………………………………………………………………………………………..117
CODE 46 XX—OVERCURRENT TO SOLENOIDS……………………………………………………………………………………………………………………………………………….119
Figure 6–20. Code 46 Schematic Drawing…………………………………………………………………………………………………………………………………………119
CODE 51 XX—OFFGOING RATIO TEST DURING SHIFT (TIE-UP TEST)……………………………………………………………………………………………………………………………121
CODE 52 XX—OFFGOING C3 PRESSURE SWITCH TEST DURING SHIFT…………………………………………………………………………………………………………………………….123
CODE 53 XX—OFFGOING SPEED TEST (DURING SHIFT)………………………………………………………………………………………………………………………………………125
CODE 54 XX—ONCOMING SPEED TEST (AFTER SHIFT)……………………………………………………………………………………………………………………………………….127
CODE 55 XX—ONCOMING C3 PRESSURE SWITCH (AFTER SHIFT)………………………………………………………………………………………………………………………………..130
CODE 56 XX—RANGE VERIFICATION RATIO TEST (BETWEEN SHIFTS)……………………………………………………………………………………………………………………………132
CODE 57 XX—RANGE VERIFICATION C3 PRESSURE TEST(BETWEEN SHIFTS)……………………………………………………………………………………………………………………….134
CODE 61 XX—RETARDER OIL TEMPERATURE HOT……………………………………………………………………………………………………………………………………………135
CODE 62 XX—RETARDER TEMPERATURE SENSOR…………………………………………………………………………………………………………………………………………….137
Figure 6–22. Code 62 Schematic Drawing…………………………………………………………………………………………………………………………………………137
CODE 63 XX—INPUT FUNCTION FAULT…………………………………………………………………………………………………………………………………………………..140
CODE 64 XX—RETARDER MODULATION REQUEST DEVICE FAULT…………………………………………………………………………………………………………………………………143
Table 6–8. RMR Device Resistance Tests…………………………………………………………………………………………………………………………………………145
CODE 65 XX—ENGINE RATING HIGH…………………………………………………………………………………………………………………………………………………….146
CODE 66 XX—SCI (SERIAL COMMUNICATION INTERFACE) FAULT……………………………………………………………………………………………………………………………….147
Figure 6–24. Code 66 Schematic Drawing…………………………………………………………………………………………………………………………………………147
CODE 69 XX—ECU MALFUNCTION……………………………………………………………………………………………………………………………………………………….149
SECTION 7—INPUT AND OUTPUT FUNCTIONS………………………………………………………………………………………………………………………………………………….150
7–1. INPUT FUNCTIONS…………………………………………………………………………………………………………………………………………………………….150
Table 7–1. Input/Output Function Availability………………………………………………………………………………………………………………………………………150
7–2. OUTPUT FUNCTIONS……………………………………………………………………………………………………………………………………………………………152
SECTION 8—GENERAL TROUBLESHOOTING OFPERFORMANCE COMPLAINTS ……………………………………………………………………………………………………………………………..154
Table 8–1. Troubleshooting Performance Complaints…………………………………………………………………………………………………………………………………..155
APPENDICES…………………………………………………………………………………………………………………………………………………………………………172
APPENDIX A—IDENTIFICATION OF POTENTIAL CIRCUIT PROBLEMS…………………………………………………………………………………………………………………………………174
APPENDIX B—MEASURING CLUTCH AND RETARDER PRESSURES……………………………………………………………………………………………………………………………………..176
Figure B–1. Clutch Pressure Test Points……………………………………………………………………………………………………………………………………………176
Table B–1. Clutch Pressure Test Conditions…………………………………………………………………………………………………………………………………………177
Table B–2. Main Pressure and Clutch Pressure Specifications(Sump Fluid Temperature Same as in Table B–1)………………………………………………………………………………….179
Table B–3. Retarder Specifications At Above Test Conditions………………………………………………………………………………………………………………………….184
Table B–4. Retarder Specifications At Above Test Conditions………………………………………………………………………………………………………………………….184
APPENDIX C—SOLENOID AND CLUTCH CHART………………………………………………………………………………………………………………………………………………….186
APPENDIX D—WIRE/CONNECTOR CHART………………………………………………………………………………………………………………………………………………………188
Table D–1. Appendix D Abbreviation Guide…………………………………………………………………………………………………………………………………………..188
ECU CONNECTOR “S” (BLACK)………………………………………………………………………………………………………………………………………………………..190
ECU CONNECTOR “T” (BLUE)…………………………………………………………………………………………………………………………………………………………191
ECU CONNECTOR “V” (GRAY)…………………………………………………………………………………………………………………………………………………………192
BULKHEAD CONNECTOR FOR “S” HARNESS………………………………………………………………………………………………………………………………………………..193
BULKHEAD CONNECTOR FOR “S” HARNESS………………………………………………………………………………………………………………………………………………..194
BULKHEAD CONNECTOR FOR “T” HARNESS………………………………………………………………………………………………………………………………………………..194
BULKHEAD CONNECTOR FOR “V” HARNESS………………………………………………………………………………………………………………………………………………..195
CANNON 37-WAY BULKHEAD CONNECTOR (FMTV ONLY)……………………………………………………………………………………………………………………………………….196
DEUTSCH TRANSMISSION CONNECTOR (Plugs With Sockets, Receptacles With Pins)…………………………………………………………………………………………………………….198
REMOTE SHIFT SELECTOR CONNECTOR—PRIMARY SELECTOR……………………………………………………………………………………………………………………………………200
REMOTE SHIFT SELECTOR CONNECTOR—SECONDARY SELECTOR………………………………………………………………………………………………………………………………….201
COMPACT PUSHBUTTON SHIFT SELECTOR…………………………………………………………………………………………………………………………………………………202
OPTIONAL DEUTSCH SENSOR HARNESS CONNECTOR………………………………………………………………………………………………………………………………………….203
ENGINE SPEED SENSOR CONNECTOR…………………………………………………………………………………………………………………………………………………….204
TURBINE SPEED SENSOR CONNECTOR (HD PRODUCT LINE ONLY)……………………………………………………………………………………………………………………………….204
OUTPUT SPEED SENSOR CONNECTOR…………………………………………………………………………………………………………………………………………………….204
ACCUMULATOR (N) SOLENOID…………………………………………………………………………………………………………………………………………………………204
3000 PRODUCT FAMILY RETARDER (H SOLENOID, TID 2)……………………………………………………………………………………………………………………………………204
DIAGNOSTIC CONNECTOR…………………………………………………………………………………………………………………………………………………………….205
OPTIONAL 6-PIN DIAGNOSTIC TOOL CONNECTOR…………………………………………………………………………………………………………………………………………..206
OPTIONAL 9-PIN DIAGNOSTIC TOOL CONNECTOR…………………………………………………………………………………………………………………………………………..206
OPTIONAL OBD–II DIAGNOSTIC CONNECTOR………………………………………………………………………………………………………………………………………………207
VIW–V CONNECTOR…………………………………………………………………………………………………………………………………………………………………208
VIW–S CONNECTOR…………………………………………………………………………………………………………………………………………………………………209
THROTTLE POSITION SENSOR CONNECTOR………………………………………………………………………………………………………………………………………………..210
TRANSFER CASE CONNECTOR (3000 PRODUCT FAMILY 7-SPEED ONLY)…………………………………………………………………………………………………………………………..211
RETARDER CONNECTOR—3000 Product Family (Pre-TransID and TID 1)……………………………………………………………………………………………………………………….212
RETARDER CONNECTOR—3000 and 4000 Product Families…………………………………………………………………………………………………………………………………..213
RETARDER RESISTANCE MODULE/INTERFACE CONNECTOR……………………………………………………………………………………………………………………………………..214
RETARDER TEMPERATURE SENSOR CONNECTOR—4000 Product Family(Pre-TransID and TransID 1)……………………………………………………………………………………………………215
RETARDER TEMPERATURE SENSOR CONNECTOR—3000 AND 4000 PRODUCT FAMILIES, TID 2 AND LATER…………………………………………………………………………………………………..216
VIM CONNECTOR (HARNESS)………………………………………………………………………………………………………………………………………………………….217
VIM CONNECTOR (HARNESS 30-WAY)……………………………………………………………………………………………………………………………………………………218
RESISTANCE MODULE TYPE 2…………………………………………………………………………………………………………………………………………………………219
SCI INTERFACE CONNECTOR………………………………………………………………………………………………………………………………………………………….219
RESISTANCE MODULE TYPE 3…………………………………………………………………………………………………………………………………………………………220
RESISTANCE MODULE TYPE 5…………………………………………………………………………………………………………………………………………………………221
RESISTANCE MODULE TYPE 7…………………………………………………………………………………………………………………………………………………………222
RESISTANCE MODULE TYPE 8…………………………………………………………………………………………………………………………………………………………223
RESISTANCE MODULE TYPE 9…………………………………………………………………………………………………………………………………………………………224
OIL LEVEL SENSOR CONNECTOR……………………………………………………………………………………………………………………………………………………….225
J1939 INTERFACE CONNECTOR………………………………………………………………………………………………………………………………………………………..226
APPENDIX E — CONNECTOR PART NUMBERS, TERMINAL PARTNUMBERS, TOOL PART NUMBERS, AND REPAIR INSTRUCTIONS………………………………………………………………………………………..228
List Of Special Tools Required To Service WTEC III Wiring Harnesses…………………………………………………………………………………………………………………..229
Figure E–1A. Delphi-Packard Micro Pack Connector (ECU)………………………………………………………………………………………………………………………………230
Figure E–1B. Delphi-Packard Micro Pack Connector (VIWV, VIWS, Shift Selector)………………………………………………………………………………………………………….231
1–1. DELPHI-PACKARD MICRO PACK 100W CONNECTORS(ECU, VIWV, VIWS, SHIFT SELECTORS)……………………………………………………………………………………………………….232
Figure E–2. Delphi-Packard Metri-Pack 150 Series Connectors—Pull-to-Seat(Speed Sensor; Accumulator Solenoid; Retarder Solenoid, TID 2; 30-Way and 18-Way VIM)…………………………………..235
1–2. DELPHI-PACKARD METRI-PACK 150 SERIES CONNECTORS—PULL-TO-SEAT(SPEED SENSOR; ACCUMULATOR SOLENOID; 30-WAY AND 18-WAY VIM)………………………………………………………………..236
Figure E–3. Delphi-Packard Metri-Pack 150 Series Connectors—Push-to-Seat (Oil Level Sensor)……………………………………………………………………………………………..239
1–3. DELPHI-PACKARD METRI-PACK 150 SERIES CONNECTORS—PUSH-TO-SEAT(OIL LEVEL SENSOR)…………………………………………………………………………………………………….240
Figure E–4. Delphi-Packard Metri-Pack 150 Series Connector—Push-To-Seat(All Models With TID 2 and Later Sump Temperature Thermistor)…………………………………………………………243
1–4. DELPHI-PACKARD METRI-PACK 150 SERIES CONNECTORS—PUSH-TO-SEAT(ALL MODELS, TID 2 AND LATER SUMP TEMPERATURE THERMISTOR)………………………………………………………………….244
Figure E–5. Delphi-Packard Metri-Pack 280 Series Connectors—Pull-to-Seat(Internal Harness Solenoid and C3 Pressure Switch)………………………………………………………………….245
1–5. DELPHI-PACKARD METRI-PACK 280 SERIES CONNECTORS—PULL-TO-SEAT(INTERNAL HARNESS SOLENOID AND C3 PRESSURE SWITCH)………………………………………………………………………..246
Figure E–6. Delphi-Packard Metri-Pack 280 Series Connectors—Push-to-Seat (Diagnostic Connector)………………………………………………………………………………………….247
1–6. DELPHI-PACKARD METRI-PACK 280 SERIES CONNECTORS—PUSH-TO-SEAT(DIAGNOSTIC CONNECTOR, SCI)…………………………………………………………………………………………….248
Figure E–7. Delphi-Packard WeatherPack Connectors (TPS; 3-Way RMR Sensor; 4000 Product Family Pre-TID andTID 1 Retarder Temperature; 4-Way RMR Device, Type 3; 3-Way RMR Device (Dedicated Pedal))….251
1–7. DELPHI-PACKARD WEATHERPACK CONNECTORS (TPS; 3-WAY RMR SENSOR;HD RETARDER TEMPERATURE; 3-WAY RMR DEVICE (DEDICATED PEDAL))………………………………………………………………252
Figure E–8. Terminal Crimping With Tool J 35606…………………………………………………………………………………………………………………………………….254
Figure E–9. Amp Products Connectors (8-Way RMR Device (Hand Lever))…………………………………………………………………………………………………………………..255
1–8. AMP PRODUCTS CONNECTORS (8-WAY RMR DEVICE (HAND LEVER))…………………………………………………………………………………………………………………………256
Figure E–10. Deutsch IPD/ECD Connectors (31-Way Bulkhead, 31-Way Feedthrough Harness;16-Way Optional Sensor Harness; 6-Way Optional Diagnostic Connector)………………………………………257
1–9. DEUTSCH IPD/ECD CONNECTORS (31-WAY BULKHEAD; 31-WAYFEEDTHROUGH HARNESS; 16-WAY OPTIONAL SENSOR HARNESS; 6-WAYOPTIONAL DIAGNOSTIC CONNECTOR)………………………………………………258
Figure E–11. ITT Cannon Connectors—Crimped (37-Way FMTV Bulkhead; 6-Way Transfer Case;8-Way 3000 Product Family Retarder)…………………………………………………………………..261
1–10. ITT CANNON CONNECTORS ⎯ CRIMPED (37-WAY FMTV BULKHEAD; 6-WAYTRANSFER CASE; 8-WAY 3000 PRODUCT FAMILY RETARDER)……………………………………………………………………….262
Figure E–12. ITT Cannon Connectors—Soldered (2-Way 4000 Product Family Retarder)……………………………………………………………………………………………………….265
1–11. ITT CANNON CONNECTORS—SOLDERED (2-WAY HD RETARDER AND MDPRE-TID AND TID 1 RETARDER)……………………………………………………………………………………………….266
Figure E–13. Deutsch DT Series Connector (3-Way J1939 Interface)……………………………………………………………………………………………………………………..269
1–12. DEUTSCH DT SERIES CONNECTORS (3-WAY J1939 INTERFACE)…………………………………………………………………………………………………………………………..270
Figure E–14. AMP MATE-N-LOK II Connector (Compact Shift Selector)…………………………………………………………………………………………………………………….273
1–13. AMP MATE-N-LOK II SERIES CONNECTORS (COMPACT SHIFT SELECTOR)……………………………………………………………………………………………………………………274
Figure E–15. Alternate AMP Crimper 58440-1…………………………………………………………………………………………………………………………………………276
1–14. REPAIR OF A BROKEN WIRE WITH IN-LINE BUTT SPLICE………………………………………………………………………………………………………………………………278
Figure E–16. Crimper J 38125-8……………………………………………………………………………………………………………………………………………………279
Figure E–17. Delphi-Packard (DHD) Connectors (31-Way); Crimping Tool………………………………………………………………………………………………………………….281
1–15. DELPHI-PACKARD (DHD) 31-WAY CONNECTOR………………………………………………………………………………………………………………………………………..282
Figure E–18. Pin and Socket Extraction…………………………………………………………………………………………………………………………………………….282
Figure E–19. Pin and Socket Insertion……………………………………………………………………………………………………………………………………………..284
Figure E–20. Auxiliary Seal Orientation……………………………………………………………………………………………………………………………………………285
APPENDIX F—THROTTLE POSITION SENSOR ADJUSTMENT…………………………………………………………………………………………………………………………………………296
Figure F–1. Throttle Position to Voltage Conversion…………………………………………………………………………………………………………………………………296
Figure F–2. Throttle Position Determination Diagram…………………………………………………………………………………………………………………………………296
Table F–1. Volts Versus Count for Throttle Sensor Display Reading…………………………………………………………………………………………………………………….298
Figure F–3. Throttle Position Sensor Adjustment…………………………………………………………………………………………………………………………………….299
APPENDIX G—WELDING ON VEHICLE/VEHICLE INTERFACE MODULE………………………………………………………………………………………………………………………………….302
1–1. WELDING ON VEHICLE………………………………………………………………………………………………………………………………………………………….302
1–2. VEHICLE INTERFACE MODULE…………………………………………………………………………………………………………………………………………………….302
Figure G–1. Vehicle Interface Module…………………………………………………………………………………………………………………………………………..302
Figure G–2. VIM Components Location and Pin-Out Diagram………………………………………………………………………………………………………………………….303
APPENDIX H—HYDRAULIC SCHEMATICS………………………………………………………………………………………………………………………………………………………304
Figure H–1. C2 Latch Valve Detail…………………………………………………………………………………………………………………………………………………305
Figure H–2. 3000 and 4000 Product Families Hydraulic Schematic (Except 3000 Product Family 7-Speed)—Neutral……………………………………………………………………………….306
Figure H–3. 3000 and 4000 Product Families Hydraulic Schematic (Except 3000 Product Family 7-Speed)—Reverse……………………………………………………………………………….308
Foldout H–4. 4000 Product Family 7-Speed Hydraulic Schematic—First Range………………………………………………………………………………………………………………310
Figure H–5. 3000 and 4000 Product Families Hydraulic Schematic (Except 3000 Product Family 7-Speed) —1st Range(2nd Range for 4000 Product Family 7-Speed Models)………………………………..311
Figure H–6. 3000 and 4000 Product Families Hydraulic Schematic (Except 3000 Product Family 7-Speed)—2nd Range(3rd Range for 4000 Product Family 7-Speed Models)…………………………………313
Figure H–7. 3000 and 4000 Product Families Hydraulic Schematic (Except 3000 Product Family 7-Speed)—3rd Range(4th Range for 4000 Product Family 7-Speed Models)…………………………………315
Figure H–8. 3000 and 4000 Product Families Hydraulic Schematic (Except 3000 Product Family 7-Speed)—4th Range(5th Range for 4000 Product Family 7-Speed Models)…………………………………317
Figure H–9. 3000 and 4000 Product Families Hydraulic Schematic (Except 3000 Product Family 7-Speed)—5th Range(6th Range for 4000 Product Family 7-Speed Models)…………………………………319
Figure H–10. 3000 and 4000 Product Families Hydraulic Schematic (Except 3000 Product Family 7-Speed)—6th Range(7th Range for 4000 Product Family 7-Speed Models)………………………………..321
Figure H–11. 3000 Product Family 7-Speed Models Hydraulic Schematic—Neutral Power On……………………………………………………………………………………………………323
Figure H–12. 3000 Product Family 7-Speed Models Hydraulic Schematic—Reverse Power On……………………………………………………………………………………………………324
Figure H–13. 3000 Product Family 7-Speed Models Hydraulic Schematic—Lo MD Power On……………………………………………………………………………………………………..325
Figure H–14. 3000 Product Family 7-Speed Models Hydraulic Schematic—1st Power On……………………………………………………………………………………………………….326
Figure H–15. 3000 Product Family 7-Speed Models Hydraulic Schematic—2nd Power On……………………………………………………………………………………………………….327
Figure H–16. 3000 Product Family 7-Speed Models Hydraulic Schematic—3rd Power On……………………………………………………………………………………………………….328
Figure H–17. 3000 Product Family 7-Speed Models Hydraulic Schematic—4th Power On……………………………………………………………………………………………………….329
Figure H–18. 3000 Product Family 7-Speed Models Hydraulic Schematic—5th Power On……………………………………………………………………………………………………….330
Figure H–19. 3000 Product Family 7-Speed Models Hydraulic Schematic—6th Power On……………………………………………………………………………………………………….331
Figure H–20. 3000 Product Family Hydraulic Schematic (Retarders Built Before January 1, 1998)—Retarder On…………………………………………………………………………………333
Figure H–21. 3000 Product Family Hydraulic Schematic (Retarders Built Before January 1, 1998)—Retarder Off………………………………………………………………………………..335
Figure H–22. 3000 Product Family Hydraulic Schematic (Retarders Built After January 1, 1998)—Retarder On………………………………………………………………………………….337
Figure H–23. 3000 Product Family Hydraulic Schematic (Retarders Built After January 1, 1998)—Retarder Off…………………………………………………………………………………339
Figure H–24. 4000 Product Family Hydraulic Schematic— Retarder On…………………………………………………………………………………………………………………….341
Figure H–25. 4000 Product Family Hydraulic Schematic— Retarder Off……………………………………………………………………………………………………………………343
APPENDIX J—3000 AND 4000 PRODUCT FAMILIES WIRING SCHEMATIC………………………………………………………………………………………………………………………………345
Figure J–1. 3000 and 4000 Product Families Wiring Schematic (TransID 1)……………………………………………………………………………………………………………….345
Figure J–2. 3000 and 4000 Product Families Wiring Schematic (TransID 2)……………………………………………………………………………………………………………….346
Figure J–3. 3000 and 4000 Product Families Wiring Schematic (TransID Details)………………………………………………………………………………………………………….347
APPENDIX K—TRANSID 1 TEMPERATURE SENSOR AND SOLENOID RESISTANCE CHARTS……………………………………………………………………………………………………………………348
Figure K–1. TransID 1 Temperature Sensor Chart……………………………………………………………………………………………………………………………………..348
Figure K–2. Solenoid Resistance vs. Temperature Chart……………………………………………………………………………………………………………………………….349
APPENDIX L—EXTERNALLY-GENERATED ELECTRONIC INTERFERENCE…………………………………………………………………………………………………………………………………350
1–1. ELECTROMAGNETIC/RADIO FREQUENCY INTERFERENCE…………………………………………………………………………………………………………………………………..350
1–2. GENERAL GUIDELINES FOR RADIO EQUIPMENT INSTALLATION…………………………………………………………………………………………………………………………….350
1–3. EXTERNALLY-GENERATED SPEED SENSOR SIGNALS……………………………………………………………………………………………………………………………………..351
APPENDIX M—DIAGNOSTIC TREE—3000 AND 4000 HYDRAULIC SYSTEM……………………………………………………………………………………………………………………………….352
Figure M–1. Diagnostic Tree—3000 and 4000 Product Families Hydraulic System With Gauges…………………………………………………………………………………………………352
Figure M–2. Diagnostic Tree—3000 and 4000 Product Families Hydraulic System Without Gauges………………………………………………………………………………………………353
APPENDIX N—DIAGNOSTIC TOOL INFORMATION………………………………………………………………………………………………………………………………………………..354
APPENDIX P—INPUT/OUTPUT FUNCTIONS…………………………………………………………………………………………………………………………………………………….358
TABLE OF CONTENTS……………………………………………………………………………………………………………………………………………………………….358
INPUT FUNCTION A. SECONDARY SHIFT SCHEDULE…………………………………………………………………………………………………………………………………………360
INPUT FUNCTION B. D1 SELECTION……………………………………………………………………………………………………………………………………………………361
INPUT FUNCTION C. PTO ENABLE—SWITCHED TO POWER (WIRE 118)……………………………………………………………………………………………………………………………362
INPUT FUNCTION C. PTO ENABLE—SWITCHED TO GROUND (WIRE 153)…………………………………………………………………………………………………………………………..363
INPUT FUNCTION C. PTO ENABLE—USING MODE BUTTON……………………………………………………………………………………………………………………………………..364
INPUT FUNCTION D. SHIFT SELECTOR TRANSITION………………………………………………………………………………………………………………………………………..365
INPUT FUNCTION E. SINGLE INPUT AUXILIARY FUNCTION RANGE INHIBIT………………………………………………………………………………………………………………………366
INPUT FUNCTION F. DUAL INPUT AUXILIARY FUNCTION RANGE INHIBIT………………………………………………………………………………………………………………………..367
INPUT FUNCTION G. AUXILIARY HOLD………………………………………………………………………………………………………………………………………………….368
INPUT FUNCTION H. ENGINE BRAKE ENABLE AND PRESELECT REQUEST PLUS ENGINE BRAKE ENABLE OUTPUT USING EXHAUST BRAKES…………………………………………………………………………..369
INPUT FUNCTION H. ENGINE BRAKE ENABLE AND PRESELECT REQUEST PLUS ENGINE BRAKE ENABLE OUTPUT USING ECM CONTROLLED EXHAUST BRAKES……………………………………………………………..370
INPUT FUNCTION H. ENGINE BRAKE ENABLE AND PRESELECT REQUEST PLUS ENGINE BRAKE ENABLE OUTPUT WITH SINGLE LEVEL COMPRESSION BRAKES…………………………………………………………….371
INPUT FUNCTION H. ENGINE BRAKE ENABLE AND PRESELECT REQUESTPLUS ENGINE BRAKE ENABLE OUTPUT WITH MULTILEVELCOMPESSION BRAKES…………………………………………………………………372
INPUT FUNCTION I. EUROPEAN ENGINE BRAKE ENABLE AND PRESELECT REQUEST PLUS ENGINE BRAKE ENABLE OUTPUT USING EXHAUST BRAKES…………………………………………………………………..373
INPUT FUNCTION I. EUROPEAN ENGINE BRAKE ENABLE AND PRESELECT REQUEST PLUS ENGINE BRAKE ENABLE OUTPUT WITH SINGLE LEVEL COMPRESSION BRAKES…………………………………………………….374
INPUT FUNCTION J. FIRE TRUCK PUMP MODE—OPERATOR AND PUMPACTIVATED…………………………………………………………………………………………………………………….375
INPUT FUNCTION J. FIRE TRUCK PUMP MODE—OPERATOR ONLY ACTIVATED……………………………………………………………………………………………………………………….376
INPUT FUNCTION L. AUTOMATIC NEUTRAL—SINGLE INPUT SWITCHED TOGROUND (WIRE 117)………………………………………………………………………………………………………….377
INPUT FUNCTION L. AUTOMATIC NEUTRAL—SINGLE INPUT SWITCHED TOPOWER (WIRE 119)…………………………………………………………………………………………………………..378
INPUT FUNCTION O. AUTOMATIC NEUTRAL……………………………………………………………………………………………………………………………………………….379
INPUT FUNCTION Q. TWO-SPEED AXLE—INPUT AND OUTPUT…………………………………………………………………………………………………………………………………..380
INPUT FUNCTION V. REVERSE ENABLE SWITCHED TO GROUND…………………………………………………………………………………………………………………………………381
INPUT FUNCTION V. REVERSE ENABLE SWITCHED TO POWER………………………………………………………………………………………………………………………………….382
INPUT FUNCTION W. DIRECTION CHANGE ENABLE SWITCHED TO GROUND…………………………………………………………………………………………………………………………383
INPUT FUNCTION W. DIRECTION CHANGE ENABLE SWITCHED TO POWER………………………………………………………………………………………………………………………….384
INPUT FUNCTION X. SHIFT IN PROCESS/SHIFT ENABLE…………………………………………………………………………………………………………………………………….385
INPUT FUNCTION Y. ANTI-LOCK BRAKE RESPONSE WITH INPUT FROM ABSCONTROLLER………………………………………………………………………………………………………………386
INPUT FUNCTION Y. ANTI-LOCK BRAKE RESPONSE WITH BRAKE PRESSURESWITCH………………………………………………………………………………………………………………….387
INPUT FUNCTION Z. RETARDER ENABLE…………………………………………………………………………………………………………………………………………………388
INPUT FUNCTION AA. SERVICE BRAKE STATUS……………………………………………………………………………………………………………………………………………389
INPUT FUNCTION AF. DIFFERENTIAL CLUTCH REQUEST……………………………………………………………………………………………………………………………………..390
INPUT FUNCTION AG. AUTOMATIC NEUTRAL—DUAL INPUT—PARK BRAKEACTIVATED…………………………………………………………………………………………………………………..391
INPUT FUNCTION AG. AUTOMATIC NEUTRAL—DUAL INPUT—WORK BRAKEACTIVATED…………………………………………………………………………………………………………………..392
INPUT FUNCTION AH. KICKDOWN………………………………………………………………………………………………………………………………………………………393
INPUT FUNCTION AI. MILITARY AUXILIARY FUNCTION RANGE INHIBIT(STANDARD…………………………………………………………………………………………………………………394
INPUT FUNCTION AJ. FOURTH LOCKUP PUMP MODE—OPERATOR AND PUMP ACTIVATED………………………………………………………………………………………………………………..395
INPUT FUNCTION AJ. FOURTH LOCKUP PUMP MODE—OPERATOR ONLY ACTIVATED……………………………………………………………………………………………………………………396
INPUT FUNCTION AK. AUTOMATIC NEUTRAL—DUAL INPUT WITH SERVICE BRAKE STATUS—AUTOMATED SIDE LOADERACTIVATED………………………………………………………………………………….397
INPUT FUNCTION AK. AUTOMATIC NEUTRAL—DUAL INPUT WITH SERVICE BRAKE STATUS—DASH SWITCH ACTIVATED………………………………………………………………………………………….398
INPUT FUNCTION AK. AUTOMATIC NEUTRAL—DUAL INPUT WITH SERVICE BRAKE STATUS—PARK BRAKE ACTIVATED…………………………………………………………………………………………..399
INPUT FUNCTION AK. AUTOMATIC NEUTRAL—DUAL INPUT WITH SERVICE BRAKE STATUS—WORK BRAKE ACTIVATED…………………………………………………………………………………………..400
INPUT FUNCTION AK. AUTOMATIC NEUTRAL—DUAL INPUT WITH SERVICE BRAKE STATUS—EMERGENCY VEHICLE OPTION……………………………………………………………………………………….401
INPUT FUNCTION AL. SHIFT SELECTOR TRANSITION AND SECONDARY SHIFT SCHEDULE WITHOUT AUTO NEUTRAL…………………………………………………………………………………………..402
INPUT FUNCTION AL. SHIFT SELECTOR TRANSITION AND SECONDARY SHIFT SCHEDULE WITH AUTO NEUTRAL……………………………………………………………………………………………..403
INPUT FUNCTION AM. REFUSE PACKER STEP SWITCH……………………………………………………………………………………………………………………………………….404
INPUT FUNCTION AN. ISO 9141 ENABLE………………………………………………………………………………………………………………………………………………..405
INPUT FUNCTION AQ. SELECTOR DISPLAY BLANKING……………………………………………………………………………………………………………………………………….406
INPUT FUNCTION AS. REDUCED ENGINE LOAD AT STOP (RELS)……………………………………………………………………………………………………………………………….407
OUTPUT FUNCTION A. ENGINE BRAKE ENABLE…………………………………………………………………………………………………………………………………………….408
OUTPUT FUNCTION BB. RELS WITH SERVICE BRAKE STATUS………………………………………………………………………………………………………………………………….409
OUTPUT FUNCTION B. SUMP/RETARDER TEMPERATURE INDICATOR………………………………………………………………………………………………………………………………410
OUTPUT FUNCTION C. RANGE INDICATOR………………………………………………………………………………………………………………………………………………..411
OUTPUT FUNCTION D. OUTPUT SPEED INDICATOR—A………………………………………………………………………………………………………………………………………..412
OUTPUT FUNCTION E. OUTPUT SPEED INDICATOR—B………………………………………………………………………………………………………………………………………..413
OUTPUT FUNCTION F. PTO OVERSPEED INDICATOR…………………………………………………………………………………………………………………………………………414
OUTPUT FUNCTION G. PTO ENABLE…………………………………………………………………………………………………………………………………………………….415
OUTPUT FUNCTION I. ENGINE OVERSPEED INDICATOR USING VIM……………………………………………………………………………………………………………………………..416
OUTPUT FUNCTION I. ENGINE OVERSPEED INDICATOR WITHOUT VIM—SWITCHED TO GROUND…………………………………………………………………………………………………………..417
OUTPUT FUNCTION J. TWO SPEED AXLE ENABLE…………………………………………………………………………………………………………………………………………..418
OUTPUT FUNCTION K. LOCKUP INDICATOR……………………………………………………………………………………………………………………………………………….419
OUTPUT FUNCTION N. SECONDARY MODE INDICATOR………………………………………………………………………………………………………………………………………..420
OUTPUT FUNCTION O. SERVICE INDICATOR………………………………………………………………………………………………………………………………………………421
OUTPUT FUNCTION Q. RETARDER INDICATOR……………………………………………………………………………………………………………………………………………..422
OUTPUT FUNCTION R. DIFFERENTIAL CLUTCH INDICATOR……………………………………………………………………………………………………………………………………423
OUTPUT FUNCTION S. NEUTRAL INDICATOR FOR PTO AND PTO ENABLE—PACK-ON-THE-FLY OPTION……………………………………………………………………………………………………..424
OUTPUT FUNCTION S. NEUTRAL INDICATOR FOR PTO AND PTO ENABLE—NEUTRAL OPERATION ONLY……………………………………………………………………………………………………..425
APPENDIX Q—TRANSID 2 AND 3 THERMISTOR TROUBLESHOOTING INFORMATION………………………………………………………………………………………………………………………..426
Graph Q–1. TransID Thermistor Characteristics………………………………………………………………………………………………………………………………………426
TRANSID 2 THERMISTORS—RESISTANCE (OHMS) VS. TEMPERATURE……………………………………………………………………………………………………………………………..427
APPENDIX R—SAE J1939 COMMUNICATION LINK……………………………………………………………………………………………………………………………………………….434
Figure R–1. J1939 Interface Wiring (ECU Pin-Out)……………………………………………………………………………………………………………………………………434
Figure R–2. J1939-11 Twisted, Shielded Pair Cable…………………………………………………………………………………………………………………………………..434
Figure R–3. J1939-11 Network Configuration…………………………………………………………………………………………………………………………………………435
Figure R–4. Termination Resisters Requirement on J1939-11 Backbone……………………………………………………………………………………………………………………436
Figure R–5. 3-Way Allison Controller Connector……………………………………………………………………………………………………………………………………..436
Figure R–6. 9-Way, In-Cab, Diagnostic Connector…………………………………………………………………………………………………………………………………….437
Table R–1. 4th Generation J1939 Message and Parameter Sent Overview…………………………………………………………………………………………………………………..441
Table R–2. 4th Generation J1939 Message and Parameter Received Overview……………………………………………………………………………………………………………….442

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