Allison HD Series Transmissions (HD4060/HD4560) WTEC II Controls OEM Service & Repair Manual

Allison Transmission, General Motors Corporation P.O. Box 894 Indianapolis, Indiana 46206-0894 www.allisontransmission.com Printed in USA Copyright © 2005 General Motors Corporation Allison Transmission MD/HD/B SERIES TRANSMISSIONS Troubleshooting Manual 1998 MAY REV. 1 1999 OCTOBER REV. 2 2004 JULY REV. 3 2005 DECEMBER TS2470EN WTEC II Controls (Pre-TransID and TID 1) MD 3060/MD 3066/MD 3560(P)(R) MD 3070PT HD 4060/HD 4560(P)(R) B 300/B 400/ B 500(P)(R)

WTEC II ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL ii Copyright © 2005 General Motors Corp. This manual provides troubleshooting information for Allison Transmission (AT), MD/HD/B Series Transmissions. Service Manuals SM2148EN and SM2457EN, and Parts Catalogs PC2150EN and PC2456EN may be used in conjunction with this manual. This manual includes: • Description of the WTEC II 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 letter suffix added to the publication number. Check with your Allison Transmission service outlet for the currently applicable publication. Additional copies of this publication may be purchased from authorized Allison Transmission service outlets. Look in your telephone directory under the heading of Transmissions — Truck, Tractor, etc. Take time to review the Table of Contents and the manual. Reviewing the Table of Contents will aid you in quickly locating information. NOTE: Allison Transmission is providing for service of WTEC II wiring harnesses and wiring harness components as follows: (See Service Information Letter 1-WT-97 for further information.) • Repair parts for the internal wiring harness and for wiring harness components attached to the shift selector will be available through the Allison Transmission Parts Distribution Center (PDC). Use the P/N from your appropriate parts catalog or from Appendix E in this manual. Allison Transmission is responsible for warranty on these parts. • Since January, 1998, all WTEC II external harnesses and external harness components must be obtained from St. Clair Technologies Inc. (SCTI). SCTI provides parts to any Allison customer or OEM and is responsible for warranty on these parts. SCTI recognizes AT, manufacturers, and SCTI part numbers. SCTI provides a technical HELPLINE at 519-627-1673 (Wallaceburg). SCTI has parts catalogs available. The SCTI addresses and phone numbers for parts outlets are: St. Clair Technologies, Inc 920 Old Glass Road Wallaceburg, Ontario N8A 4L8 Phone: 519-627-1673 Fax: 519-627-4227 St. Clair Technologies, Inc. Calle Damante S/N Col Guadalupe – Guaymas Sonora, Mexico CP85440 Phone: 011-526-2222-43834 Fax: 011-526-2222-43553 FOREWORD — How to Use This Manual

Copyright © 2005 General Motors Corp. iii IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings and cautions used in this manual. These warnings and cautions advise against using specific service procedures that can result in personal injury, equipment damage, or cause the equipment to become unsafe. These warnings and cautions are not exhaustive. Allison Transmission could not possibly know, evaluate, or advise the service trade of all conceivable procedures by which service might be performed or of the possible hazardous consequences of each procedure. Consequently, Allison Transmission has not undertaken any such broad evaluation. Accordingly, ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT RECOMMENDED BY ALLISON TRANSMISSION MUST first be thoroughly satisfied that neither personal safety nor equipment safety will be jeopardized by the service procedures used. Also, be sure to review and observe WARNINGS, CAUTIONS, and NOTES provided by the vehicle manufacturer and/or body builder before servicing the Allison transmission in that vehicle. Proper service and repair is important to the safe and reliable operation of the equipment. The service procedures recommended by Allison Transmission and described in this manual are effective methods for performing troubleshooting operations. Some procedures require using specially designed tools. Use special tools when and in the manner recommended. WARNINGS, CAUTIONS, AND NOTES Three types of headings are used in this manual to attract your attention: NOTE: Is used when an operating procedure, practice, etc., is essential to highlight. WARNING! Is used when an operating procedure, practice, etc., which, if not correctly followed, could result in injury or loss of life. CAUTION: Is used when an operating procedure, practice, etc., which, if not strictly observed, could result in damage to or destruction of equipment. WTEC III ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL The WARNINGS, CAUTIONS, and NOTES in this manual apply only to the Allison transmission and not to other vehicle systems which may interact with the transmission. Be sure to review and observe any vehicle system information provided by the vehicle manufacturer and/or body builder at all times the Allison transmission is being serviced. IMPORTANT SAFETY NOTICE

WTEC II ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL iv Copyright © 2005 General Motors Corp. The following trademarks are the property of the companies indicated: • LPS ® Cleaner is a registered trademark of LPS Laboratories. • Biobor JF ® is the registered trademark for a biological inhibitor manufactured by Hammonds Fuel Additives Corporation. • Loctite ® is a registered trademark of the Loctite Corporation. • Teflon ® is a registered trademark of the DuPont Corporation. • Allison DOC For PC–Service Tool is a registered trademark of General Motors Corporation. SHIFT SELECTOR TERMS AND DISPLAY INDICATIONS Shift selector terms and displays are represented in this manual as follows: • Button Names — ↑↓, DISPLAY MODE, MONITOR, SELECT, etc. • Transmission Ranges — D (Drive), N (Neutral), 1 (First), R (Reverse), etc. • Displays — “OL”, “OK”, etc. TRADEMARKS USED IN THIS MANUAL

Copyright © 2005 General Motors Corp. v WTEC II ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL Page Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii SAFETY INFORMATION Important Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii Warnings, Cautions, and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii Trademarks Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv Shift Selector Terms and Display Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv SECTION 1. GENERAL DESCRIPTION 1–1. TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 1–2. ELECTRONIC CONTROL UNIT (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 1–3. SHIFT SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 A. Pushbutton Shift Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 B. Lever Shift Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 1–4. THROTTLE POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5 1–5. SPEED SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5 1–6. CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6 1–7. WIRING HARNESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7 A. External Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7 B. Internal Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9 1–8. VEHICLE INTERFACE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10 1–9. TRANSID FEATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11 A. General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1_11 B. Transmission Changes Versus TransID Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11 C. Compatibility Between TransID Level and ECU Calibration Level . . . . . . . . . . . . . . . . . . . . . . 1–12 SECTION 2. DEFINITIONS AND ABBREVIATIONS 2–1. DO NOT SHIFT LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 2–2. ALLISON TRANSMISSION DIAGNOSTIC TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 2–3. ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3 SECTION 3. BASIC KNOWLEDGE 3–1. BASIC KNOWLEDGE REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 3–2. USING THE TROUBLESHOOTING MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2 3–3. SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2 3–4. IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS . . . . . . . . . . . . . . . . 3–2 3–5. BEGINNING THE TROUBLESHOOTING PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3

WTEC II ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL vi Copyright © 2005 General Motors Corp. SECTION 4. WIRE TESTING PROCEDURES Page 4–1. TESTING FOR OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 4–2. TESTING AT TRANSMISSION CONNECTOR AND THE INTERNAL HARNESS FOR OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND . . . . . . . . . . . . . . . 4–2 SECTION 5. OIL LEVEL SENSOR 5–1. ELECTRONIC FLUID LEVEL TEST (SHIFT SELECTOR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 A. Fluid Level Test Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 5–2. ELECTRONIC FLUID LEVEL TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4 A. Fluid Level Test Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4 SECTION 6. DIAGNOSTIC CODES 6–1. DIAGNOSTIC CODE MEMORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 6–2. CODE READING AND CODE CLEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 A. Reading Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 B. Clearing Active Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2 C. Manually Clearing Codes and Active Indicators From the Code List . . . . . . . . . . . . . . . . . . . 6–2 D. Exiting the Diagnostic Display Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3 6–3. DIAGNOSTIC CODE RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3 6–4. SHIFT SELECTOR DISPLAYS RELATED TO ACTIVE CODES . . . . . . . . . . . . . . . . . . . . . . . 6–3 6–5. DIAGNOSTIC CODE LIST AND DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4 6–6. DIAGNOSTIC CODE TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–17 A. Beginning the Troubleshooting Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–17 B. Solenoid Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–17 C. Diagnostic Code Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–18 D. Diagnostic Code 13 and 35 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–18 SECTION 7. INPUT AND OUTPUT FUNCTIONS A. INPUT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 B. OUTPUT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3 SECTION 8. GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS GENERAL NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 TROUBLESHOOTING PERFORMANCE COMPLAINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2

Copyright © 2005 General Motors Corp. vii WTEC II ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL APPENDICES Page A. IDENTIFICATION OF POTENTIAL CIRCUIT PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1 B. TESTING CLUTCH PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–1 C. SOLENOID AND CLUTCH CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C–1 D. WIRE/CONNECTOR CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–1 E. CONNECTOR PART NUMBERS, TERMINAL PART NUMBERS, TOOL PART NUMBERS, AND REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–1 F. THROTTLE POSITION SENSOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F–1 G. MISCELLANEOUS ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G–1 H. HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H–1 J. MD/HD/B WIRING SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J–1 K. SOLENOID AND TEMPERATURE CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K–1 L. EXTERNALLY-GENERATED ELECTRONIC INTERFERENCE . . . . . . . . . . . . . . . . . . . . . . . . L–1 M. DIAGNOSTIC TREE — MD/HD/B SERIES HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . M–1 N. ALLISON DOC™ FOR PC–SERVICE TOOL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . N–1 P. INPUT/OUTPUT FUNCTION WIRING SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–1

Copyright © 2005 General Motors Corp. 1–1 WTEC II ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL 1–1. TRANSMISSION The World Transmission Electronic Controls WTEC II system features closed-loop clutch control to provide superior shift quality over a wide range of operating conditions. MD 3000 (except 3070), HD 4000, and B Series configurations can be programmed to have up to six forward ranges, neutral, and one reverse range. The MD 3070 has seven forward ranges and one reverse range. Figures 1–1 and 1–2 show electronic control unit components. WTEC II Electronic Controls consist of the following components: • Basic or Max Feature Electronic Control Unit (ECU) • Pushbutton or Lever Shift Selectors (remote or integral to the ECU) • Optional Secondary Shift Selector • Engine, Turbine and Output Speed Sensors • Throttle Position Sensor (TPS) (or electronic engine throttle signal or PWM signal) • Control Module (Electro-Hydraulic Valve Body) • Wiring Harnesses • Vehicle Interface Module (VIM) • Optional Retarder Controls • TransID Feature NOTE: Model Year ’94 and earlier MD/HD/B Series Electronic Controls operate on 12VDC. Vehicles with a 24VDC system require a voltage equalizer or converter to supply 12V to the electronic control system. Model Year ’95 and later transmissions operating on 24VDC require a 24V VIM and a 24V wiring harness which includes shielding for the turbine and output speed sensors. Figure 1–1. WTEC II Electronic Control Components (Units Produced Before 9/94) #1 DIAGNOSTIC TOOL CONNECTOR #2 OPTIONAL DEUTSCH DIAGNOSTIC TOOL CONNECTOR INTEGRAL ECU/ SHIFT SELECTORS REMOTE ECU RETARDER MODULATION REQUEST (RMR) SENSOR CONNECTOR ELECTRONIC CONTROL UNIT (ECU) CONNECTORS THROTTLE POSITION SENSOR VEHICLE INTERFACE MODULE (VIM) MD/B 300/B 400 RETARDER CONNECTOR (INCLUDES OUTPUT SPEED SENSOR) MD 3070 TRANSFER CASE CONNECTOR OUTPUT SPEED SENSOR *CONNECTOR TRANSMISSION CONNECTOR ENGINE SPEED SENSOR CONNECTOR V01634.02.01 TPS CONNECTOR TURBINE SPEED SENSOR CONNECTOR (HD/B 500) HD/B 500 RETARDER TEMPERATURE SENSOR CONNECTOR REMOTE SERIAL INTERFACE CONNECTOR REMOTE PUSHBUTTON SHIFT SELECTOR STRIP PUSHBUTTON SHIFT SELECTOR REMOTE LEVER SHIFT SELECTOR RETARDER “K” CONNECTOR (HD/B 500) HD/MD/B RETARDER ACCUMULATOR “H” SOLENOID CONNECTOR OPTIONAL BULKHEAD CONNECTOR WIRING HARNESS NOTE: Illustration is not to scale. *All HD/B 500 models All Non-Retarder MD/B 300/B 400 models 1 2 D N R D N R VEHICLE INTERFACE WIRING (VIW) CONNECTOR ALLISON DOC ™ FOR PC ALLISON DOC ™ FOR PDA SECTION 1—GENERAL DESCRIPTION

WTEC II ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL 1–2 Copyright © 2005 General Motors Corp. GENERAL DESCRIPTION Figure 1–2. Electronic Control Unit Components (Units Produced 9/94–12/97) Figure 1–3 is a block diagram of the basic system’s inputs and outputs. Figure 1–3. Electronic Control Unit Block Diagram INTEGRAL ECU/ SHIFT SELECTORS REMOTE ECU THROTTLE POSITION SENSOR MD/B 300/B 400 RETARDER CONNECTOR (INCLUDES OUTPUT SPEED SENSOR) MD 3070 TRANSFER CASE CONNECTOR OUTPUT SPEED SENSOR *CONNECTOR TRANSMISSION CONNECTOR ENGINE SPEED SENSOR CONNECTOR V01587.02.01 TPS CONNECTOR TURBINE SPEED SENSOR CONNECTOR (HD/B 500) HD/B 500 RETARDER TEMPERATURE SENSOR CONNECTOR REMOTE SERIAL INTERFACE CONNECTOR RETARDER “K” CONNECTOR (HD/B 500) HD/MD/B RETARDER ACCUMULATOR “H” SOLENOID CONNECTOR OPTIONAL BULKHEAD CONNECTOR WIRING HARNESS NOTE: Illustration is not to scale. *All HD/B 500 models All Non-Retarder MD/B 300/B 400 models 1 2 D N R D N R ELECTRONIC CONTROL UNIT (ECU) CONNECTORS VEHICLE INTERFACE MODULE (VIM) VEHICLE INTERFACE WIRING (VIW) CONNECTOR RETARDER MODULATION REQUEST (RMR) SENSOR CONNECTOR REMOTE PUSHBUTTON SHIFT SELECTOR STRIP PUSHBUTTON SHIFT SELECTOR REMOTE LEVER SHIFT SELECTOR #2 OPTIONAL DEUTSCH DIAGNOSTIC TOOL CONNECTOR #1 DIAGNOSTIC TOOL CONNECTOR ALLISON DOC ™ ALLISON DOC ™ FOR PC FOR PDA SHIFT SELECTOR RANGE AND MODE SWITCH TONE/DISPLAY VIM INPUTS OUTPUTS ECU SPEED SENSORS THROTTLE POSITION SENSOR RETARDER MODULATION V01812 TEMPERATURE SENSOR (SUMP/RETARDER) SOLENOIDS OIL LEVEL SENSOR C3 PRESSURE SWITCH

Allison HD Series Transmissions (HD4060/HD4560) WTEC II Controls OEM Service & Repair Manual

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