3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL — ALLISON 4* GENERATION CONTROLS SECTION 4—WIRE CHECK PROCEDURES 4-1. CHECKING OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND (Use Digital Volt/Ohmmeter J 34520-A and Jumper Wire Set J 39197) NOTE: Please refer to Paragraph 3-5 to begin the troubleshooting process. 1, Make sure all connectors are tightly connected and re-check the circuit. 2. Disconnect and inspect all connectors, 3. Thoroughly clean corroded or dirty terminals. If dirty or corroded terminals are the probable cause of the problems, reconnect the clean connectors and operate the vehicle normally. If the problem recurs, proceed with Step (4). 4. Review the Allison 4" Generation Controls wire numbering system described in Paragraph 3~4. 5. Ifall connectors are clean and connected correctly, determine which wires in the chassis harness are indicated by the diagnostic code. For example, Code P0960, indicates an open in the pressure control solenoid circuit, wires 111 and 174, a. Check continuity of wires 111 and 174 by performing the following (Figure 4-1): (Q) Disconnect the 80-way connector from the TCM and disconnect the hamess from the transmission ‘main connector. At one end of the hamess, using jumper wire kit J 39197, connect wires 111 and 174 to each other, being careful not to distort the terminals. Jumpering the wires together creates a circuit between wires 111 and 174, (2) On the opposite end of the harness, check the continuity of the jumpered pair. No continuity in a jumpered pair circuit (infinite resistance reading) indicates an open in the wire being tested. ‘Locate and repair the damaged portion of the wire, Copyright © 2005 General Motors Corp. a3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL — ALLISON 4! GENERATION CONTROLS WIRE CHECK PROCEDURES ’. Ifthe continuity check is good (0-2 Ohms resistance), remove the jumpers. Check the harness for shorts between wires and shorts-to-ground by performing the following (Figure 4-2): (1) At the TCM end of the hamess, touch one probe of a DVOM to one wire of the circuit being tested and touch the other probe to each terminal in the same connector, then touch the probe to chassis ground and to the transmission main housing. Do this for both wires in the circuit being tested (1) Ifat any time the DVOM shows zero to Jow resistance, or the meter’s continuity beeper sounds, there is a short between the two points being probed —wire-to-wire or wire-to-ground. Isolate and repair the shor ‘BULKHEAD CONNECTOR ‘WIRING HARNESS. FEEDTHROUGH HARNESS (CONNECTOR Cireit has continuity. Circuit doesnot have continuity due Jumper between wies produces Toa broken wi open cul. ‘complete cru ‘DVOI reading is very high BVOM readings near zero Ohms. (ifiito Ohms oF Lover, Figure 4-1. Open Circuit ‘TRANSMISSION CONNECTOR: DIGITAL VOLTIONM-METER ovoMy 0 OHMS 0 OHMS “Two wre have frayed and ae shorted together. Hamess has bon chafed and one or more wies are ‘Continuity beeper of DVOM wil Sound, shortodto-ground. DVOM coninuty boape wl sound, ‘or reading wil goto er0 Ofms when these ‘oF reading wil go to zoo Ohms when metre prbing {two wires are probed withthe OYOM. ‘between this wire and chassis ground Figure 4-2. Short Between Wires and to Ground 42 Copyright © 2005 General Motors Corp.3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL — ALLISON 4 GENERATION CONTROLS WIRE CHECK PROCEDURES 4-2. CHECKING AT TRANSMISSION FEEDTHROUGH CONNECTOR FOR INTERNAL HARNESS OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND 1, Disconnect the external wiring harness from the transmission. 2. Inspect the connectors. Any terminals which are corroded or dirty must be thoroughly cleaned, 3. If the connectors are clean and connected correctly, determine which wires in the harness to test. Use the diagnostic code system schematic to locate the wire terminals. For this example, Code P0960 indicates an open in pressure control solenoid 1 circuit, wires 111 and 174 (Figures 4~3 and 4-4). a. At the transmission connector, check the resistance of pressure control solenoid 1 circuit Resistance of a solenoid circuit should be 4.0 TO 7.8 Ohms, covering a temperature range of 20°C to 140°C (4°F to 284°F). Refer to Solenoid Resistance vs. Temperature chart in Appendix K. No continuity in the circuit (infinite resistance) indicates an open in the internal harness, the feedthrough connector, of the solenoid coil. Locate and repair the open in the internal harness or replace the internal harness, replace the feedthrough connector, or the solenoid. FEEDTHROUGH 2-5 OHMS INFINITE (Co) OHMS: eee «at ee Soeerae. Cretan ota Tivcaldsuob sre opin soa Lea ares Figure 4-3. Checking Continuity Copyright © 2005 General Motors Corp. 433000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL — ALLISON 4 GENERATION CONTROLS WIRE CHECK PROCEDURES b. Ifthe resistance check is good, check the harness for shorts between wires and (o ground by per- forming the following (Figure 4-4) (1) At the transmission connector, touch one probe of the DVOM to one wire of the circuit being tested and touch the other probe to each terminal in the connector and to chassis ground and the transmission main housing, Do this for both wires in the circuit being tested. (2) Ifthe DVOM shows zero to low resistance, or the continuity beeper sounds, there is a short between the two points being probed, wire-to-wire or wire-to-ground. An indication of a short may be caused by a splice to the wire being checked. Check the wiring diagram in Appendix J for splice locations. If the short is not a splice, then isolate and repair the short. LOCATED IN INTERNAL FeeoTuRoucn WIRING HARNESS HARNESS CONNECTOR 0 OHMS 0 OHMS Two wires have frayed and are shorted together. Hamess has been chated and one or more wies are Continuity beeper of DVOM wil sound, shorted-o-ground. DVOM continuity boeper will sound, or reading wil go to ero Ohms when these ‘of reading wil goo zero Ohms when meters probing |wo wires ar probed withthe DYOM. tween this wre and chasse ground. Figure 4-4. Short Between Wires and to Ground When conducting circuit checks that include the external harness, add one (1) Ohm to the values shown. Speed sensor resistance is 270-330 Ohms. PSI diagnostic pressure switch resistance is two (2) Ohms maximum when switch is closed and 20,000 Ohms minimum when switch is open. 44 Copyright © 2005 General Motors Corp.3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL — ALLISON 4 GENERATION CONTROLS SECTION 5—OIL LEVEL SENSOR (OLS) 5-1. INTRODUCTION The oil level sensor (Figure 5-1) provides a means of electronically checking the transmission fluid level from: + The shift selector display + Allison DOC™ diagnostic tools + A customer-furnished remote display. Figure 5-1. Oil Level Sensor The Allison 4% Generation Controls oil level sensor (OLS) is a one-piece unit with a molded 3-terminal connector built into the sensor housing (sce Figure 5-1 and SIL 19-WT-99 for more details). The internal wiring hamesses have been designed to include the 3-terminal connector for the OLS. NOTE: The OLS is standard on the 3000 MH, 4000 MH, and all T Series transmissions. Figure 5-2 shows the position and orientation of the OLS on the control modules of the 3000 and 4000 Product Families transmissions. The OLS must be correctly positioned, so the internal harness connector reaches the ‘connector on the sensor. The control module must fit onto the transmission main case without interference. The one piece design reduces the complexity of the manufacturing and installation of the sensor. The current OLS uses shoulder bolts and Viton® ferrules to provide vibration dampening in the mounting. Copyright © 2005 General Motors Corp. Sa3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL — ALLISON 4* GENERATION CONTROLS OIL LEVEL SENSOR (OLS) 6-SPEED 3000 PRODUCT FAMILY CONTROL MODULE OIL LEVEL SENSOR -SPEI - 4000 PRODUCT FAMILY 4000 PRODUCT FAMILY CONTROL MODULE CONTROL MODULE. Figure 5-2. Current Oil Level Sensor Orientation 52 Copyright © 2005 General Motors Corp.3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL — ALLISON 4" GENERATION CONTROLS SecTION 8—GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS IMPORTANT: Make the following general checks before beginning specific troubleshooting, removing the transmission, or removing attached components. Are there active diagnostic codes? Is the lever shift selector lever in N (Neutral) to allow starting the engine? Is the battery properly connected and charged? Is isolated battery properly connected (if used)? Is the fluid level correct? Is voltage to the TCM correct? Is the engine properly tuned? Is fuel flow to the engine correct? ‘Are wheel chocks in place? Is air low to the cooler and radiator unrestricted? Is the driveline properly connected? Are there signs of fluid leakage under the vehicle? What is the origination point? ‘Are hydraulic connections correctly made and not leaking? Is vehicle acceleration from a stop changed? Are electrical connections correctly made? Are there any other obvious vehicle or transmission problems? ‘Are clutch pressures within specified limits? After making these general checks use the various sections of this manual to isolate the listed problems. The following charts address specific vehicle complaints. Some complaints involve diagnostic codes, so all troubleshooting checks should involve checking the system for diagnostic codes. Copyright © 2005 General Motors Corp. 813000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL — ALLISON 4* ‘ATION CONTROLS GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS Table 8-1. Troubleshooting Performance Complaints Problem Probable Cause Suggested Remedy SHIFT SELECTOR DISPLAYS No communication between the Refer to code U0103 or U0291 in “CATEYE” AND VEHICLE IS TCM and a remote shift selector Troubleshooting Procedure NOT OPERABLE SHIFT SELECTOR DISPLAY IS VIM fuse is blown Replace VIM fuse BLANK Fuse blown in OEM substitute Replace VIM fuse Failed CAN (J1939) Data Link Should change to “cateye” within 12 seconds (see Code U0103 ot u0291) SHIFT SELECTOR NOT ‘OEM input wire at pin 3 of shift Find wire at pin 3 and connect it or LIGHTED AT NIGHT (WHEN _ selector connector not connected or install it, if necessary. HEADLIGHTS ARE ON) improperly connected. VEHICLE WILL NOT START —_Lever shift selector not in N (Neutral) Select N (Neutral) and restart (ENGINE WILL NOT CRANK) Dead battery Recharge battery Disconnected battery Reconnect battery Faulty starter circuit Repair vehicle starter circuit Faulty,neutral start relay Replace neutral start relay Faulty wiring in neutral start circuit Repair wiring Calibration programmed to J 1939 Troubleshoot J1939 wiring neutral start message (neutral start (CAN link) relay not used) ‘Voltage to TCM too low ‘Check battery and charging system voltage Faulty ignition wire (163) Repair wire 163 Faulty lever shift selector Replace lever shift selector Lack of battery voltage on Circuit Repair Circuit 141 or replace TCM 141 from TCM when in neutral Alldisplay segments of display Shift selector in initialization None, normal lighted (approximately 2 seconds) Faulty TCM Replace the TCM 82 Copyright © 2005 General Motors Corp,3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4 GENERATION CONTROLS GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS Table 8-1. Troubleshooting Performance Complaints (cont'd) Problem CHECK TRANS LIGHT WILL NOT GO OUT AT START-UP A. Vehicle Drives Normally B. Vehicle Does Not Drive Probable Cause Faulty CHECK TRANS light, relay, or circuit ‘An LED rather than a lamp is installed for the CHECK TRANS light and the LED is partially lighted from leakage current Engine does not start Faulty harness Suggested Remedy Replace relay or repair circuit Install a lamp rather than an LED for the CHECK TRANS light Repair engine starting system Repair harness (Section 4 and Appendix E) Faulty interface wiring to vehicle Repair wiring (Appendix E) electrical system Faulty TCM Replace the TCM CHECK TRANS LIGHT Intermittent power to TCM ‘Check input power to the TCM and FLASHES INTERMITTENTLY Loose wiring to CHECK TRANS light Faulty or incorrect ground wire attachment Intermittent opening in Circuit 129 correct if necessary Repair wiring Repair ground circuit Repair Circuit 129 NO CHECK TRANS LIGHT AT IGNITION Faulty light bulb or socket Incorrect wiring to and from CHECK TRANS light bulb Faulty wiring harness Circuit 129 open Vehicle wired for 11939 CHECK ‘TRANS light but calibration doesn't support that message Faulty TCM Copyright © 2005 General Motors Corp. Replace light bulb or socket Repair wiring (Appendix B) Check wiring between TCM and CHECK TRANS light, and repair ‘where necessary (Appendix B) Repair Circuit 129 Reprogram with correct calibration Replace TCM 833000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL~ ALLISON 4! GENERATION CONTROLS GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS -- Table 8-1. Troubleshooting Performance Complaints (cont'd) Problem Probable Cause Suggested Remedy TCM WILL NOT TURN OFF Faulty ignition switch Replace ignition switch WHEN IGNITION SWITCH OFF Extemally-generated speed sensor Find source of false speed sensor signal(s). Refer to Appendix L for _signal(s) and correct problem detailed inspection. TRANSMISSION WILLNOT —_Engine rpm too high* Reduce engine rpm. Also, it may be SHIFT TO FORWARD OR necessary to reselect N (Neutral) REVERSE (STAYS IN and then D (Drive) or R (Reverse). NEUTRAL) * Flashing digital display on shifter. a4 Low fluid level ‘Throttle position sensor or linkage is not functioning properly* ‘Voltage to TCM too low* Shift selector is not functioning Properly Disconnected or dirty connectors Faulty wiring hamesses Speed sensor(s) not functioning properly* Faulty TCM Input function wire open and “auxiliary function range inhibit", or “direction change enable” in the calibration* “Auxiliary Function Range Inhibit-Standard” or “direction change enable” —hooked up to brake pressure* Copyright © 2005 General Motors Corp. Add fluid to proper level. Refer to transmission Mechanic’s Tips for proper dipstick calibration. Refer to throttle position sensor for correct set-up (Appendix F) Check vehicle battery and charging system Replace shift selector Perform connector checkout (Appendix E) Repair harness (Appendix E) Repair or replace speed sensor(s) or circuitry. See transmission Service Manual and Appendix E. Replace the TCM Check input function programming with Allison DOC™ For PC. Correct wiring or switch problem which does not allow input function wire to be grounded. Apply brakes with high force[Geee Ano «on PRODUCT FAMILIES TROUBLESHIOOTING MANUAL-—ALLISON #* GENERATION CONTROLS GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS Table 8-1. Troubleshooting Performance Complaints (cont'd) Problem Probable Cause Suggested Remedy TRANSMISSION WILL NOT ——Auto-neutral or quick-to-neutral Repair quick-to-neutral circuit STAY IN FORWARD OR ‘circuit (input function) faulty REVERSE. Leaking at solenoid assembly Rebuild solenoid assembly. See transmission Service Manual Faulty solenoid—leaking Replace solenoid. See transmission Service Manual. TRANSMISSION WILL NOT Low engine power Correct engine problem. See MAKE A SPECIFIC SHIFT Engine Service Manual. Incorrect fluid level Correct fluid level. Refer to transmission Mechanic’s Tips for proper dipstick calibration. Extreme fluid temperature Inspect cooling system and fluid level Faulty speed sensoricircuit Repair circuit or replace speed sensor(s) (refer to codes PO716, PO721, or PO726) Faulty temperature sensor/citcuit Check for temperature reading which inhibits shifts Incorrect calibration Install proper calibration Faulty shift selector Replace shift selector Hydraulic problem Refer to Range Clutch ‘Troubleshooting section Faulty TCM Replace TCM TRANSMISSION LOCKUP ABS fault active Correct ABS fault CLUTCH WILL NOT ENGAGE ‘Copyright © 2005 General Motors Corp. 853000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL — ALLISON 4* GENERATION CONTROLS. GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS Table 8-1. Troubleshooting Performance Complaints (cont'd) Problem Probable Cause ‘Suggested Remedy ‘TRANSMISSION DOES Engine ile sped too fast (neutral Adjust engine il speed Refer to NOT SHIFT PROPERLY to range shift) le Service Manual. (ROUGH SHIFTS, SHIFTS OCCURRING AT TOO LOW Faulty throttle sensor/circuit Refer to throttle sensor section for OR TOO HIGH SPEED) installation and operation information (refer to Appendix F) ‘TCM input voltage low Check power, ground, charging Incorrect shift calibration for vehicle Instrument panel tachometer incorrect Incorrectly calibrated electronic speedometer Faulty speed sensor/circuit Loose speed sensor Incorrect fluid level Crossed wires in harness Intermittent problems ‘Loose or damaged speed gear Logic latch valve sticking Sticking solenoid regulator valve Incorrect calibration 86 Copyright © 2005 General Motors Corp. system, and battery function Install correct calibration Repair or replace tachometer Calibrate electronic speedometer Repair circuit or replace speed sensor (refer to codes P0716, P0721, or PO726) Tighten speed sensor retaining, bracket bolt Correct fluid level, Refer to ‘Mechanic’ Tips for proper dipstick calibration, Check for crossed wires and correct Check wiring hamesses and connectors (Appendix E) Replace output bearing nut sensor retainer Overhaul valve body assembly. Refer to transmission Service Manual. Overhaul valve body assembly Refer to transmission Service Manual. Install correct calibration3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL — ALLISON 4# GENERATION CONTROLS GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS Table 8-1. Troubleshooting Performance Complaints (cont'd) Problem Probable Cause Suggested Remedy A. Cruise Control Shift Cycles Performance shift schedule is being used. Incorrect droop settings CRUISE CONTROL COMPLAINTS Switch to economy shift schedule. Modify engine droop settings to provide a larger speed variation before reaction occurs (CAT engines should be set on “soft, cruise”. Cummins engines droop settings should be +2 mph and -3mph) RETARDER PERFORMANCE COMPLAINTS. A. Retarder Does Not Apply Retarder enable input not activated Retarder enable switch not working ABS input is active (if vehicle is equipped with ABS) Retarder Request below 10.2 percent Closed throttle not sensed Active code inhibiting retarder Transmission output speed below 350 rpm (3000 Product Family) 450 rpm (4000 Product Family) Transmission not in a forward range Copyright © 2005 General Motors Corp. Tum on retarder enable switch (if present) Replace retarder enable switch (if present), None—This is normal. If ABS is active, retarder will not apply, Use Allison DOC™ diagnostic tool to determine retarder request voltage signaled by each RMR device present. Replace RMR device, based on test results. Use Allison DOC™ diagnostic tool to check throttle signal, Throttle ‘must be below 9.8 percent before retarder will apply. Adjust or replace TPS, Exception: If TPS has failed and Service Brake Status input is sensed by TCM, the retarder will still be applied. Correct cause for setting these codes: P2685, P2686, P2736, P2738, P2739, C1312, or C1313. Raise output speed to above 350 rpm (3000 Product Family) 450 spm (4000 Product Family) Shift to a forward range a73000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL — ALLISON 4" GENERATION CONTROLS: GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS Table 8-1. Troubleshooting Performance Complaints (cont'd) Problem Probable Cause Suggested Remedy B. Reduced Retarder Effect, Retarder accumulator solenoid not Correct cause for setting these being energized codes: P2685, P2686, P2736, 2738, P2739, C1312, or C1313. ‘TCM sensing false overheat Use Allison DOC™ diagnostic tool condition or VOM to check retarder temperature sensor. Replace sensor as required. Normal response to overheating: See Table 6~7 in Section 6 + higher retarder fluid temperature (DTC P0218, P2740) + higher engine coolant temperature + higher sump temperature C. Less Retarder Effect Than ‘Transmission fluid aerated due to. Check transmission fluid level and Expected incorrect level correct as required. Wrong retarder control calibration Check retarder charging pressure. Change retarder control calibration, if necessary. ABNORMAL ACTIVITIES OR RESPONSES A. Excessive Creep in First and Engine idle speed too high Adjust to correct idle speed— Reverse Gears between 500-800 rpm. Refer to ‘Vehicle Service Manual. B. No Response to Shift Selector Shift selector not properly Check shift selector response with connected Allison DOC™ diagnostic tool. If no response, check remote connection and replace if necessary Using wrong shift selector on dual Use other selector station equipment Faulty shift selector Replace shift selector Incorrect fluid level Correct fluid level. Refer to transmission Mechanic’s Tips for proper dipstick calibration, Main pressure low Refer to Low Pressure section Logic latch valves sticking (C1, C3, Overhaul valve body assembly. ‘or C5 clutch pressure low) Refer to transmission Service ‘Manual. C. Vehicle Moves Forward in Clclutch failed or not released Rebuild Cl clutch assembly. Refer Neutral* to transmission Service Manual. D. Vehicle Moves Backward in C3 clutch failed or notreleased Rebuild C3 clutch assembly. Refer Neutral* to transmission Service Manual * ‘See explanation of NVL in Section 2-3. £8 Copyright © 2005 General Motors Comp.3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL — ALLISON 4* GENERATION CONTROLS GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS = ~ Table 8-1. Troubleshooting Performance Complaints (cont'd) Problem Probable Cause ‘Suggested Remedy EXCESSIVE FLARE — ‘TPS Adjustment: ENGINE OVERSPEED ON . FULL-THROTTLE UPSHIFTS — Overstroke — Adjust TPS linkage for proper stroke (Appendix F) — Loose — Tighten loose bolts or connections Incorrect calibration Correct calibration TCM input voltage low Check electrical system and all connections from battery and TCM Incorrect fluid level Correct fluid level. Refer to Mechanic's Tips for proper dipstick calibration measurements. Low main pressure See Low Pressure section Erratic speed sensor signal Refer to DTC P0716, P0721, or P0726 Sticking solenoid regulator valve Clean and repair solenoid regulator (See Solenoid and Clutch sections) _ valve, Refer to transmission Service Manual. Piston seals leaking or clutch plates | Overhaul transmission. Refer to slipping in range involved (see transmission Service Manual. Range Clutch Troubleshooting section) RANGE CLUTCH TROUBLESHOOTING SECTION EXCESSIVE SLIPPAGE AND —_Incorrect calibration Verify calibration CLUTCH CHATTER TCM input voltage low Check power, ground, charging system, and battery functions Throttle position sensor out of Adjust or replace throttle position adjustment or failed sensor (Appendix F) Incorrect speed sensor readings Refer to DTC P0716, PO72I, or P0726 Incorrect fluid level Correct fluid level. Refer to ‘Mechanic's Tips for proper dipstick calibration measurements. Main pressure low Refer to the Low Pressure section See Appendix B—Check main pressure, clutch pressure, and pressure specifications. Copyright © 2005 General Motors Corp. 893000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL — ALLISON 4 GENERATION CONTROLS GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS Table 8-1. Troubleshooting Performance Complaints (cont'd) Problem Probable Cause Suggested Remedy EXCESSIVE SLIPPAGE AND —_Lockup clutch not applied Inspect lockup clutch system CLUTCH CHATTER (cont'd) wiring, pressure, and controls; A. Ranges 1, 2,3, 4 Only (6-speed and 3000 7-speed) Ranges Lo, 1, 2,3, 4 only (4000 7-Speed) B. Ranges 4, 5, 6 Only (6-speed, 7-speed) C. Ranges 3, 5, R Only (6-speed and 4000 7-speed) Ranges Lo, 3, 5, R only (3000 7-speed) D, Ranges 2, 6 Only (6-speed and 7-speed) E. Ranges 1, R Only (6-speed and 7-speed) F. Range Lo Only (7-Speed) Cl clutch slipping, leaks at splitline gasket, leaks at rotating clutch seals, leaks at piston seals, C1 clutch plates worn C2 clutch slipping, leaks at splitline gasket, leaks at rotating clutch seals, leaks at piston seals, C2 clutch plates worn C3 clutch slipping, leaks at face seals, leaks at piston seals, C3 clutch plates worn C4 clutch slipping, leaks at face seals, leaks at piston seals, C4 clutch plates worn C5 clutch slipping, leaks at face seals, leaks at piston seals, C5 clutch plates wom C6 clutch slipping, leaks at splitline sgasket(s), leaks at piston seals, C6 clutch plates worn repair as necessary. Refer to transmission Service Manual.* Inspect control module gasket, C1 clutch plates, and piston and rotating seals; replace/rebuild as necessary. Refer to transmission Service Manual.* Inspect control module gasket, C2 clutch plates, and piston and rotating seals; replace/rebuild as necessary. Refer to transmission Service Manual.* Inspect control module face seals, C3 clutch plates, and piston seals; replace/rebuild as necessary. Refer to transmission Service Manual.* Inspect control module face seals, C4 clutch plates, and piston seals; replace/rebuild as necessary. Refer to transmission Service Manual.* Inspect control module face seals, C5 clutch plates, and piston seals; replace/rebuild as necessary. Refer to transmission Service Manual. Inspect control module gasket, adapter gasket, T-Case gasket(s) C6 clutch plates, and piston seals; replace/rebuild as necessary. Refer to transmission Service Manual.” A. Low Main Pressure in All Ranges (Including C6, T-Case) LOW PRESSURE SECTION Incorrect fluid level Oil filter element clogged or faulty Correct fluid level. Refer to the ‘Mechanic's Tips Handbook for correct dipstick calibration. * Replace oil filter. Refer to transmission Mechanic’s Tips. * See Appendix B— Check main pressure, clutch pressure, and pressure specifications. 810 Copyright © 2005 General Motors Corp.3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL — ALLISON 4! GENERATION CONTROLS. ~ GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS Table 8-1. Troubleshooting Performance Complaints (cont'd) Problem ‘A. Low Main Pressure in All Ranges (including C6, T-Case) (cont'd) B. Clutch Pressure Low in Specific Ranges, Normal Pressure in Other Ranges C. Low Lubrication Pressure Probable Cause Plugged or faulty suction filter Main pressure regulator valve sticking, Main pressure regulator valve spring weak, broken, or missing Control module body leakage (Separator plate not flat, separator plate gasket leakage, loose control valve body bolts) Faulty or incorrect fluid pressure ‘gauge Oil pump worn or damaged Incorrect fluid level Plugged lube filter Excessive internal fluid leakage Broken or damaged converter regulator retaining pin Cooler lines restricted or leaking ‘Copyright © 2005 General Motors Corp. Suggested Remedy Clean or replace oil suction filter clement and refill the transmission. Refer to transmission Mechanic’s Tips. Overhaul control module assembly. Refer to transmission Service Manual, Check spring and replace if necessary. Refer to transmission Service Manual Replace or rebuild control module assembly. Care should be taken when removing and labeling shift springs. Refer to transmission Service Manual. Repair or replace gauge Replace or rebuild oil pump. Refer to transmission Service Manual. See Range Clutch Troubleshooting section and Appendix B Correct fluid level. Refer to the Mechanic's Tips Handbook for proper dipstick calibration, Change filter. Refer to Transmission ‘Mechanic's Tips. Check other pressures (above items); also check control module ‘mounting bolts; lubrication valve and spring. Refer to transmission Service Manual. Replace damaged or broken parts. Refer to transmission Service ‘Manual, (Check for kinks, leakage; reroute or replace lines as necessary 8413000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL — ALLISON 4* GENERATION CONTROLS. GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS Table 8-1. Troubleshooting Performance Complaints (cont'd) Problem Probable Cause Suggested Remedy €. Low Lubrication Pressure Lubrication valve sticking Replace lubrication valve (cont'd) Cooler plugged Clean or replace cooler Faulty gauge Repair or replace gauge STALLS IN FIRST RANGE A. High Stall Speeds Not in gear Select D (Drive) Low fluid level, aerated fluid ‘Ada fluid to proper level. Refer to ‘Mechanic’s Tips for proper dipstick calibration. Incorrect torque converter Replace torque converter. Refer to transmission Service Manual. Clutch pressure low Refer to Low Pressure section and Appendix B C1 or C5 clutch slipping, Rebuild C1 or C5 clutch. Refer to Note: Use the Allison DOC™ transmission Service Manual. diagnostic tool to check turbine speed. Higher power engine Confirm proper engine match B. Low Stall Speeds Engine not performing efficiently Refer to Vehicle Engine (may be due to plugged or restricted | Manufacturer’s Manual or Vehicle injectors, high altitude conditions, Service Manual. dirty air filters, out of time, throttle linkage, electronic engine controls problem) Stall speeds of 66 percent of normal Replace or rebuild converter implies freewheeling stator assembly. Refer to transmission Service Manual. Incorrect torque converter Install correct torque converter. Refer to transmission Service Manual. OVERHEATING IN ALL Aerated fluid—incorrect fluid level Adjust fluid to proper level, check RANGES for defective pump. Refer to Air flow to cooler obstructed Engine overheat 812 Copyright © 2005 General Motors Corp. ‘Mechanic’s Tips and transmission Service Manual. Remove air flow obstruction Correct overheat situation. Refer to Vehicle Service Manual3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL — ALLISON 4* GENERATION CONTROLS GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS Table 8-1. Troubleshooting Performance Complaints (cont’d) Problem OVERHEATING IN ALL RANGES (cont'd) FLUID COMES OUT OF THE FLUID FILL TUBE AND/OR BREATHER Probable Cause Inaccurate temperature gauge or sending unit Inaccurate sump temperature sensor Transmission cooler lines reversed Fluid cooler lines restricted ‘Torque converter (wrong converter, no lockup, stuck stator, or slipping stator) Cooler flow loss due to internal leakage Inadequate cooler sizing Excessive cooler circuit pressure drop Dipstick loose Fluid level too high Fluid level too low Breather stopped up—clogged Fluid contaminated with foreign liquid Dipstick or fill tbe seal worn Incorrect dipstick marking Copyright © 2005 General Motors Comp. Suggested Remedy Replace gauge and/or sending unit Replace temperature sensor or internal hamess. Refer to transmission Service Manual Connect cooler lines properly (oil ‘and water should flow in opposite directions) Remove restrictions, clean or replace lines. Refer to Vehicle Service Manual. Replace or repair converter assembly. Refer to transmission Service Manual. Note: Stuck stator will not allow cool down in neutral, Overhaul transmission. Refer to transmission Service Manual. See vehicle OEM for specifications Check for plugged cooler, lines too small, collapsed hose, too many elbows in circuit Tighten cap, replace if necessary Drain to proper level. Refer to transmission Mechanic's Tips. Add fluid to proper level Clean or replace breather. Refer to transmission Service Manual. Drain and replace fluid. Locate and fix source of additional fluid. Refer to transmission Service Manual if repair is needed. Replace seal or dipstick. Calibrate dipstick. Refer to transmission Mechanic's Tips.3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL — ALLISON 4® GENERATION CONTROLS GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS: Table 8-1. Troubleshooting Performance Complaints (cont'd) Problem Probable Cause Suggested Remedy NOISE OCCURRING Low fluid level ‘Add fluid to proper level. Refer to INTERMITTENTLY (BUZZING) transmission Mechanic’s Tips for Air leak in oil suction screen canister Clogged filters Aerated fluid causes noisy pump Low main pressure causes main regulator valve to oscillate LEAKING FLUID Faulty or missing seal at output (OUTPUT SHAFT) flange Machine lead on output flange seal surface Flange worn at seal surface Insufficient seal around seal OD Damaged, missing, or loose output flange bolts ‘Damaged or missing flange button O-ring Damaged or missing bolt O-rings proper dipstick calibration Replace oil suction screen canister. Refer to transmission Service Manual, Replace filters. Refer to ‘transmission Mechanic's Tips. Correct fluid level. Refer to transmission Mechanic’s Tips for proper dipstick calibration, See Low Pressure section Install new lip-type seal in rear of transmission housing. Refer to ‘transmission Service Manual, Replace flange Replace flange ‘When replacing seal, apply sealant. Refer to transmission Service Manual. Replace and/or torque output flange bolts Replace flange button O-ring, Replace O-rings TRANSMISSION INPUT Front seal leaks Converter leaks PTO driveline out of specification a1 Copyright © 2005 General Motors Corp. Replace front seal. Refer to transmission Service Manual Check converter seals, cracked converter pump tangs, converter cover, or converter housing porosity; replace parts as required. Refer to transmission Service Manual. Bring driveline into specification3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL — ALLISON 42 GENERATION CONTROLS GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS Table 8-1. Troubleshooting Performance Complaints (cont'd) Problem Probable Cause Suggested Remedy DIRTY FLUID Failure to change fluid and filters. Change fluid and install new filters mn Mechanic's Excessive heat Refer to Overheating section Damaged fluid filter/seals Replace oil fiter/seals. Refer to transmission Mechanic’s Tips. Substandard fluid Use recommended fluid. Refer to transmission Mechanic’s Tips. Clutchitransmission failure Overhaul transmission. Refer to transmission Service Manual. POWER TAKEOFF (PTO)* A. Leaks Damaged or cocked seal Replace seal PTO flange grooved at seal Replace PTO flange Loose flange Inspect flange and bolts; replace if necessary and properly torque bolts Loose bolts or damaged gaskets Replace gasket and/os properly torque bolts Loose or damaged hydraulic lines Tighten fittings. Replace if (clutched drive) necessary. B. Noisy PTO Faulty driven component Replace faulty driven component C. No of Intermittent Operation (Clutched Drive) Gears or bearings worn, damaged, or contaminated Electrical problem (switch, ‘connectors, solenoid, or wires) Damaged or worn clutch Clutch piston seals damaged or missing Inadequate fluid pressure to PTO Engine speed outside operating band Drive or driven gear teeth damaged Rebuild PTO with new gears or bearings Inspect for electrical problem and repair (Appendix E) Rebuild clutch assembly Rebuild clutch assembly Inspect and repair fluid pressure supply; line kinked, loose, or plugged; orifice too small Increase or reduce engine speed to ‘move within operating band Replace damaged gears. Refer to ‘transmission Service Manual. * Contact your nearest Allison dealerdistributor with specific questions relating to PTO repair. Copyright © 2005 General Motors Corp. 8.453000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL~ ALLISON 4* GENERATION CONTROLS: GENERAL TROUBLESHOOTING-OF PERFORMANCE COMPLAINTS = Table 8-1. Troubleshooting Performance Complaints (cont'd) Problem Probable Cause Suggested Remedy A, Will Not Go Into Lo Range Makes Excessive Noise C. No Front Output Drive D. Transmission Fluid Leaks 816 TRANSFER CASE (T-CASE) ‘TPS adjustment Engine speed too high Wrong calibration ‘Wrong control module (6 speed instead of 7 speed) Faulty wiring, solenoid connectors Faulty C6 seals Wor C6 clutch plates Improperly shimmed bearings Differential clutch bad (C7 piston seals, C7 rotating seals, C7 clutch plates, C7 check ball) C7 electrical (wires, solenoids, terminals, connectors) Damaged output seal, output flange seal journal, gasketed mating surfaces, bearing endcaps, electrical ‘connector, oil scavenge line Copyright © 2005 General Motors Corp. Properly adjust TPS (Appendix F) Reduce Engine Speed Calibrate properly Install correct control module Check wiring and connectors in control module. Refer to transmission Service Manual, Replace C6 assembly piston seals Refer to transmission Service Manual. Rebuild C6, Refer to transmission Service Manual, Check all T-case bearings as directed in transmission repair ‘manual. Reshim as necessary. Rebuild differential clutch. Refer to transmission Service Manual. Inspect and repair C7 electrical system (Appendix E) Determine source of leak and repair. Refer to transmission Service Manual,3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL~ ALLISON 4 GENERATION CONTROLS: GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS ‘Table 8-2. Resistance Module Troubleshooting Data Resistance Check in Wiring to Resistance Module* Voltage Signal"* Control Device Resistance—Ohms | % Retarder | Voltage Description Terminals 25% Application | +0.2V | Device Terminal Auto Full On AtoC 12k 100 36 No connections Pressure Switch Ato 32k 0 1 A Full On 100 36 B High 3-Step E-10R Bendix | Ato 32k 0 Li A Pedal 2 19 B 38 28 ie} 100 3.6 D 6-Step Hand Lever— | AtoC 32kQ Off 0 rr + Position 1 16 15 1 Position 2 2B 19 2 Position 3 48 23 3 Position 4 65 28 4 Position 5 84 32 5 Position 6 100 3.6 6 Auto “On Aw 12k 50 24 No connections 3 Pressure Switches— | AtoC 32k2 0 1 Low 32 19 A B Medium 68 23 A B High 100 36 K B Auto % On Atoc 21.4kQ 2 Pressure Switches Auto 2 19 Medium 68 28 A High 100 36 g B Dedicated Pedal No Checks | Interface not a 0 07-12 A resistance module 100 34-35 B c * Resistance module must be disconnected from the wiring hamess and retarder control devices. ™* These voltages must be measured between terminals A and B. Copyright © 2005 General Motors Corp, 847[3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL— ALLISON 4® GENERATION CONTROLS. APPENDIX J—3000 AND 4000 PRODUCT FAMILIES WIRING SCHEMATICS