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PCS 4LHD Application Manual

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PCS 4LHD/4LHDX APPLICATION GUIDE
Ph: 1.804.227.3023 | www.powertraincontrolsolutions.com

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Summary of Contents for PCS 4LHD

  • Page 1 PCS 4LHD/4LHDX APPLICATION GUIDE Ph: 1.804.227.3023 | www.powertraincontrolsolutions.com...
  • Page 2 Password: pcs4LHDapp No part of any PCS publication may be reproduced, stored in any retrieval system, or transmitted in any form by any means, including but not limited to electronic, mechanical, photocopying, recording, or otherwise without the prior written permission of Powertrain Control Solutions.

  • Page 3: Table Of Contents

    Table of Contents Section 1: Transmission Specifications and Attributes ............................1 - 18 Section 1.1 General Description .................................. 1 - 4 Section 1.1.1 Identification ................................2 Section 1.1.2 Feature Locations ...............................3 Section 1.1.3 Gear Ratios .................................4 Section 1.2 Physical Specifications ................................4 - 7 Section 1.2.1 Mass Properties ................................4 Section 1.2.2 Driveline Lengths ................................5 Section 1.2.3 Center of Gravity ..............................
  • Page 4 Table of Contents Section 2.3.6 Fluid Capacity ................................45 Section 2.3.7 Check Fluid Level .............................. 45 - 47 Section 2.3.8 Fluid Change ..............................48 - 52 Section 2.4 Transmission Shift Lever ..............................53 - 60 Section 2.4.1 Shaft Specs ................................54 Section 2.4.2 Lever Specs ............................... 55 - 58 Section 2.4.3 Electronic Range ..............................
  • Page 5 SECTION 1 TRANSMISSION SPECIFICATION AND ATTRIBUTES...

  • Page 6: Section 1: Transmission Specifications And Attributes

    Section 1. Transmission Specifications and Attributes 1.1 General Description The 4LHD/4LHDX is a fully automatic, electronically controlled, RWD/4WD transmission. It consists primarily of a three element hydraulic torque converter with a converter clutch, two planetary gear sets, various clutches, an oil pump, and a control valve body.

  • Page 7: Section 1.1.1 Identification

    4.4.1. VIN The following procedure is recommended for VIN operation. Typical locations are shown in Figure 4.4.1-1. 4LHD/4LHDX Application Manual 1. Scan bar-code on transmission. 2. Place etcher on transmission in designsted GMPT approved VIN number area or 1.1.1 Identification use hand stamp and imprint VIN number into transmission in designated GMPT approved area.

  • Page 8: Section 1.1.2 Feature Locations

    MOUNTING PAD TRANSMISSION CONTROL CONNECTOR HEAT SHIELD LOCATION (S) ATTACHMENT Figure 1.1.2-1: PCS 4LHD/4LHDX with GM GEN III Bellhousing and 2WD Extension Housing (Right Side View) FIGURE 2.4.6.1-2 2-Piece Transmission Case with Small Bell Housing (245mm/258mm) LINE Right Side View PRESSURE...

  • Page 9: Section 1.2 Physical Specifications

    4LHD/4LHDX Application Manual 1.1.3 Gear Ratios Gear Ratio 3.059:1 1.625:1 1.000:1 0.696:1 Reverse 2.294:1 1.2 Physical Specifications 1.2.1 Mass Properties Transmission Mass As Installed 4LHD/4LHDX 75 kg (165 lbs)* * This can vary +/- 3kg (6.6lbs) based on torque converter and output shaft...

  • Page 10: Section 1.2.2 Driveline Lengths

    ➤ ➤ ➤ ➤ ➤ ➤ ➤ ➤ ➤ ➤ Figure 1.2.2-1: PCS 4LHD/4LHDX with GM GEN III Bellhousing and 2WD Extension Housing Dimensions Type DIM (mm) GM GEN III Bell 176.3 259.2 618.0 794.3 568.0 226.3 C-6 Bell 142.3 225.2...

  • Page 11: Section 1.2.3 Center Of Gravity

    Object Weight 83.9 kg (185.00 lb) -253 mm (-9.96 in) 3 mm (.12 in) 17 mm (.67 in) Figure 1.2.3-1 4LHD/4LHDX with 2WD Extension Housing Object Weight 85.28 kg (188.00 lb) -251 mm (-9.90 in) 10 mm (.40 in) 18 mm (.70 in) Figure 1.2.3-2 4LHD/4LHDX with 4WD Extension Housing...

  • Page 12: Section 1.2.4 Inertia Properties

    Powertrain Control Solutions 1.2.3 Center of Gravity Cont’d Approximate location of CG; actual location will depend on transmission model. Contact PCS if actual is desired. 258 mm Torque Converter -253 mm -251 mm 3 mm 10 mm 17 mm 18 mm 1.2.4 Inertia Properties...

  • Page 13: Section 1.3 Maximum Performance Limitations

    1.3 Maximum Performance Limitations 1.3.1 Torque Limitations Engine Input Torque 4LHD with 258 MM Converter - 340 Nm (250 lb-ft) Maximum 4LHDX with 300 MM Converter - 542 Nm (400 lfb-ft) Maximum Gearbox Input Torque 4LHD with 258 MM Converter - 660 Nm (487 lb-ft) Maximum...

  • Page 14: Section 1.3.2 Rpm Limitations

    Control Solutions must be consulted for application specific maximum speeds. 1.3.3 Acceleration Limitations The 4LHD/4LHDX automatic transmission has been tested for longitudinal and lateral acceleration capability in vehicles under the following maneuvers at the entire temperature range: W.O.T. acceleration on level road. Panic stop from 30 mph followed by W.O.T. acceleration.

  • Page 15: Section 1.3.4 Temperature Limitations

    4LHD/4LHDX Application Manual 1.3.4 Temperature Limitations Functional Range: -40˚C to 55˚C (-40˚F to 131˚F) Defined as the ambient range where the vehicle will function without causing transmission operational concerns or thermal distress in adequately cooled installations. Underbody Temperature Life of the transmission gaskets, seals and connectors is affected by elevated temperatures. Airflow around the transmission and the proximity to heat sources such as catalytic converter or exhaust system influence the temperature build up at the transmission surface.

  • Page 16: Section 1.3.5 Grade Limitations

    Heat Shield Shown in Figure 1.3.4-1 is an available heat shield that protects the gasket, connector, and accumulator from common exhaust positions. Consult with PCS if this is necessary or adequate for your application. Figure 1.3.4-1: Heat Shield Exploded View 1.3.5 Grade Limitations...

  • Page 17: Section 1.4 Valvebody Features And Specifcations

    1.4.2 Neutral Idle As an option, the PCS valve body can disengage the forward gears when the vehicle is stopped and the brake pedal is pressed. By reducing the number of rotating components during idle, fuel consumption can be reduced especially for vehicles that spend a lot of time idling in gear.

  • Page 18: Section 1.5 Electrical Specifications

    Powertrain Control Solutions 1.5 Electrical Specifications 1.5.1 Solenoids Shift Abuse Reverse Forward Overrun Forward LO/REV Solenoid Solenoid Range Gear Input Sprag CL. Roller Band Clutch Clutch Clutch Clutch Clutch Assembly Clutch Applied Park Applied Applied Reverse Neutral Applied Holding Holding Applied Applied Holding...
  • Page 19 SHIFT PRESSURE CONTROL SOLENOID VALVE (SLS) 4LHD/4LHDX Application Manual d valve resistance should ohms when measured at FLUID PRESSURE TEST HOLE PLUG (334) SHIFT PRESSURE CONTROL Abuse Protection Solenoid (Non-Electronic Range) SOLENOID VALVE (SLS) (340) The identical Forward/Reverse Abuse Protection Solenoids (Non-ER) three port linear pressure control solenoids...

  • Page 20: Section 2.1 Transmission Input

    information to temperature. transmission fluid Powertrain Control Solutions assembly which submersed in flu internal electrical TRANSMISSION Transmission Fluid Temperature Sensor the operating temp FLUID PRESSURE MANUAL VALVE The PCM sends a • The Transmission Fluid Temperature Sensor is a negative temperature coefficient temperature sensitive resistor that POSITION SWITCH sensor and measu drops an input 5V signal to the values shown below.
  • Page 21 • The speed sensor will produce a maximum voltage (loaded) of 100 V peak positive and 100 negative at a maximum speed of 7200 RPM. • All available GM and PCS extension housings use a symmetrical 40 tooth speed gear on the output shaft, resulting in 40 pulses per revolution to the TCM.

  • Page 22: Section 1.5.2 Internal Wiring

    Powertrain Control Solutions 1.5.2 Internal Wiring Unless otherwise specified, electrical components operating range shall be 8.0 to 18.0 VDC. It is recommended that the transmission controls solenoids are not engaged without the engine running. Transmission electrical components should be fused separately from other vehicle components. Electrical Connections Two connections must be made to the transmission to interface with the TCM.
  • Page 23 4LHD/4LHDX Application Manual TRANSMISSION VALVE BODY SHIFT SOLENOID A SHIFT SOLENOID B TCC ENABLE SOLENOID (ON/OFF) TCC CONTROL PWM SOLENOID FORWARD CLUTCH SOLENOID REVERSE CLUTCH SOLENOID VEHICLE CONNECTOR PRESSURE CONTROL SOLENOID TEMP SENSOR Internal Mode Switch OUTPUT TURBINE SPEED SPEED...

  • Page 24: Section 2: Transmission To Vehicle Interfaces

    SECTION 2 TRANSMISSION TO VEHICLE INTERFACES...

  • Page 25: Section 2.1 Transmission Input

    Powertrain Control Solutions Section 2 Transmission to Vehicle Interfaces 2.1 Transmission Input 2.1.1 Torque Converters Power input and torque multiplication are accomplished by the transmission torque converter. Converters are available with a variety of internal components that offer torque ratios up to 1.95 to 2.1 (Refer to Section 2.2.4). A spring damper smooths out torsional variation when the converter clutch is locked.

  • Page 26: Section 2.1.2 Flexplate

    Powertrain Control Solutions 4.2.4. Flexplate to Converter Connection Converter piloting is provided by a counterbore in the end of the engine crankshaft, shown in Figure 4.2.4-1. Axial movement of the converter is contained within this “floating pilot” to Converter piloting is provided by a counter bore in the end of the engine crankshaft or flywheel adapter, shown in ensure that thrust loads are not transferred to the crankshaft thrust bearing.
  • Page 27 Dimension A: Rear face of engine to torque converter mounting lug. Dimension B: Rear face of engine to flexplate. The flexplate shown above is PCS part number TRN7007, reference Section 2.1.2 in this document or the PCS OEM Parts Catalog for more information.
  • Page 28 300 mm CONVERTER LUG TO REAR FACE OF ENGINE Powertrain Control Solutions ➤ ➤ 21.667mm±1.181 (ENGINE OFF) SECTION A - A CONVERTER PILOT .016 Ø43.234± .015 mm 281.0mm ENGINE BLOCK 258 mm CONVERTER LUG TO REAR FACE OF ENGINE ➤ ➤...
  • Page 29 4LHD/4LHDX Application Manual Figure 2.1.1-6: C6 Torque Converter Attachment Features Ph: 804.227.3023 Page 23 REV 1.1 10511 Old Ridge Rd. Ashland, VA 23005...
  • Page 30 Powertrain Control Solutions 2.1.2 Flexplate PCS uses a universal flexplate for our GM and SAE applications, while the C6 converter is designed for the stock C6 flexplate. Figure 2.1.2-1 GM Flexplate Figure 2.1.2-2 C6 Flexplate Ph: 804.227.3023 Page 24 REV 1.1...

  • Page 31: Section 2.1.3 Flywheel Interface

    To adapt to a wide variety of flywheels and bellhousing combinations, PCS uses Flywheel Kits (a combination of Engine Spacers and Flywheel Adapters as shown in Figure 2.1.1-3) to mate the 4LHD/4LHDX flexplate/torque converter with the engine’s flywheel. These parts must not be swapped between different Flywheel Kits.

  • Page 32: Section 2.1.4 Bellhousing To Flywheel Housing Interface

    The configuration of the engine mounting face varies according to engine usage. The 4LHD/4LHDX currently supports five types of mounting faces. Contact PCS for an updated list. Figures 2.1.4-1 to 2.1.4-5 show these bellhousing configurations. Dimensions are for reference only.
  • Page 33 4LHD/4LHDX Application Manual Figure 2.1.4-2: PCS SAE3 Bellhousing Front View Ph: 804.227.3023 Page 27 REV 1.1 10511 Old Ridge Rd. Ashland, VA 23005...
  • Page 34 Powertrain Control Solutions Figure 2.1.4-3: PCS SAE4 Bellhousing Front View Ph: 804.227.3023 Page 28 REV 1.1 10511 Old Ridge Rd. Ashland, VA 23005...
  • Page 35 4LHD/4LHDX Application Manual Figure 2.1.4-4 PCS SAE5 Bellhousing Adapter Front View Ph: 804.227.3023 Page 29 REV 1.1 10511 Old Ridge Rd. Ashland, VA 23005...
  • Page 36 Powertrain Control Solutions Figure 2.1.4-5: PCS C6 Bellhousing Front View Ph: 804.227.3023 Page 30 REV 1.1 10511 Old Ridge Rd. Ashland, VA 23005...

  • Page 37: Section 2.2 Transmission Output

    It is critical that the extension housing is properly sealed from the environment and transfer case oil. Fluid enters the cavity from both the oil jet and output shaft bearing, and drains to the oil pan through the return vent. PCS uses a universal extension housing to transmission seal.

  • Page 38: Section 2.2.3 Extension Housings

    PCS Engineering approval for load analysis. Mount loads should be supplied by the customer. For an updated list of vehicle mount options reference the PCS OEM Parts Catalog. The factory torque rating for the six transmission to extension housing bolts is 37 ft*lbs / 45 N*m. In addition, the speed sensor bolt in 2WD applications has a torque rating of 8 lb*ft / 11 N*m.
  • Page 39 4LHD/4LHDX Application Manual 2WD SPLINE DATA Number of Teeth Form Diameter 27.94 mm Module 1.0583 mm Min Effective Tooth Thickness (Reference) 1.732 mm Diameter Pitch 24.000 mm Max Effective Tooth Thickness 1.821 mm Min Actual Tooth Pressure Angle 30.0˚ 1.719 mm...
  • Page 40 Shown in Figures 2.2.3-2 and 2.2.3-3 is the PCS approved two speed electronic shifting transfer case. 2Hi, 4Hi, Neutral, and 4Lo are controlled via an external PCS Transfer Case Module. The rear output shaft takes a GM 32 tooth female yoke, while the front output shaft takes a GM 32 tooth make yoke.
  • Page 41 4LHD/4LHDX Application Manual Figure 2.2.3-3: GM 4WD Transfer Case Ph: 804.227.3023 Page 35 REV 1.1 10511 Old Ridge Rd. Ashland, VA 23005...
  • Page 42 PCS Parking Brake The PCS parking brake is a disk style brake that attaches to the 4LHD/4LHDX in rear wheel drive applications. It provides a mechanical brake and also has an optional hydraulic brake that can be used for certain applications. It also can be electronically controlled with the Parking Brake Module.
  • Page 43 Figure 2.2.3-8. A common example, shown in figure 2.2.3-7 is the Spicer 3-2-159. This is a parking brake only, not an emergency brake. Max vehicle holding weight is dependant on final gear ratio and tire size. Contact PCS for application engineering.
  • Page 44 Powertrain Control Solutions PCS C6 Extension Housing This replacement package holds all the same specifications as the old Ford C6 w/ drum parking brake option. Shown in Figures 2.2.3-9 to 2.2.3-10. This utilizes the original brake housing, drum, driveshaft yoke, and other hardware to correctly seal and operate.
  • Page 45 4LHD/4LHDX Application Manual Figure 2.2.3-10: PCS C6 Extension Housing Ph: 804.227.3023 Page 39 REV 1.1 10511 Old Ridge Rd. Ashland, VA 23005...

  • Page 46: Section 2.3 Transmission Cooling

    Fluid Specification The ATF to be used in any PCS 4LHD/4LHDX shall be Dexron® VI or equivalent. Transmission damage caused by the use of improper fluid will not be covered under warranty. Ph: 804.227.3023 Page 40 REV 1.1...

  • Page 47: Section 2.3.2 Cooler Requirements

    4LHD/4LHDX Application Manual 2.3.2 Cooler Requirements To provide proper operation and longevity, the cooling system must maintain the transmission sump temperature below 132°C (270°F) and stator temperature below 177°C (350°F) at all times. This is defined as a “never exceed” limit under all operating conditions.
  • Page 48 Powertrain Control Solutions The cooler line interface exiting the case of the 4LHD/4LHDX is a #6 SAE Dash Size ORB (O-Ring Boss) for the hydraulic fitting. Reference figure 2.3.3-2 for dimensions and SAE J514 for more detailed specifications. SAE J514 Dimensions...

  • Page 49: Section 2.3.4 Dipstick

    The procedure to develop the indicator markings from the functional level limits must take into account the tolerance added by the indicator stick. The 4LHD/4LHDX system depends on the tip of the indicator contacting the indicator stop. The system depends on the indicator being longer than the nominal path thru the center of the fill tube.

  • Page 50: Section 2.3.5 Overflow Vent

    Remotely attached breathers are required, new designs must be provided by the vehicle manufacturer to be reviewed with Powertrain Control Solutions Engineering. PCS overflow vent kits serve this purpose and are available for purchase. Reference the PCS OEM Parts Catalog for part numbers.

  • Page 51: Section 2.3.6 Fluid Capacity

    4LHD/4LHDX Application Manual 2.3.6 Fluid Capacity A universal bottom pan is provided with the PCS 4LHD/4LHDX. Approximate total fluid capacity values are listed below. Cooler size and cooler line lengths will alter these values. • 8.4 L (8.8 qt) with 258 mm torque converter •...
  • Page 52 Powertrain Control Solutions NOTE: Always check the fluid level at least twice. Consistent readings are important to maintaining proper fluid level. If inconsistent readings are noted, inspect the transmission vent assembly to ensure it is clean and unclogged. 4. Keep the dipstick pointing down and check both sides of the dipstick, and read the lower level. Repeat the check procedure to verify the reading.
  • Page 53 4LHD/4LHDX Application Manual 5. Inspect the color of the fluid on the dipstick. 6. A safe operating fluid level is within the HOT crosshatch band on the dipstick. If the fluid level is not within the HOT band, and the transmission temperature is between 82–93°C (180–200°F), add or drain fluid as necessary to bring the level into the HOT band.

  • Page 54: Section 2.3.8 Fluid Change

    Powertrain Control Solutions 2.3.8 Fluid Change The useful life of the transmission depends on the time at temperature of the ATF, which is a function of the transmission duty cycle, cooling system efficiency and local ambient temperatures. Transmission Fluid must be changed as listed below.
  • Page 55 4LHD/4LHDX Application Manual 5. Loosen the rear oil pan bolts approximately 4 turns. 6. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. Reference Figure 2.3.8-1. 7. Remove the remaining oil pan bolts. Reference Figure 2.3.8-2.
  • Page 56 Powertrain Control Solutions 9. Grasp filter firmly while pulling down with a twisting motion in order to remove the filter. Reference Figure 2.3.8-4. Figure 2.3.8-4 10. If the filter is going to be replaced, remove the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal.
  • Page 57 4LHD/4LHDX Application Manual 1. Coat the new filter seal with automatic transmission fluid. 2. Install the new filter seal into the transmission case. Tap the seal into place using a suitable size socket. Reference Figure 2.3.8-6. 3. Install the new filter into the case.
  • Page 58 Powertrain Control Solutions 5. Install the oil pan bolts and tighten alternately and evenly to 11 Nm (97 lb in). Reference Figure 2.3.8-8. 6. If previously removed, reinstall the exhaust heat shield. 7. Lower the vehicle. 8. Fill the transmission to the proper level with DEXRON® VI transmission fluid.

  • Page 59: Section 2.4 Transmission Shift Lever

    4LHD/4LHDX Application Manual 2.4 Transmission Shift Lever Driver selection of the transmission range is normally accomplished through a cable linkage connecting a floor or column mounted selection lever to a transmission shift lever on the manual shaft. The vehicle manufacturer must make provisions to provide all the linkage and controls up to the transmission manual shaft.

  • Page 60: Section 2.4.1 Shaft Specs

    Powertrain Control Solutions 2.4.1 Shaft Specs The shift lever (which is to be supplied by the vehicle manufacturer) must conform to the following specification: Stock Thickness: 4.3 to 4.7 mm (0.169 to 0.185 in) 3.4.2. Manual Shaft/Lever Interface Hardness: Surface file hard Rc 59 min. The shift lever (which is to be supplied by the vehicle assembly division) must conform to Case depth 0.12 to 0.25 mm (0.005 to 0.010 in) the following specification:...

  • Page 61: Section 2.4.2 Lever Specs

    4LHD/4LHDX Application Manual 2.4.2 Lever Specs Angular positions of the nominal transmission range detents are shown in the following figure. FLATS IN PARK 8.405±0.025MM 10.7° 21.5° 32.2° 43.4° 18.0° 54.6° 77.8° Figure 2.4.2-1 Transmission Detent Angles Shift System Assembly Process FIGURE 3.4.1-1 Transmission Detent Angles...

  • Page 62: Section 2.4 Transmission Shift Lever

    Powertrain Control Solutions Transmission Range Selection System Requirements System Drag: The maximum amount of drag associated with the shifter system as seen by the transmission must be a minimum of 0.45 Nm (4.0 in lb) lower than the detent centering torque provided by the transmission. (See following figure.) This will enable the transmission to control the position of the range selection system within each gear range.
  • Page 63 4LHD/4LHDX Application Manual Transmission Range Selection System Kinematic Relationship 3.4.4. Transmission Range Selection System Kinematic Relationship Requirements Requirements The transmission Park system is designed for park engagement with the transmission detent roller located in the Park The transmission Park system is designed for park engagement with the valley of the detent lever.
  • Page 64 3.4.4.2. Kinematic Requirements Powertrain Control Solutions Under minimum stack conditions and neglecting lost system motion, the kinematic relationship between the detent lever and the range selection lever is to ensure that the detent roller is in the Park valley when the range selection lever is in the minimum Park gate as seen in the following figure.

  • Page 65: Section 2.4.3 Electronic Range

    2.4.3 Electronic Range Use of a PCS valve body and PCS TCM can eliminate the shift cable. This allows for electronic shifting of the transmission with the push of a button or movement of an electronic lever. In this application the transmission manual shaft must be engaged in neutral at all times.

  • Page 66: Section 2.4.3 Electronic Range

    Powertrain Control Solutions Figure 2.4.3-2: Electronic Range Shifter Shifter Specifications Column Size 38mm, 45mm, 55mm Neutral Lock none, drop-down Speeds 2, 3, 4, and 6 Lights Wiper Speeds Buttons Horn, Wash, Drop- Down Connectors integral Packard, integral Deutsch, wire harness Expected Life Cycle 1 million (rotary);...

  • Page 67: Section 2.5 Tcm Interface

    -40°C to 105°C for under the hood mounting locations. The customer is responsible for meeting the agreed temperature limitations. PCS offers a bracket kit to mount the TCM on the transmission case. Reference Figure 2.5.2-1 and the PCS OEM Parts Catalog for more information.
  • Page 68 Powertrain Control Solutions Water/Dust Intrusion PCS and the customer must agree upon applicable water and dust intrusion specifications, test levels, and report formats. More stringent requirements will increase TCM costs due to enclosure and connector sealing requirements. Electromagnetic Compatibility (EMC) PCS and the customer must agree upon applicable EMC specifications, PCS shall be responsible for TCM testing to applicable EMC specifications.

  • Page 69: Section 2.5.2 Vehicle Electrical Interface And Diagnostics

    • 2 X CAN 2.0b • 1x RS-232, 1 x J1850 All PCS TCMs are based on the PCS proprietary real-time operating system which contains the functionality to control nearly any automatic transmission with PCS controls and includes diagnostics. The customer shall be responsible for service tool system testing and certification.
  • Page 70 The PCS TCM can receive and transmit data over CAN. J1939 is supported as well as PCS proprietary communication. Refer to the document PCS J1939 Messages for more information. If CAN is not available for receiving inputs, refer to the discrete signal descriptions below.
  • Page 71 Engine Speed: The engine speed is a frequency input provided by either a magnetic pickup or a conditioned signal source. It requires a range of 300 to 7000 RPM. Signal output methods are developed with PCS and the engine supplier.
  • Page 72 CAN1 H Measurement CAN1 L Programmable Bridge Mode CAN2 H Battery Constant +12V CAN2 L PCS Tuning Interface Programmable 120 Ohm terminating resistor Ground Ground Input: 8-16 VDC Comm Serial: Use TCM4181 Cable Data Logging Interface USB: Use TCM4180 Cable...

  • Page 73: Section 2.5.3 Harness Overview

    4LHD/4LHDX Application Manual 2.5.3 Harness Overview At PCS, we design and produce our harnesses using decades of automotive experience and customer feedback. We have many standard 4LHD/4LHDX harnesses available, and we are eager to assist vehicle manufacturers in developing vehicle specific units.

  • Page 74: Section 2.6 Throttle Position Sensor

    The throttle position sensor is a critical input to the TCM. Failure to properly install the throttle position sensor will result in improper transmission operation and damage. PCS can provide a throttle position kit as shown in Figure 2.6-1. Figure 2.6-1 PCS TPS Overview Position 1: LOW FAILURE POSITION.
  • Page 75 TCM software monitor screen is between 3.5V and 4.5V. It is strongly recommended to use the arm provided by PCS. In situations where the vehicle manufacturer must design a custom arm, refer to figure 2.6.8.12-3 provided for the design of the arm to the sensor.
  • Page 76 SECTION 3 PRODUCTION LINE PROCEDURES...

  • Page 77: Section 3 Production Line Procedures

    Powertrain Control Solutions Section 3 Production Line Procedures 3.1 Assembly Procedures 3.1.1 Storage Requirements The transmission shipping containers are designed to protect the transmission from some environmental conditions. They are only effective if they are properly closed. Verify the top cover on the cocoons is properly aligned to insure no foreign materials such as water can get inside.

  • Page 78: Section 3.1.3 Assembly Requirements

    Nm ±10 Nm. The checking torque, or static torque, should be 55 Nm ±15 Nm. An access area 85 mm long by 25 mm in diameter is recommended for accessibility to the transmission to engine fasteners. When using the PCS provided adapters all necessary hardware including the bolts are provided.

  • Page 79: Section 3.2 End-Of-Line Inspection Procedures

    3.2.2 Stationary Engine-Off Checks Firmware Turn the ignition on (do not start the engine) and connect to the TCM with the PCS TCM Diagnostic Software. Verify the firmware version is the current, recommended version on the PCS website referenced below. Perform a firmware upgrade if necessary.

  • Page 80: Section 3.2.3 Stationary Engine-Running Checks

    Diagnostic Code Verification Upon completion of the test drive, check to see if any diagnostic codes have been set. If any are present refer to the PCS 4LHD/4LHDX Technicians Guide for a full list of these codes and troubleshooting instructions.

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