Workhorse ALLISON 1000MH Service Manual

Automatic transmission

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WORKHORSE CUSTOM CHASSIS

Service Manual

AUTOMATIC TRANSMISSION

WSM082106

ALLISON 1000MH/2100MH/LCT1000

TRANSMISSION

SELECTED RANGE

GEAR ATTAINED

HIGHLIGHTED

9999.9mi

PRND321

OVERDRIVE (O/D) SWITCH "OFF"

(DEPRESSED AT THE TOP)

PAGE

SECTION

7.2

Automatic Transmission – Allison

2007

MAXIMUM/

SELECTED

GEAR

gear

2007 W Series Chassis

REMOTE

SHIFTER

2007 W Series

Table of Contents

Summary of Contents for Workhorse ALLISON 1000MH

Page 1 2007 AUTOMATIC TRANSMISSION ALLISON 1000MH/2100MH/LCT1000 TRANSMISSION MAXIMUM/ SELECTED RANGE GEAR ATTAINED SELECTED HIGHLIGHTED GEAR gear 9999.9mi REMOTE PRND321 SHIFTER OVERDRIVE (O/D) SWITCH "OFF" (DEPRESSED AT THE TOP) WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 2: Table Of Contents
Oil Pump Cover/Oil Pump Assembly and INTRODUCTION ............. 50 Associated Parts Disassembled View ....29 Objectives Of This Section ........50 1-2-3-4, 4-5-6 Clutch Assembly Disassembled Description and Operation ........50 WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 3 DTC P0872 ............294 DTC P0712 ............160 DTC P0873 ............299 DTC P0713 ............164 DTC P0873 ............304 DTC P0716 ............169 DTC P0877 ............309 WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 4 DTC P2764 ............432 Reverse .............. 479 DTC P2771 ............436 Transmission Will Not Shift to Forward or Symptoms - Automatic Transmission ....440 Reverse .............. 480 WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 5 Transmission Heat Shield Replacement ....501 Transmission Mount Replacement ....... 502 Transmission Replacement (L18) Engine) ... 504 Emergency Removal From Park ......522 Electronic Shift Controller (ECS) Actuator Initial Installation ............522 WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 6: Specifications
20 lb ft Output Speed Sensor to Rear Cover 12 N·m 108 lb in Bolt Power Take-Off (PTO) Cover to Main 43 N·m 32 lb ft Housing Bolts WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 7: Fluid Capacity Specifications
11.5 Shift Solenoid 1 (SS1), SS2, SS3, and Modulated Main Pressure (MAIN MOD) Solenoid Speciﬁ cations Sump Temperature Resistance Degrees C Degrees F Ohms 20.0 22.0 24.5 WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 8: Transmission Fluid Temperature (Tft) Sensor Temperature Vs. Resistance Specifications
1424 1459 1493 1163 1191 1218 955.0 977.1 999.2 788.6 806.5 824.5 654.7 669.3 683.9 546.3 558.3 570.2 458.1 467.9 477.8 385.9 394.1 402.2 326.6 333.3 340.1 WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 9: Temperature Versus Resistance (Speed Sensor)
1.93 2.14 2.36 2.16 2.40 2.64 2.34 2.60 2.86 2.61 2.90 3.20 2.84 3.16 3.47 3.07 3.41 3.75 3.30 3.67 4.03 3.48 3.87 4.26 WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 10: Temperature Versus Resistance (Solenoid)
HIGH Closed Open HIGH N/C = Normally Closed N/O = Normally Open * Pressure switch 1 (PS1) reverts to the Closed/LOW state with throttle applied in REVERSE. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 11: Transmission Internal Mode Switch Logic
Reverse Clutch Trimming On Steady State N or P De-energized; Low and Reverse De-energized; Exhausted Clutch Applied Upshift De-energized; Low and Reverse Energized; 1-2-3-4 Clutch Clutch Applied Trimming On WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 12 De-energized; 3rd, 5th, and De-energized; 2-6 Clutch Clutch Reverse Clutch Trimming On Trimming Off Steady State 4-5-6 Energized; 3rd, 5th, and Reverse Energized; 2-6 Clutch Applied Clutch Clutch Exhausted WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 13: Solenoid And Clutch Chart (Tow/Haul)
Energized; 3rd, 5th, and Reverse Energized; 4-5-6 Clutch Trimming Off Clutch Clutch Trimming On Steady State 4-5-6 Energized; 3rd, 5th, and Reverse Energized; 1-2-3-4 Clutch Applied Clutch Clutch Exhausted WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 14: Shift Speed (1-2 And 2-3 Shifts)
1185 1474 2370 1647 2081 3237 2451 2451 3488 1994 1517 1243 8.1L Tow/Haul 2023 1965 2399 2875 2774 3352 2976 3038 3756 2514 2167 1532 1040 WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 15 ** = The state of the solenoid follows a shift pattern, which depends upon vehicle speed and throttleposition. The pattern does not depend upon the selected gear. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 16: Line Pressure
Tool Number/ Description Scan Tool J 8092 Universal Driver Handle - 3/4 in - 10 J 5959 Dial Indicator Clamp and Adjuster J 21366 Torque Converter Retaining Strap WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 17 Bar and Stud Assembly Bushing and Bearing Remover 3-4 in J 24420-B J 33163 Valve Tray Set Universal Puller J 24446 J 36850 Rear Bearing Installer Transjel® Lubricant WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 18 J 43770 Torque Converter End Play Gage Main Lube, Converter Relief Valve Spring Compressor J 43765 J 43771 Stator Shaft Installer/Remover Pump Bushing Removal and Installation Tool WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 19 J 43774 J 43780 Stator Shaft Bushing Installer Transmission Case Locating Pin Installer J 43775 J 43781 Oil Pump Cover Needle Bearing Input Carrier Bushing Remover/ Installer Installer WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 20 Installer J 43791 J 43911 Output/Turbine Shaft Bushing Installer Manual Shift Shaft Seal Remover J 43797 J 44247 Output Carrier Bearing Race Installer Internal Wiring Harness Installer WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 21 Main Shaft Holder Remover J 44528 J 44723 Output Carrier Bearing Race Remover Transmission/Stand Adapter Plate J 44529 J 45023 Stator Shaft Bushing Remover Control Main Filter Wrench WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 22: Component Locator
(3) Output Speed Sensor Harness Connector (4) Transfer Case Selector Shift Control Switch (5) Transmission Connector Harness (6) Allison Transmission (7) Engine Harness (8) Automatic Transmission Input Shaft Speed (ISS) Sensor WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 23: Automatic Transmission Inline Harness Connector End View
Fluid Pressure Switch 2 (PS2) Signal 1225 Fluid Pressure Switch 2 (PS2) Signal YE/BK 1227 Transmission Fluid Temperature (TFT) 1227 Transmission Fluid Temperature (TFT) Sensor Signal Sensor Signal WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 24 Pressure Control Solenoid 2 (PCS2) Actuator Supply Voltage 2 (HSD2) RD/BK Actuator Supply Voltage 2 (HSD2) BN/WH 2469 Pressure Control Solenoid 1 (PCS1) L-BU 2469 Pressure Control Solenoid 1 (PCS1) WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 25 Internal Mode Switch Signal B BK/WH Internal Mode Switch Signal A YE/BK Internal Mode Switch Signal A Internal Mode Switch Signal P Internal Mode Switch Signal P WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 26: Engine Harness To Transmission
Input Speed Sensor Vehicle Speed Sensor O-ring Torque Converter Housing Bolt, M10 x 1.5 x 25 (10) Transmission Oil Cooler Pipe Connector (2) Torque Converter Housing Access Hole Cover WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 27: Components Disassembled View
3rd, 5th, and Reverse Clutch Piston Return Spring Assembly (3) 10 3rd, 5th, and Reverse Clutch Spring Plate 11 3rd, 5th, and Reverse Clutch Piston Assembly (Bonded Seals) WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 28: Oil Pump Assembly Disassembled View
Bushing, 33.8 mm (1.33 in) ID Stator Shaft Torque Converter Clutch Valve Torque Converter Clutch Valve Spring Torque Converter Clutch Valve Stop Torque Converter Clutch Valve Retainer WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 29: Oil Pump Cover/Oil Pump Assembly And Associated Parts Disassembled View
2 Oil Pump Assembly 1 1-2-3-4, 4-5-6 Clutch Assembly 3 Torque Converter Housing to Case Channel Plate 2 Overlap Seal Ring (2) 4 Overlap Seal Ring, End WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 30: Torque Converter Housing/Automatic Transmission Case And Associated Components Disassembled View
31 1-2-3-4 Clutch Backing Plate Internal Retainer Ring 20 Torque Converter Housing 32 1-2-3-4 Clutch Hub Thrust Bearing Assembly 50 Transmission Case 33 1-2-3-4 Clutch Hub 70 Transmission Fill Tube Plug WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 31: Automatic Transmission Case Disassembled View
Automatic Transmission Case Transmission Case Locating Pin Transmission Vent Assembly Transmission Vent Cap Transmission Vent Nameplate Rivet Nameplate Vehicle Speed Sensor Bolt, M6 x 1.0 x 13 WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 32: Clutch/Low And Reverse Clutch Disassembled View
2-6 Clutch Backing Plate Internal Retaining Ring Internal Retaining Ring Low and Reverse Clutch Backing Plate Low and Reverse Clutch Fiber Plate (6) Low and Reverse Clutch Steel Plate (5) WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 33: Input Carrier, Intermediate Carrier, And Main Shaft Disassembled View
5 Intermediate and 2-6 Clutch Ring Gear Intermediate Carrier and Ring Gear Assembly Intermediate Carrier Thrust Bearing Main Shaft Intermediate Sun Gear Intermediate Sun Gear Spacer Output Sun Gear WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 34: Output Carrier Disassembled View
Input Carrier Thrust Washer (4) Output Carrier and Low and Reverse Clutch Ring Gear Input Carrier Roller Bearing Assembly (8) Input Carrier Pinion Gear (4) Input Carrier Thrust Washer (4) WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 35: Intermediate Carrier Assembly Disassembled View
Intermediate Carrier Pinion Gear (4) Bushing, 20 mm (0.8 in) ID Intermediate Carrier Thrust Washer (4) Output Shaft, 2WD Intermediate Carrier Spindle (4) Output Shaft, 4WD (Not Used) Output Carrier Assembly WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 36: Low And Reverse Clutch Piston Housing Disassembled View
Output Carrier Thrust Washer (4) Output Nut, 4WD (Not Used) Output Carrier Planetary Spindle (4) Rear Shipping Cover, 2WD Output Carrier Bearing Race Rear Shipping Cover, 4WD (Not Used) WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 37: Low And Reverse Clutch Housing Assembly Disassembled View
Output Carrier Support Bearing Output Speed Sensor Reluctor Wheel Low and Reverse Clutch Housing, Vehicle Speed Sensor Bolt, M6 x 1.0 x 13 10 Sensor Shipping Cover WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 38: Control Valve Body Assembly Disassembled View
12 Bolt, M6 x 10 x 50 13 O-Rings 14 Modulated Main Pressure (MAIN MOD) Solenoid 15 6 Speed Pipe Control Valve Body Assembly Shift Valve Body Assembly Separator Plate WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 39: Shift Valve Body Assembly
Shift Valve Body Assembly Retaining Clip Shift Solenoid 2 (SS2) Shift Plug SS2 Shift Spring SS2 Shift Valve Retaining Clip SS3 Shift Plug SS3 Shift Spring SS3 Shift Valve WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 40: Main Valve Body Assembly Disassembled View
Exhaust Pressure Regulator Valve 37 Accumulator Spring (2) Retaining Clip 38 PCS1 and PCS2 Retaining Bracket Control Relief Spring Control Relief Valve Main Valve Body Locating Pin (4) WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 41: Bearing And Bushing Locations
1-2-3-4 Clutch Drive Hub Thrust Bearing 4-5-6 Clutch Hub Thrust Bearing Input Carrier Thrust Bearing Stator Shaft Overlap Seal Ring Intermediate Carrier Bushing Stator Shaft Overlap Seal Ring WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 42: Automatic Transmission Internal Connector End Views
• Description: 2-Way F Metri-Pack 150.2 Series P2S (MD-GY) Pin Wire Color Circuit No. Function Actuator Supply Voltage 1 (HSD1) 1532 Modulated Main Pressure Control Solenoid Low Pressure Control Solenoid 1 (PCS1) WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 43 Pin Wire Color Circuit No. Function Actuator Supply Voltage 1 (HSD1) RD/BK Actuator Supply Voltage 2 (HSD2) L-BU 1526 Pressure Control Solenoid 2 (PCS2) D-BU 1525 Pressure Control Solenoid 1 (PCS1) WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 44 Signal 1226 Fluid Pressure Switch 3 (PS3) Signal Fluid Pressure Switch 4 (PS4) Signal 1227 Transmission Fluid Temperature (TFT) Sensor Signal Transmission Fluid Temperature (TFT) Sensor Low WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 45 Function RD/BK Actuator Supply Voltage 2 (HSD2) RD/BK Actuator Supply Voltage 2 (HSD2) YE/BK 1528 Shift Solenoid 2 (SS2) Low BK/WH 1529 Shift Solenoid 3 (SS3) Low WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 46 PK/BK Transmission Range Switch Signal Control Solenoid (TCC PCS) Low YE/BK Transmission Range Switch Signal TN/WH Transmission Range Switch Signal BK/WH 1995 Transmission Range Switch Signal Ground WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 47 Speed Sensor (AT ISS) Signal - Sensor Signal High L-BU 1984 Transmission Turbine Speed D-BU/WH 1231 Automatic Transmission Input Sensor Low Reference Speed Sensor (AT ISS) Signal - WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 48 Vehicle Speed Sensor (VSS) Signal Low 4440 Battery Positive Voltage Not Used RD/BK 1228 Actuator Supply Voltage 1 (HSD1) GY/BK 1694 Four Wheel Drive (4WD) Low 12-13 Not Used Signal WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 49 Function Not Used PU/WH Vehicle Speed Sensor (VSS) Signal Actuator Supply Voltage 2 (HSD2) Not Used L-GN/BK Vehicle Speed Sensor (VSS) Signal BK/WH Transmission Range Switch Signal WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 51 Extended Soft: A slow, almost unnoticeable, clutch apply Double Bump: Two bumps felt during a clutch apply Surge: A repeating engine-related condition of WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 52: Transmission Abbreviations
TPS: Throttle Position Sensor AC: Alternating Current VBS: Variable Bleed Solenoid DC: Direct Current WOT: Wide-Open Throttle DLC: Diagnostic Link Connector 2WD: Two-Wheel Drive DMM: Digital Multimeter WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 53: Transmission Identification Information
(1) Nameplate (1) Model (Series) (2) Date of Manufacture (3) Engineering Feature Conﬁ guration Number (4) Transmission Identiﬁ cation Number (5) Engineering Group Number (6) Serial Number WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 54: Transmission General Description
10. Inspect to ensure a properly grounded drain wire. 11. Inspect for the presence of a strong external AC signal. 12. Repair or replace parts as required. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 55: Transmission Component And System Description
By the engagement of the clutches in various combinations, the planetary sets act singly or together to provide 6 forward WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 56 All 1000 Series transmissions have a park pawl. The internal parking pawl is engaged by selection of the • Tow/haul is designed to be most effective when the WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 57 Sixth that constantly adjusts shift characteristics for changes in operating conditions. These adjustments are based on vehicle conditions, such as grade, load, and engine power. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 58: Transmission Indicators And Messages
Extremely Low ATF temperature: A shift out of NEUTRAL when the ATF temperature is below -45°C (- 49°F) may be inhibited. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 59: Electronic Component Description
TCM. Other data sent to the TCM include throttle position, engine, turbine, and output speeds, and sump temperature. Any active special function, such as anti-lock brakes or power take-off, is also an input WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 60 TCM. The IMS detects clutch apply pressures, resulting in the best possible the angular position of the shift selector shaft. This shift quality. Hydraulic conditions are detected by WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 63 (MOD MAIN) pressure solenoid (9) current to ﬂ ow from the positive contact and through the and the IMS (10). All of these connectors go to the main WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 64 3 stays de-stroked and main Normally closed PCS1 blocks the exhaust of the PCS1 pressure is blocked from reaching the manual selector WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 65 TCC valve and shift valve 2 to low and reverse clutch. 3rd, 5th, and reverse clutch remains on with low and reverse clutch, resulting in Reverse (R) range being attained. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 66 WORKHORSE CUSTOM CHASSIS 2007 W Series Chassis PAGE SECTION Service Manual Automatic Transmission – Allison Neutral WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 67 “latched” down), allowing both valves keeping the low and reverse clutch applied. Main to de-stroke. PCS2 is also de-energized, exhausting pressure continues to be directed through shift valve WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 68 2 will stay de-stroked, directing fluid to the 3rd, 5th, and 2 will stay de-stroked, directing fluid to the 3rd, 5th, and reverse clutch, resulting in third range operation. reverse clutch, resulting in third range operation. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 69 WORKHORSE CUSTOM CHASSIS 2007 W Series Chassis PAGE SECTION Service Manual Automatic Transmission – Allison First Range WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 70 The 3rd, 5th, and reverse clutch has remains applied. Because only one clutch is applied, the an exhaust path through shift valve 2 to the pressure WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 71 The combination of the 3rd, 5th, and reverse clutch and the low and reverse clutch application produces reverse range operation for limp home capability. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 72 WORKHORSE CUSTOM CHASSIS 2007 W Series Chassis PAGE SECTION Service Manual Automatic Transmission – Allison Second Range WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 73 PCS1 pressures. The PCS1 pressure is directed through of the 2-6 clutch to pressure control valve 2. Normally shift valve 2 to the 3rd, 5th, and reverse clutch. The WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 74 Main pressure goes through shift valve 3, the manual selector valve and shift valve 2 to the low and reverse clutch, applying the clutch. The combination of WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 75 WORKHORSE CUSTOM CHASSIS 2007 W Series Chassis PAGE SECTION Service Manual Automatic Transmission – Allison Third Range WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 76 3, stroking the valve. In the stroked position, The converter ﬂ ow valve de-strokes, redirecting main main pressure is redirected through shift valve 2 and the WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 77 ﬁ fth range and neutral operation, the engine may be shut down and restarted to attain neutral, third, and reverse operation. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 78 WORKHORSE CUSTOM CHASSIS 2007 W Series Chassis PAGE SECTION Service Manual Automatic Transmission – Allison Fourth Range WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 79 2 are in the de-stroked position, and pressure switch 3 the 4-5-6 clutch exhausts through the manual selector remains ON, providing feedback that shift valve 3 is in WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 80 ﬁ fth range, resulting in only ﬁ fth and neutral operation, the engine may be shut down and restarted to attain neutral, third and reverse operation. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 81 WORKHORSE CUSTOM CHASSIS 2007 W Series Chassis PAGE SECTION Service Manual Automatic Transmission – Allison Fifth Range WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 82 The TCC is (OFF) providing feedback that shift valve 1 and shift now released. valve 2 remain in the de-stroked position, and pressure WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 83 ﬁ fth range and neutral operation, the engine may be shut down and restarted to attain neutral, drive, and reverse operation. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 84 WORKHORSE CUSTOM CHASSIS 2007 W Series Chassis PAGE SECTION Service Manual Automatic Transmission – Allison Sixth Range WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 85 3rd, 5th, and reverse clutch. When the valve is moved to Neutral (N) or a forward range, the shift to reverse is complete, PCS2 fully energizes and WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 86 If electrical power is interrupted with the transmission operating in reverse range, resulting in neutral operation, the engine may be shut down and restarted to attain neutral, third and reverse operation. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 87 WORKHORSE CUSTOM CHASSIS 2007 W Series Chassis PAGE SECTION Service Manual Automatic Transmission – Allison Reverse Range WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 88 If electrical power is interrupted with the transmission operating in reverse range, resulting in neutral operation, the engine may be shut down and restarted to attain neutral, third and reverse operation. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 89 WORKHORSE CUSTOM CHASSIS 2007 W Series Chassis PAGE SECTION Service Manual Automatic Transmission – Allison Reverse Range - Limp Home WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 90 ﬂ ow valve. The converter ﬂ ow valve de-strokes, redirecting main overage to converter in and converter out to the cooler. The TCC is now released. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 91 WORKHORSE CUSTOM CHASSIS 2007 W Series Chassis PAGE SECTION Service Manual Automatic Transmission – Allison Third Range - Limp Home WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 92: Electronic Controlled Shifter (Ecs) System
The Interface Module communicates electronically with Allison TCM and Park-Neutral-Position (PNP) switch. The Actuator Control communicates with the Arens 12VDC actuator and the integrated Position Sensor. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 93 Pressing the “N” button shifts the transmission to allows the transmission to shift automatically. allows the transmission to shift automatically. Neutral. Neutral can be used to start the vehicle. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 95: Diagnostic Information And Procedures
Varies 2-1 TAP Cell 7 Varies a malfunction exists, identify the concern by referring to 2-1 TAP Cell 8 Varies Symptoms - Automatic Transmission . The Symptoms WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 96 4-5 Adapt Status Cell 2 Fast/Slow Varies 3-2 TAV Cell 2 CM[caret ]3 Varies 4-5 TAP Cell 1 Varies 3-4 Adapt Status Cell 0 Fast/Slow Varies 4-5 TAP Cell 2 Varies WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 97 Engine Torque F5, F6, F7, R Cell 1 GS TAV From Drive 4 to CM[caret ]3 Varies Driver-Reverse Adapt Numeric Varies R Cell 2 Status Cell 0 Value WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 98 Varies Short to GND Current TCC Duty Cycle Short Yes/No PC Sol. B Ref. Current F0, F3 Amps Varies to Volts TCC Slip Speed F0, F1 Varies WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 99: Scan Tool Data Definitions
(0 V). When the ECT is low -40°C (-40°F), the signal voltage is high (5 V). Engine Run Time: Displays a range of 0:00:00- WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 100 In the current gear of D5, with TCC locked, the gear ratio is calculated by dividing the turbine PC Sol. A Ref. Current: Displays 0.00-1.1 amps. This WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 101 No. This parameter indicates if an open or a short not depressed. Disabled indicates that the brake pedal to ground exists in the feedback signal from the shift WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 102 A negative value indicates the TR Sw. A/B/C/P: Displays On/Off, On/Off, On/Off, engine speed is less than the input speed, deceleration. On/Off. These parameters are the four inputs from the WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 103: Diagnostic Trouble Code (Dtc) Type Definitions
DTC are met. The 4WD low. Disabled indicates a B+ voltage signal, which control module stores the DTC in History and Freeze WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 104: Diagnostic Trouble Code (Dtc) List/Type
Domestic DTC P0721 calibrations apply to vehicles sold in the United States, DTC P0722 Canada and Japan. Export calibrations exist for both WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 105 DTC P0847 DTC P2727 DTC P0848 DTC P2729 DTC P0872 DTC P2730 DTC P0873 DTC P2761 DTC P0877 DTC P2763 DTC P0878 DTC P2764 DTC P0880 DTC P2771 WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 106: Dtc P0218
• The TCM cancels the DTC default actions when the condition no longer exists and the DTC passes the test. DTC Descriptor This diagnostic procedure supports the following DTC: WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 107 The number below refers to the step number on the diagnostic table. 3. This step inspects for air restriction and loss of transmission ﬂ uid ﬂ ow, causing an extremely high TFT. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 108 Did you find and correct the condition? Perform the Line Pressure Check Procedure. Refer to Line Pressure Check Procedure. Go to Step 6 Go to Step 5 Is the line pressure correct? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 109 With the scan tool, observe the stored information, capture info, and DTC Info. Go to Diagnostic System OK Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 110: Dtc P0561
(MIL). transmission. • The transmission fails to hydraulic default. • DTC P0561 is stored in TCM history. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 111 The number below refers to the step number on the diagnostic table. 3. This step observes battery feed. 4. This step observes ignition feed. 7. This step observes accessories for voltage ﬂ uctuations. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 112 Test the battery positive voltage circuit for an open or short to ground. — Go to Step 10 Go to Diagnostic Aids Refer to Circuit Testing and Wiring Repairs . Did you find and correct the condition? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 113 With the scan tool, observe the stored information, capture info, and — Go to Diagnostic System OK DTC Info. Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 114: Dtc P0562
• The TCM does not illuminate the malfunction indicator lamp (MIL). • The transmission fails to hydraulic default. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 115 Did you resolve the condition or complete the replacement? Repair the charging system. Refer to Charging System Test or — Go to Step 6 — Generator Replacement . Did you complete the repair? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 116 With the scan tool, observe the stored information, capture info, and — Go to Diagnostic System OK DTC Info. Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 117: Dtc P0563
• The transmission fails to hydraulic default. • DTC P0563 is stored in TCM history. • The TCM inhibits torque converter clutch (TCC) engagement. • The TCM freezes shift adapts. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 118 Did you resolve the condition or complete the replacement? Repair the charging system. Refer to Charging System Test or — Go to Step 6 — Generator Replacement. Did you complete the repair? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 119 With the scan tool, observe the stored information, capture info, and — Go to Diagnostic System OK DTC Info. Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 120: Dtc P0602
• The transmission is limited to forward range, due to presence of default calibration. • The TCM returns to the boot program, and then waits to be calibrated. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 121 In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. replacing the TCM. Replace the TCM. Refer to Control Module References for replacement, setup, and programming. Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 122 With the scan tool, observe the stored information, capture info, and DTC Info. Go to Diagnostic System OK Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 123: Dtc P0613
• The TCM does not illuminate the malfunction indicator lamp (MIL). • The TCM commands all transmission solenoids to OFF. • DTC P0613 is stored in TCM history. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 124 Did you resolve the condition or complete the replacement? Repair the charging system. Refer to Charging System Test or — Go to Step 6 — Generator Replacement . Did you complete the repair? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 125 With the scan tool, observe the stored information, capture info, and — Go to Diagnostic System OK DTC Info. Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 126: Dtc P0634
• The TCM illuminates the malfunction indicator lamp (MIL) during the second consecutive trip in which the Conditions for Setting the DTC are met. • When DTC P0613 is active, the TCM commands all WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 127 3. Using the scan tool, drive the vehicle and monitor TCM internal temperature. 4. Select Specific DTC. 5. Enter DTC P0634. Has the test run and passed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 128 With the scan tool, observe the stored information, capture info, and DTC Info. Go to Diagnostic System OK Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 129: Dtc P0658
• If the failure occurs while in a forward range, a shift to • You may have to drive the vehicle in order to experience WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 130 4. Turn ON the ignition, with the engine OFF. 5. Using the DMM, measure voltage at terminal 11 and ground. Is the voltage within the specified value? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 131 Did you find and correct the condition? Replace the AT internal wiring harness. Refer to Wiring Harness — Go to Step 11 — Replacement . Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 132 With the scan tool, observe the stored information, capture info, and — Go to Diagnostic System OK DTC Info. Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 133: Dtc P0659
• A broken wire inside the insulation • The TCM illuminates the malfunction indicator lamp • When diagnosing for an intermittent short or open, (MIL). massage the wiring harness while watching the test WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 134 2007 W Series Chassis PAGE SECTION Service Manual Automatic Transmission – Allison equipment for a change. • You may have to drive the vehicle in order to experience a condition. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 135 4. Using the DMM, measure voltage on the engine side of the AT inline 20-way connector terminal L and ground. Is the voltage greater than the specified value? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 136 With the scan tool, observe the stored information, capture info, and — Go to Diagnostic System OK DTC Info. Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 137: Dtc P0700
• The ECM illuminates the MIL when the diagnostic runs and fails. • The ECM records the operating conditions at the time the diagnostic fails. The control module stores this information in the Freeze Frame/Failure Records. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 138 DTCs must be diagnosed ﬁ rst. Refer to Obtaining Diagnostic Trouble Codes . 2. Turn ON the ignition, with the engine OFF. Does the scan tool display any DTCs other than DTC P0700? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 139: Dtc P0701
• DTC P0701 may be logged if a forward or REVERSE • Forward or REVERSE range is selected. range is selected immediately after the engine is started, and before the TCM detects pressure at the switches, 2- WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 140 Have any of these conditions occurred?DTC P0701 can set after performing fluid ser- vice and filter change, after replacement of the pressure switch manifold (PSM), or after a long period of storage. Have any of these conditions occurred? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 141 With the scan tool, observe the stored information, capture info, and DTC Info. Go to Diagnostic System OK Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 142: Dtc P0703
• The TCM inhibits torque converter clutch (TCC) 2. This step tests brake switch status. engagement. 3. This step tests for voltage at the TCM. • The TCM inhibits grade braking. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 143 SIR system repairs. 5. Apply and release the service brake. Does the scan tool indicate that the brake switch is toggling off and on? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 144 Inspect the engine wiring harness for an open or short to ground. Refer — Go to Step 9 — to Circuit Testing and Wiring Repairs . Did you find and correct the condition? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 145 With the scan tool, observe the stored information, capture info, and — Go to Diagnostic System OK DTC Info. Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 146: Dtc P0706
• You may have to drive the vehicle in order to experience a condition. range input at engine start-up. NEUTRAL or PARK is not indicated. • Due to this failure and associated response, DTC P0722 may also set. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 147 6. Using the scan tool, monitor IMS A/B/C/P status. HIGH = Open Does each IMS signal indicate LOW when grounded and HIGH when open? LOW = Grounded WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 148 Did you complete the replacement? Replace the internal mode switch. Refer to Transmission Internal Mode Switch — Go to Step 11 — Replacement . Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 149 With the scan tool, observe the stored information, capture info, and DTC Info. — Go to Diagnostic System OK Trouble Code (DTC) List - Does the scan tool display any DTCs that you have not diagnosed? Vehicle WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 150: Dtc P0708
– A backed-out terminal DTC P0708 sets when the TCM detects an invalid – A damaged terminal condition and parity error occurring over consecutive – Poor terminal tension ignition cycles. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 151 Inspect the shift linkage for proper adjustment. Refer to Automatic — Go to Step 3 — Transmission Range Selector Cable Adjustment . Is the shift linkage properly adjusted? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 152 6. Using the scan tool, monitor IMS A/B/C/P status. HIGH = Open Does each IMS signal indicate LOW when grounded and HIGH when open? LOW = Grounded WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 153 Did you complete the replacement? Replace the internal mode switch. Refer to Transmission Internal Mode Switch — Go to Step 11 — Replacement . Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 154 With the scan tool, observe the stored information, capture info, and DTC Info. — Go to Diagnostic System OK Trouble Code (DTC) List - Does the scan tool display any DTCs that you have not diagnosed? Vehicle WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 155: Dtc P0711
• The components are powered and ignition voltage is greater than 9.0 volts and less than 18 volts. • Engine speed is greater than 200 RPM and less than WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 156 However, the transmission will still inhibit shift adapts and TCC operation. It may take several minutes before DTC P0711 is set to indicate a WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 157 4. Turn ON the ignition, with the engine OFF. 5. Using the DMM, measure voltage at connector terminal 54 and ground. Is voltage within the specified value? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 158 Replacement . Did you complete the replacement? Replace the PSM. Refer to Pressure Switch Manifold Replacement . — Go to Step 12 — Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 159 With the scan tool, observe the stored information, capture info, and DTC — Go to Diagnostic System OK Info. Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 160: Dtc P0712
9.0 volts and less than 18 volts. – A damaged terminal • Engine speed is greater than 200 RPM and less than – Poor terminal tension 7,500 RPM for 5 seconds. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 161 Measure the transmission fluid level. Refer to Transmission Fluid Checking. — Go to Step 3 Go to Transmission Fluid Checking Procedure Is the transmission fluid level correct? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 162 G and H of the J 44152 . Refer to Automatic 177.9 ohms @ Transmission Inline Harness Connector End View. 100°C (212°F) Is the resistance within the specified value? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 163 3. Drive the vehicle under normal operating conditions. Watch for sig- nificant changes in the TFT. 4. Select Specific DTC. 5. Enter DTC P0712. Has the test run and passed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 164: Dtc P0713
Conditions for Clearing the DTC Conditions for Running the DTC A scan tool can clear the code from TCM history. The • DTC P0711 and P0712 are not active. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 165 4. This step tests 5-volt reference. 6. This step tests the TFT sensor and internal wiring harness. 7. This step tests the resistance of the TFT sensor. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 166 4. Turn ON the ignition, with the engine OFF. 5. Using the DMM, measure voltage at connector terminal 54 and ground. Is voltage within the specified value? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 167 Harness Replacement . Did you complete the replacement? Replace the PSM. Refer to Pressure Switch Manifold Replacement . — Go to Step 12 — Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 168 With the scan tool, observe the stored information, capture info, and — Go to Diagnostic System OK DTC Info. Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 169: Dtc P0716
• DTC P0716 is stored in TCM history. DTC Descriptor • The TCM inhibits torque converter clutch (TCC) engagement. This diagnostic procedure supports the following DTC: • DTC P0716 Turbine Speed Sensor Circuit Performance WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 170 – Inspect that the speed sensor wiring consists of twisted pairs at the rate of 12-16 twists per 300 mm (12 in). These twists must extend the entire length of the WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 171 Go to Step 7 — speed sensor for an open or short to ground condition. Refer to Circuit Testing . Did you find and correct the condition? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 172: Automatic Transmission - Allison
With the scan tool, observe the stored information, capture info, and — Go to Diagnostic System OK DTC Info. Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 173: Dtc P0717
REVERSE, or selecting DRIVE again, the transmission will lock in NEUTRAL. This diagnostic procedure supports the following DTC: • DTC P0717 is stored in TCM history. • DTC P0717 Turbine Speed Sensor WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 174 – Excessive vibration, such as driveline or engine torsionals – Irregular sensor gap, such as a loose sensor, a loose tone wheel or a damaged tone wheel WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 175 Go to Step 7 — speed sensor for an open or short to ground condition. Refer to Circuit Testing . Did you find and correct the condition? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 176 With the scan tool, observe the stored information, capture info, and — Go to Diagnostic System OK DTC Info. Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 177: Dtc P0721
• The TCM freezes shift adapts. • The TCM inhibits torque converter clutch (TCC) This diagnostic procedure supports the following DTC: engagement. • DTC P0721 Output Speed Sensor Circuit Performance WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 178 – Inspect that the speed sensor wiring consists of twisted pairs at the rate of 12-16 twists per 300 mm (12 in). These twists must extend the entire length of the WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 179 Test the output speed sensor circuit between the TCM and output speed sensor — Go to Step 7 — for an open or short to ground condition. Refer to Circuit Testing. Did you find and correct the condition? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 180 With the scan tool, observe the stored information, capture info, and DTC Info. — Go to Diagnostic System OK Trouble Code (DTC) List - Does the scan tool display any DTCs that you have not diagnosed? Vehicle WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 181: Dtc P0722
NEUTRAL. This diagnostic procedure supports the following DTC: • DTC P0722 is stored in TCM history. • DTC P0722 Output Speed Sensor Circuit No Signal WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 182 – Excessive vibration, such as driveline or engine torsionals – Irregular sensor gap, such as a loose sensor, a loose tone wheel or a damaged tone wheel WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 183 — Go to Step 7 — sensor for an open or short to ground condition. Refer to Circuit Testing . Did you find and correct the condition? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 184 With the scan tool, observe the stored information, capture info, and DTC — Go to Diagnostic System OK Info. Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 185: Dtc P0726
TCM. Inspect for the following conditions: This diagnostic procedure supports the following DTC: – A bent terminal • DTC P0726 Engine Speed Sensor Circuit Performance – A backed-out terminal WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 186 Schematic Reference: Automatic Transmission Controls Schematics Did you perform the Diagnostic System Check - Vehicle? — Go to Step 2 Go to Diagnostic System Check - Vehicle WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 187 Go to Step 7 — speed sensor for an open or short to ground condition. Refer to Circuit Testing . Did you find and correct the condition? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 188 With the scan tool, observe the stored information, capture info, and — Go to Diagnostic System OK DTC Info. Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 189: Dtc P0727
– A bent terminal – A backed-out terminal This diagnostic procedure supports the following DTC: – A damaged terminal • DTC P0727 Engine Speed Sensor Circuit No Signal WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 190 The numbers below refer to the step numbers on the diagnostic table. 2. This step tests ignition voltage. 3. This step tests the wiring at the TCM. 4. This step tests engine speed sensor resistance. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 191 — Go to Step 7 speed sensor for an open or short to ground condition. Refer to Circuit Testing . Did you find and correct the condition? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 192 With the scan tool, observe the stored information, capture info, and — Go to Diagnostic System OK DTC Info. Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 193: Dtc P0729
• The TCM illuminates the malfunction indicator lamp • You may have to drive the vehicle in order to experience (MIL). a condition. • The transmission defaults to 4th range while diagnostic WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 194 Go to the appropri- Go to Step 5 ate speed sensor 2. Using the scan tool, monitor engine, turbine and output-speed read- ings. Is speed sensor data erratic? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 195 3. Using the scan tool operate the vehicle under normal operating condi- tions. 4. Select Specific DTC. 5. Enter DTC P0729. Has the test run and passed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 196: Dtc P0731
40 warm-up cycles without failure. Diagnostic Aids Conditions for Setting the DTC • Incorrect ratio codes typically indicate mechanical DTC P0731 sets when the calculated 1st range ratio, steady WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 197 Measure the transmission fluid level. Refer to Transmission Fluid Checking — Go to Step 3 Go to Transmission Procedure . Fluid Checking Procedure Is the transmission fluid level correct? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 198 Is the fluid contaminated or excessive material found in the pan? Remove the transmission for overhaul or replacement. Refer to Transmission — Go to Step 11 — Replacement . Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 199 With the scan tool, observe the stored information, capture info, and DTC Info. — Go to Diagnostic System OK Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 200: Dtc P0732
• The TCM illuminates the malfunction indicator lamp (MIL). diagnostic table. • The transmission defaults to 3rd range while diagnostic 3. This step tests ignition voltage. response is active. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 201 Refer to Transmission Stall Test Notice. — Go to Diagnostic Go to Step 6 Aids Conduct a clutch test for 2nd range. Refer to Clutch Test. Did turbine speed remain at zero? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 202 With the scan tool, observe the stored information, capture info, and DTC — Go to Diagnostic System OK Info. Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 203: Dtc P0733
• The TCM illuminates the malfunction indicator lamp The numbers below refer to the step numbers on the (MIL). diagnostic table. • The transmission defaults to 4th range while diagnostic WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 204 — Go to Diagnostic Go to Step 6 Aids Conduct a clutch test for 3rd range. Refer to Clutch Test . Did turbine speed remain at zero? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 205 With the scan tool, observe the stored information, capture info, and DTC Info. — Go to Diagnostic System OK Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 206: Dtc P0734
• You may have to drive the vehicle in order to experience • The TCM illuminates the malfunction indicator lamp a condition. (MIL). • The transmission defaults to 5th range while diagnostic WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 207 Go to the appropri- Go to Step 5 ate speed sensor 2. Using the scan tool, monitor engine, turbine and output-speed readings. Is speed sensor data erratic? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 208 With the scan tool, observe the stored information, capture info, and DTC Info. — Go to Diagnostic System OK Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 209: Dtc P0735
• You may have to drive the vehicle in order to experience • The TCM illuminates the malfunction indicator lamp a condition. (MIL). • The transmission defaults to 4th range while diagnostic WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 210 Go to the appropri- Go to Step 5 ate speed sensor 2. Using the scan tool, monitor engine, turbine and output-speed readings. Is speed sensor data erratic? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 211 With the scan tool, observe the stored information, capture info, and DTC Info. — Go to Diagnostic System OK Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 212: Dtc P0736
TCM differs from the known REVERSE range ratio. Action Taken When the DTC Sets • The TCM illuminates the malfunction indicator lamp (MIL). • The transmission will lock in NEUTRAL. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 213 2. Start the engine and run at idle. 3. Using the scan tool, monitor engine, turbine, and output speed readings in REVERSE range with the vehicle brakes applied. Is speed sensor data erratic? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 214 Did you find and correct a condition? Replace pressure control solenoid 2 (PCS2). Refer to Control Valve Solenoid — Go to Step 11 — Replacement . Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 215 With the scan tool, observe the stored information, capture info, and DTC Info. — Go to Diagnostic System OK Trouble Code (DTC) List - Does the scan tool display any DTCs that you have not diagnosed? Vehicle WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 216: Dtc P0741
DTC P0741 sets when the TCM detects one of the following • You may have to drive the vehicle in order to experience WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 217 2. Using the scan tool, monitor converter slip speed indicated when a range is attained where the TCC should be applied. Is the slip speed value at or greater than the specified value when the TCC should be applied? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 218 With the scan tool, observe the stored information, capture info, and DTC Info. — Go to Diagnostic System OK Trouble Code (DTC) List - Does the scan tool display any DTCs that you have not diagnosed? Vehicle WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 219: Dtc P0742
TCM. Inspect for the following conditions: – A bent terminal DTC P0742 sets when the TCM detects TCC slip speed values – A backed-out terminal – A damaged terminal WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 220 Action Schematic Reference: Automatic Transmission Controls Schematics Did you perform the Diagnostic System Check – Vehicle? Go to Step 2 Go to Diagnostic System Check - Vehicle WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 221 Did you find and repair a condition? Remove the transmission for overhaul or replacement. Refer to Transmission Go to Step 6 — Replacement . Did you complete the repair or replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 222: Dtc P0751
• DTC P0751 Shift Solenoid (SS) 1 Valve Performance - direction change, then the transmission will shift to Stuck Off WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 223 – A chafed wire – A broken wire inside the insulation • When diagnosing for an intermittent short or open, massage the wiring harness while watching the test WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 224 4. Turn ON the ignition, with the engine OFF. 5. Connect terminal 17 to ground. Does the scan tool indicate PS1 status is LOW when grounded and HIGH when open? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 225 Clean and inspect the related valves, bores and the valve body for debris or contami- Go to Step 16 — nation. Refer to Control Valve Body Cleaning and Inspection . Did you complete the repair? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 226 With the scan tool, observe the stored information, capture info, and DTC Info. Go to Diagnostic System OK Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 227: Dtc P0752
ON for 2-16 seconds depending on ﬂ uid temperature. – A bent terminal Action Taken When the DTC Sets – A backed-out terminal • The TCM illuminates the malfunction indicator lamp – A damaged terminal WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 228 Action Schematic Reference: Automatic Transmission Controls Schematics Did you perform the Diagnostic System Check - Vehicle? Go to Step 2 Go to Diagnostic System Check - Vehicle WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 229 4. Turn ON the ignition, with the engine OFF. 5. Connect terminal 17 to ground. Does the scan tool indicate PS1 status is LOW when grounded and HIGH when open? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 230 Go to Step 16 — control valve body assembly. Refer to Control Valve Body Cleaning and Inspection . Did you restore free movement or replace the valve body? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 231 With the scan tool, observe the stored information, capture info, and DTC Info. Go to Diagnostic System OK Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 232: Dtc P0756
TCM. Inspect for the following conditions: remains OFF for 5 seconds, depending on ﬂ uid temperature. – A bent terminal – A backed-out terminal Action Taken When the DTC Sets WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 233 Action Schematic Reference: Automatic Transmission Controls Schematics Did you perform the Diagnostic System Check - Vehicle? Go to Step 2 Go to Diagnostic System Check - Vehicle WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 234 4. Turn ON the ignition, with the engine OFF. 5. Connect terminal 79 to ground. Does the scan tool indicate PS2 status is LOW when grounded and HIGH when open? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 235 Clean and inspect the related valves, bores and the valve body for debris or contami- Go to Step 16 — nation. Refer to Control Valve Body Cleaning and Inspection . Did you complete the repair? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 236 With the scan tool, observe the stored information, capture info, and DTC Info. Go to Diagnostic System OK Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 237: Dtc P0757
ON for 2-16 seconds, depending on ﬂ uid temperature. – A bent terminal Action Taken When the DTC Sets – A backed-out terminal • The TCM illuminates the malfunction indicator lamp – A damaged terminal WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 238 Action Schematic Reference: Automatic Transmission Controls Schematics Did you perform the Diagnostic System Check - Vehicle? Go to Step 2 Go to Diagnostic System Check - Vehicle WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 239 4. Turn ON the ignition, with the engine OFF. 5. Connect terminal 79 to ground. Does the scan tool indicate PS2 status is LOW when grounded and HIGH when open? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 240 Go to Step 16 — control valve body assembly. Refer to Control Valve Body Cleaning and Inspection . Was free movement restored or the valve body replaced? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 241 With the scan tool, observe the stored information, capture info, and DTC Info. Go to Diagnostic System OK Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 242: Dtc P0761
OFF for 5 seconds, depending on ﬂ uid temperature. – A bent terminal Action Taken When the DTC Sets – A backed-out terminal • The TCM illuminates the malfunction indicator lamp – A damaged terminal WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 243 Action Schematic Reference: Automatic Transmission Controls Schematics Did you perform the Diagnostic System Check - Vehicle? Go to Step 2 Go to Diagnostic System Check - Vehicle WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 244 4. Turn ON the ignition, with the engine OFF. 5. Connect terminal 57 to ground. Does the scan tool indicate PS3 status is LOW when grounded and HIGH when open? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 245 Clean and inspect the related valves, bores and the valve body for debris or contami- Go to Step 16 — nation. Refer to Control Valve Body Cleaning and Inspection . Did you complete the repair? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 246 With the scan tool, observe the stored information, capture info, and DTC Info. Go to Diagnostic System OK Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 247: Dtc P0762
ON for 2-16 seconds, depending on ﬂ uid temperature. – A bent terminal Action Taken When the DTC Sets – A backed-out terminal • The TCM illuminates the malfunction indicator lamp – A damaged terminal WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 248 Action Schematic Reference: Automatic Transmission Controls Schematics Did you perform the Diagnostic System Check - Vehicle? Go to Step 2 Go to Diagnostic System Check - Vehicle WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 249 E of the J 44152 to ground. Refer to Automatic Transmission Inline Harness Connector End View . Does the scan tool indicate PS3 status is LOW when grounded and HIGH when open? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 250 Go to Step 16 — control valve body assembly. Refer to Control Valve Body Cleaning and Inspection. Did you restore free movement or replace the valve body? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 251 With the scan tool, observe the stored information, capture info, and DTC Info. Go to Diagnostic System OK Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 252: Dtc P0776
• The transmission is at normal operating temperature. the vehicle completes 40 warm-up cycles without failure. Diagnostic Aids • Inspect the wiring for poor electrical connections at the WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 253 When engine horsepower or torque is increased over factory rating, a shift ﬂ are condition may occur. Test Description The numbers below refer to the step numbers on the WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 254 Record line pressure in each range. Was the line pressure low in a specific range or in ranges where the same clutch was applied? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 255 With the scan tool, observe the stored information, capture info, and DTC Info. — Go to Diagnostic System OK Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 256: Dtc P0777
40 warm-up cycles without failure. • Turbine speed is greater than 200 RPM. Diagnostic Aids • Inspect the wiring for poor electrical connections at the WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 257 When engine horsepower or torque is increased over factory rating, a shift ﬂ are condition may occur. Test Description The numbers below refer to the step numbers on the WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 258 Record line pressure in each range. Was the line pressure low in a specific range or in ranges where the same clutch was applied? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 259 With the scan tool, observe the stored information, capture info, and DTC Info. — Go to Diagnostic System OK Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 260: Dtc P0826
TAP up/down shift switch Test Description circuit for greater than 6 seconds when driver shift request is The numbers below refer to the step numbers on the WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 261 5. Using the DMM, measure voltage at terminal 56 and a known good ground. 6. Operate the driver shift request switch in the TAP up and TAP down position. Is the voltage within the specified value? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 262 AT driver shift request switch. Refer to Testing for Continuity and Wiring Repairs . Did you find and correct the condition? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 263 With the scan tool, observe the stored information, capture info, and DTC Info. — Go to Diagnostic System OK Trouble Code (DTC) List - Does the scan tool display any DTCs that you have not diagnosed? Vehicle WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 264: Dtc P0827
TAP up/down shift Test Description switch circuit for greater than 6 seconds when driver shift request The numbers below refer to the step numbers on the WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 265 5. Using the DMM, measure voltage at terminal 56 and a known good ground. 6. Operate the driver shift request switch in the TAP up and TAP down position. Is the voltage within the specified value? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 266 AT driver shift request switch. Refer to Testing for Short to Ground and Wiring Repairs . Did you find and correct the condition? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 267 With the scan tool, observe the stored information, capture info, and DTC Info. — Go to Diagnostic System OK Trouble Code (DTC) List - Does the scan tool display any DTCs that you have not diagnosed? Vehicle WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 268: Dtc P0828
TAP up/down shift Test Description switch circuit for greater than 6 seconds when driver shift request The numbers below refer to the step numbers on the WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 269 5. Using the DMM, measure voltage at terminal 56 and a known good ground. 6. Operate the driver shift request switch in the TAP up and TAP down position. Is the voltage within the specified value? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 270 AT driver shift request switch. Refer to Testing for a Short to Voltage and Wiring Repairs . Did you find and correct the condition? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 271 With the scan tool, observe the stored information, capture info, and DTC Info. — Go to Diagnostic System OK Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 272: Dtc P0842
– Poor terminal tension Action Taken When the DTC Sets – A chafed wire • The TCM illuminates the malfunction indicator lamp – A broken wire inside the insulation (MIL). WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 273 Is the transmission fluid level correct? Measure line pressure. Refer to Line Pressure Check . Go to Step 4 Go to Symptoms - Automatic Transmission Is the pressure within the specified value? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 274 D of the J 44152 to ground. Refer to Automatic Transmission Inline Harness Connector End View. Does the scan tool indicate PS1 status is LOW when grounded and HIGH when open? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 275 In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. replacing the TCM. Replace the TCM. Refer to Control Module References for replacement, setup, and programming. Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 276 With the scan tool, observe the stored information, capture info, and DTC Info. Go to Diagnostic System OK Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 277: Dtc P0843
– A backed-out terminal Action Taken When the DTC Sets • The TCM illuminates the malfunction indicator lamp – A damaged terminal (MIL). – Poor terminal tension WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 278 Action Schematic Reference: Automatic Transmission Controls Schematics Did you perform the Diagnostic System Check – Vehicle? Go to Step 2 Go to Diagnostic System Check - Vehicle WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 279 4. Turn ON the ignition, with the engine OFF. 5. Connect terminal 17 to ground. Does the scan tool indicate PS1 status is LOW when grounded and HIGH when open? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 280 Clean and inspect the related valves, bores, and the valve body for debris or contami- Go to Step 16 — nation. Refer to Control Valve Body Cleaning and Inspection . Did you complete the repair? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 281 With the scan tool, observe the stored information, capture info, and DTC Info. Go to Diagnostic System OK Trouble Code (DTC) Does the scan tool display any DTCs that you have not diagnosed? List - Vehicle WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 282: Dtc P0847
– A backed-out terminal Action Taken When the DTC Sets – A damaged terminal • The TCM illuminates the malfunction indicator lamp – Poor terminal tension (MIL). WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 283 Action Schematic Reference: Automatic Transmission Controls Schematics Did you perform the Diagnostic System Check - Vehicle? Go to Step 2 Go to Diagnostic System Check - Vehicle WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 284 4. Turn ON the ignition, with the engine OFF. 5. Connect terminal 79 to ground. Does the scan tool indicate PS2 status is LOW when grounded and HIGH when open? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 285 Go to Step 16 — valve body assembly. Refer to Control Valve Body Cleaning and Inspection . Did you restore free movement or replace the valve body? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 286 With the scan tool, observe the stored information, capture info, and DTC Info. Go to Diagnostic System OK Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 287: Dtc P0848
– A backed-out terminal Action Taken When the DTC Sets • The TCM illuminates the malfunction indicator lamp – A damaged terminal (MIL). – Poor terminal tension WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 288 Action Schematic Reference: Automatic Transmission Controls Schematics Did you perform the Diagnostic System Check – Vehicle? Go to Step 2 Go to Diagnostic System Check - Vehicle WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 289 4. Turn ON the ignition, with the engine OFF. 5. Connect terminal 79 to ground. Does the scan tool indicate PS2 status is LOW when grounded and HIGH when open? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 290 Did you replace the solenoid and install the control valve body? Replace the control valve body assembly. Refer to Control Valve Body Replacement . Go to Step 16 — Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 291 With the scan tool, observe the stored information, capture info, and DTC Info. Go to Diagnostic System OK Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 292: Dtc P0851 Or 0852
• Vehicle speed is more than 24 km/h (15 mph). Park/Neutral Park/Neutral In-Gear In-Gear Signal Conditions for Setting the DTC Circuit/System Description DTC P0851 The engine control module (ECM)/powertrain control WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 293 Park/Neutral switch parameter in the • Schematic Reference engine controls data list and move the gear shift lever from Park, to Reverse and through all the ranges and WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 294: Dtc P0872
If the • Shift valve 3 is commanded to the OFF, destroked, circuit tests normal, replace the ECM/PCM. position. Repair Instructions Perform the Diagnostic Repair Veriﬁ cation after WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 295 8. This step tests the PSM for a failed condition. Diagnostic Aids • Inspect the wiring for poor electrical connections at the TCM. Inspect for the following conditions: WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 296 4. Turn ON the ignition, with the engine OFF. 5. Connect terminal 57 to ground. Does the scan tool indicate PS3 status is LOW when grounded and HIGH when open? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 297 Test the PS3 circuit between the TCM and AT inline 20-way connector for an open or Go to Step 13 — short condition. Refer to Circuit Testing . Did you find and correct the condition? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 298 With the scan tool, observe the stored information, capture info, and DTC Info. Go to Diagnostic System OK Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 299: Dtc P0873
– A backed-out terminal Action Taken When the DTC Sets • The TCM illuminates the malfunction indicator lamp – A damaged terminal (MIL). – Poor terminal tension WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 300 Action Schematic Reference: Automatic Transmission Controls Schematics Did you perform the Diagnostic System Check - Vehicle? Go to Step 2 Go to Diagnostic System Check - Vehicle WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 301 4. Turn ON the ignition, with the engine OFF. 5. Connect terminal 57 to ground. Does the scan tool indicate PS3 status is LOW when grounded and HIGH when open? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 302 Clean and/or polish the sticking valve to restore free movement or replace the control Go to Step 16 — valve body assembly. Refer to Control Valve Body Replacement . Did you restore free movement or replace the valve body? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 303 With the scan tool, observe the stored information, capture info, and DTC Info. Go to Diagnostic System OK Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 304: Dtc P0873
– A backed-out terminal Action Taken When the DTC Sets • The TCM illuminates the malfunction indicator lamp – A damaged terminal (MIL). – Poor terminal tension WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 305 Action Schematic Reference: Automatic Transmission Controls Schematics Did you perform the Diagnostic System Check - Vehicle? Go to Step 2 Go to Diagnostic System Check - Vehicle WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 306 4. Turn ON the ignition, with the engine OFF. 5. Connect terminal 57 to ground. Does the scan tool indicate PS3 status is LOW when grounded and HIGH when open? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 307 Clean and/or polish the sticking valve to restore free movement or replace the control Go to Step 16 — valve body assembly. Refer to Control Valve Body Replacement . Did you restore free movement or replace the valve body? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 308 With the scan tool, observe the stored information, capture info, and DTC Info. Go to Diagnostic System OK Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 310 Is the transmission fluid level correct? Measure line pressure. Refer to Line Pressure Check . Go to Step 4 Go to Symptoms - Automatic Transmission Is the pressure within the specified value? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 311 K of the J 44152 to ground. Refer to Automatic Transmission Inline Harness Connector End View. Does the scan tool indicate PS4 status is LOW when grounded and HIGH when open? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 312 In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. replacing the TCM. Replace the TCM. Refer to Control Module References for replacement, setup, and programming. Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 313 With the scan tool, observe the stored information, capture info, and DTC Info. Go to Diagnostic System OK Trouble Code (DTC) Does the scan tool display any DTCs that you have not diagnosed? List - Vehicle WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 315 Is the transmission fluid level correct? Measure line pressure. Refer to Line Pressure Check . Go to Step 4 Go to Symptoms - Automatic Transmission Is the pressure within the specified value? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 316 K of the J 44152 to ground. Refer to Automatic Transmission Inline Harness Connector End View . Does the scan tool indicate PS4 status is LOW when grounded and HIGH when open? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 317 In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. replacing the TCM. Replace the TCM. Refer to Control Module References for replacement, setup, and programming. Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 318: Dtc P0880
• Loss of adaptive information for drive cycle. Revert to • DTC P0880 Transmission Control Module (TCM) Power previous adaptive settings. Input Signal • The TCM inhibits torque converter clutch (TCC) WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 319 2. This step tests the system voltage. 4. This step tests the vehicle charging system. 5. This step tests the wiring harness for opens or shorts. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 320 1. Increase the engine speed to 1,000-1,500 RPM. 13-15 V Go to Step 5 Go to Charging System Test 2. Observe the system voltage on the scan tool. Is voltage within the specified range? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 321 TCM to confirm diagnosis. good TCM to confirm diagnosis. Replace the TCM. Refer to Control Module References for replacement, setup, and programming. Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 322: Dtc P0881
– A bent terminal DTC P0881 sets when the TCM detects a battery direct – A backed-out terminal voltage variation of 4.0 volts or greater for 30 seconds. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 323 DTC to set. Test Description The number below refers to the step number on the diagnostic table. 3. This step tests for proper TCM battery direct voltage. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 324 In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. before replacing the TCM. Replace the TCM. Refer to Control Module References for replacement, setup, and programming. Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 325 With the scan tool, observe the stored information, capture info, and DTC — Go to Diagnostic System OK Info. Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 326: Dtc P0882
• Hydraulic default is commanded. Shift selector position and hydraulic state of logic valves determine range. • The TCM inhibits main modulation. • The TCM inhibits torque converter clutch (TCC) engagement. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 327 Did you replace the battery or resolve the battery condition? Repair the charging system. Refer to Charging System Test or Generator — Go to Step 6 — Replacement . Did you complete the repair? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 328 With the scan tool, observe the stored information, capture info, and DTC — Go to Diagnostic System OK Info. Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 329: Dtc P0883
• The TCM inhibits torque converter clutch (TCC) engagement. Conditions for Clearing the DTC A scan tool can clear the code from TCM history. The TCM automatically clears the DTC from TCM history if WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 330 Go to Step 2 1. Clear the DTC. 2. Using the scan tool, monitor TCM voltage. 3. Select Specific DTC. 4. Enter DTC P0883. Has the test run and passed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 331: Dtc P0960
TCM automatically clears the DTC from TCM history if • DTC P0960 Pressure Control Solenoid (PCS) Main the vehicle completes 40 warm-up cycles without failure. Modulation (MAIN MOD) Circuit Open WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 332 5. This step tests the resistance value of the solenoid and tests the internal wiring harness for opens. 6. This step tests the resistance value of the solenoid. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 333 Go to Step 5 (68°F) for Intermittent 2. Using the DMM, measure resistance at terminals 11 and 74. Conditions and Poor Connections Is the resistance reading within the specified value? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 334 TCM. ly before replacing the TCM. Replace the TCM. Refer to Control Module References for replacement, setup, and programming. Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 335 With the scan tool, observe the stored information, capture info, and DTC — Go to Diagnostic System OK Info. Trouble Code (DTC) List - Does the scan tool display any DTCs that you have not diagnosed? Vehicle WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 336: Dtc P0962
200 RPM and less than 7,500 RPM for less • You may have to drive the vehicle in order to experience than 5 seconds. a condition. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 337 2. Disconnect the TCM from the J 39700 . Additional DTCs may set. 3. Using the DMM, measure resistance at terminals 11 and 74. Is the resistance reading within the specified value? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 338 TCM. oughly before replacing the TCM. Replace the TCM. Refer to Control Module References for replacement, setup, and programming. Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 339 With the scan tool, observe the stored information, capture info, and DTC — Go to Diagnostic System OK Info. Trouble Code (DTC) List - Does the scan tool display any DTCs that you have not diagnosed? Vehicle WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 340: Dtc P0963
• You may have to drive the vehicle in order to experience • The TCM must auto-detect the MAIN MOD solenoid for a condition. this test to run. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 341 3. Turn ON the ignition, with the engine OFF. and Poor 4. Using the DMM, measure voltage at terminal 74 and ground. Connections Is the voltage greater than the specified value? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 342 Did you complete the replacement? Replace the MAIN MOD solenoid. Refer to Control Valve Solenoid — Go to Step 11 — Replacement . Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 343: Dtc P0964
Action Taken When the DTC Sets • The TCM illuminates the malfunction indicator lamp This diagnostic procedure supports the following DTC: (MIL). • DTC P0964 Pressure Control Solenoid 2 (PCS2) Control WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 344 – A chafed wire – A broken wire inside the insulation • When diagnosing for an intermittent short or open, massage the wiring harness while watching the test WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 345 N and P of the J 44152 . Refer to Automatic Transmission Inline Harness Connector End View. Is the resistance within the specified value? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 346 Go to Step 2 1. Clear the DTC. 2. Drive the vehicle under normal operating conditions. 3. Select Specific DTC. 4. Enter DTC P0964. Has the test run and passed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 347: Dtc P0966
• The TCM inhibits torque converter clutch (TCC) • TCM initialization is in process or engine speed is greater engagement. than 200 RPM and less than 7,500 RPM for 5 seconds. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 348 Schematic Reference: Automatic Transmission Controls Schematics Did you perform the Diagnostic System Check - Vehicle? — Go to Step 2 Go to Diagnostic System Check - Vehicle WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 349 Go to Step 5 ohms 2. Using the DMM, measure resistance at terminals 36 and 71. at 20°C (68°F) Is the resistance reading within the specified value? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 350 TCM. ly before replacing the TCM. Replace the TCM. Refer to Control Module References for replacement, setup, and programming. Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 351: Dtc P0967
• If the failure occurs while in a forward range, a shift to • DTC P0967 Pressure Control Solenoid 2 (PCS2) Control 1st, 3rd or 5th range is made. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 352 • When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change. • You may have to drive the vehicle in order to experience WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 353 3. Turn ON the ignition, with the engine OFF. Poor Connections 4. Using the DMM, measure voltage at terminals 36 and ground. Is the voltage greater than the specified value? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 354 Replacement . Did you complete the replacement? Replace the PCS2. Refer to Control Valve Solenoid Replacement . — Go to Step 11 — Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 355: Dtc P0972
SS1 return circuit for greater than 2 has a pressure switch, located in the pressure switch seconds. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 356 • Inspect the wiring for poor electrical connections at the TCM. Inspect for the following conditions: – A bent terminal – A backed-out terminal – A damaged terminal – Poor terminal tension – A chafed wire WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 357 < 0.5 volts Go to Testing Go to Step 10 for Intermittent Conditions and Did you get less than 0.5 volts with the solenoid commanded ON? Poor Connections WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 358 TCM to confirm diagnosis. good TCM to confirm diagnosis. Replace the TCM. Refer to Control Module References for replacement, setup and programming. Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 360 • Inspect the wiring for poor electrical connections at the TCM. Inspect for the following conditions: – A bent terminal – A backed-out terminal – A damaged terminal – Poor terminal tension – A chafed wire WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 361 2. Disconnect the TCM from the J 39700 . Additional DTCs may set. 3. Using the DMM, measure resistance at terminals 52 and 71. Is the resistance reading within the specified value? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 362 TCM to confirm diagnosis. good TCM to confirm diagnosis. Replace the TCM. Refer to Control Module References for replacement, setup and programming. Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 363: Dtc P0974
• The TCM illuminates the malfunction indicator lamp manifold, to provide feedback to the TCM about the (MIL). WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 364 – A chafed wire – A broken wire inside the insulation • When diagnosing for an intermittent short or open, massage the wiring harness while watching the test WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 365 3. Turn ON the ignition, with the engine OFF. and Poor 4. Using the DMM, measure voltage at terminal 52 and ground. Connections Is the voltage greater than the specified value? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 366 Replacement . Did you complete the replacement? Replace the SS1. Refer to Control Valve Solenoid Replacement . — Go to Step 11 — Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 368 • Inspect the wiring for poor electrical connections at the TCM. Inspect for the following conditions: – A bent terminal – A backed-out terminal – A damaged terminal – Poor terminal tension – A chafed wire WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 369 < 0.5 volts Go to Testing Go to Step 10 for Intermittent Conditions and Did you get less than 0.5 volts with the solenoid commanded ON? Poor Connections WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 370 TCM to confirm diagnosis. good TCM to confirm diagnosis. Replace the TCM. Refer to Control Module References for replacement, setup and programming. Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 372 – A bent terminal – A backed-out terminal – A damaged terminal – Poor terminal tension – A chafed wire – A broken wire inside the insulation WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 373 2. Disconnect the TCM from the J 39700 . Additional DTCs may set. 3. Using the DMM, measure resistance at terminals 33 and 71. Is the resistance reading within the specified value? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 374 TCM to confirm diagnosis. good TCM to confirm diagnosis. Replace the TCM. Refer to Control Module References for replacement, setup and programming. Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 375: Dtc P0977
SS2 return circuit for greater than 2 seconds. providing the correct transmission range, the shift valve has a pressure switch, located in the pressure switch manifold, to provide feedback to the TCM about the WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 376 • Inspect the wiring for poor electrical connections at the TCM. Inspect for the following conditions: – A bent terminal – A backed-out terminal – A damaged terminal – Poor terminal tension – A chafed wire WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 377 3. Turn ON the ignition, with the engine OFF. Poor Connections 4. Using the DMM, measure voltage at terminal 33 and ground. Is the voltage greater than the specified value? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 378 Replacement . Did you complete the replacement? Replace the SS2. Refer to Control Valve Solenoid Replacement . — Go to Step 11 — Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 380 • Inspect the wiring for poor electrical connections at the TCM. Inspect for the following conditions: – A bent terminal – A backed-out terminal – A damaged terminal – Poor terminal tension – A chafed wire WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 381 < 5.0 volts Go to Testing Go to Step 10 for Intermittent Conditions and Did you get less than 5 volts with the solenoid commanded ON? Poor Connections WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 382 TCM to confirm diagnosis. good TCM to confirm diagnosis. Replace the TCM. Refer to Control Module References for replacement, setup and programming. Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 384 • Inspect the wiring for poor electrical connections at the TCM. Inspect for the following conditions: – A bent terminal – A backed-out terminal – A damaged terminal – Poor terminal tension – A chafed wire WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 385 2. Disconnect the TCM from the J 39700 . Additional DTCs may set. 3. Using the DMM, measure resistance at terminals 51 and 71. Is the resistance reading within the specified value? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 386 TCM to confirm diagnosis. good TCM to confirm diagnosis. Replace the TCM. Refer to Control Module References for replacement, setup and programming. Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 387: Dtc P0980
SS3 return circuit for greater than 2 seconds. providing the correct transmission range, the shift valve has a pressure switch, located in the pressure switch manifold, to provide feedback to the TCM about the WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 388 • Inspect the wiring for poor electrical connections at the TCM. Inspect for the following conditions: – A bent terminal – A backed-out terminal – A damaged terminal – Poor terminal tension – A chafed wire WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 389 3. Turn ON the ignition, with the engine OFF. and Poor 4. Using the DMM, measure voltage at terminal 51 and ground. Connections Is the voltage greater than the specified value? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 390 Replacement . Did you complete the replacement? Replace the SS3. Refer to Control Valve Solenoid Replacement . — Go to Step 11 — Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 391: Dtc P1688
• The TCM inhibits torque converter clutch (TCC) Conditions for Running the DTC engagement. • The components are powered and ignition voltage is greater than 9.0 volts and less than 18 volts. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 392 The numbers below refer to the step numbers on the diagnostic table. 2. This step tests for a damaged terminal or connector in the TCM connector. 4 This step tests for an open/short. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 393 Was the software and calibration current and proper for the engine? Install the correct ECM calibration. Refer to Control Module References for replace- Go to Step 8 — ment, setup, and programming. Is the calibration complete? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 394: Dtc P1779
DTC P1779 sets if managed engine torque, net, signal DTC Descriptor is less than 1.5 percent or greater than 98.5 percent for greater than 2 seconds. This diagnostic procedure supports the following DTC: WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 395 • When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change. • You may have to drive the vehicle in order to experience WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 396 Was the software and calibration current and proper for the engine? Install the correct ECM calibration. Refer to Control Module References for replace- Go to Step 8 — ment, setup, and programming. Is the calibration complete? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 397 With the scan tool, observe the stored information, capture info and DTC info. Go to Diagnostic System OK Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 398: Dtc P2670
• When diagnosing for an intermittent short or open, (MIL). massage the wiring harness while watching the test equipment for a change. • If the failure occurs while in a forward range, a shift to WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 399 4. Turn ON the ignition, with the engine OFF. 5. Using the DMM, measure the voltage at terminal 71 and ground. Is the voltage within the specified value? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 400 Did you complete the replacement? Replace the open or shorted solenoid. Refer to Control Valve Solenoid — Go to Step 11 — Replacement . Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 401: Dtc P2671
2 (HSD2). HSD2 is continuously ON during normal Conditions for Running the DTC operation, except during a brief circuit test. The TCM • The components are powered and ignition voltage is WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 402 A scan tool can clear the code from TCM history. The TCM automatically clears the DTC from TCM history if the vehicle completes 40 warm-up cycles without failure. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 403 4. Using the DMM, measure voltage on the engine side of the AT inline 20-way connector terminal N and ground. Is the voltage within the specified value? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 404 With the scan tool, observe the stored information, capture info, and DTC — Go to Diagnostic System OK Info. Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 405: Dtc P2723
• Output speed is greater than 125 RPM. TCM automatically clears the DTC from TCM history if • The transmission is at normal operating temperature. the vehicle completes 40 warm-up cycles without failure. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 406 Inspect for the presence of an add-on engine power package. When engine horsepower or torque is increased over factory rating, a shift ﬂ are condition may occur. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 407 Record line pressure in each range. Was the line pressure low in a specific range or in ranges where the same clutch was applied? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 408 With the scan tool, observe the stored information, capture info, and DTC — Go to Diagnostic System OK Info. Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 409: Dtc P2724
40 warm-up cycles without failure. • Turbine speed is greater than 200 RPM. Diagnostic Aids • Inspect the wiring for poor electrical connections at the WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 410 When engine horsepower or torque is increased over factory rating, a shift ﬂ are condition may occur. Test Description The numbers below refer to the step numbers on the WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 411 Record line pressure in each range. Was the line pressure low in a specific range or in ranges where the same clutch was applied? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 412 3. Use the scan tool to reset adaptive values for all shifts. 4. Operate the vehicle in all ranges under normal driving conditions. 5. Select Specific DTC. 6. Enter DTC P2724. Has the test run and passed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 413: Dtc P2727
• The components are powered and ignition voltage is greater than 9.0 volts and less than 18 volts. • Engine speed is greater than 200 RPM and less than WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 414 Schematic Reference: Automatic Transmission Controls Schematics Did you perform the Diagnostic System Check - Vehicle? — Go to Step 2 Go to Diagnostic System Check - Vehicle WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 415 2. Remove the AT internal wiring harness at the PCS1 connector. 3. Using the DMM, measure the resistance of the PCS1. Is the solenoid resistance within the specified value? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 416 With the scan tool, observe the stored information, capture info, and DTC — Go to Diagnostic System OK Info. Trouble Code (DTC) List - Vehicle Does the scan tool display any DTCs that you have not diagnosed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 417: Dtc P2729
– A damaged terminal Conditions for Setting the DTC – Poor terminal tension DTC P2729 sets when the TCM detects a short to – A chafed wire WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 418 5. Using the DMM, measure voltage between connector terminal 55 and ground. 6. Using the scan tool, command PCS1 OFF. Is the voltage within the specified value when the PCS1 is commanded OFF? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 419 Replacement . Did you complete the replacement? Replace the PCS1. Refer to Control Valve Solenoid Replacement . — Go to Step 11 — Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 420: Dtc P2730
• Engine speed is greater than 200 RPM and less than (HSD1). The TCM regulates the amount of current to the 7,500 RPM for 5 seconds. PCS1 by switching the low side driver ON and OFF. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 421 TCM automatically clears the DTC from TCM history if the vehicle completes 40 warm-up cycles without failure. Diagnostic Aids • Inspect the wiring for poor electrical connections at the TCM. Inspect for the following conditions: WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 422 3. Turn ON the ignition, with the engine OFF. Poor Connections 4. Using the DMM, measure voltage at terminal 55 and ground. Is the voltage greater than the specified value? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 423 Replacement . Did you complete the replacement? Replace the PCS1. Refer to Control Valve Solenoid Replacement . — Go to Step 11 — Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 424: Dtc P2761
• If the failure occurs while in a forward range, a shift to • DTC P2761 Torque Converter Clutch (TCC) Pressure 1st, 3rd or 5th range is made. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 425 • When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change. • You may have to drive the vehicle in order to experience WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 426 L and J of the J 44152 . Refer to Automatic Transmission Inline Harness Connector End View . Is the resistance within the specified value? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 427 Go to Step 2 1. Clear the DTC. 2. Drive the vehicle under normal operating conditions. 3. Select Specific DTC. 4. Enter DTC P2761. Has the test run and passed? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 428: Dtc P2763
• The TCM freezes shift adapts. greater than 9.0 volts and less than 18 volts. • The TCM inhibits TCC engagement. • Engine speed is greater than 200 RPM and less than WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 429 Schematic Reference: Automatic Transmission Controls Schematics Did you perform the Diagnostic System Check - Vehicle? — Go to Step 2 Go to Diagnostic System Check - Vehicle WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 430 3. Turn ON the ignition, with the engine OFF. Poor Connections 4. Using the DMM, measure voltage at terminal 78 and ground. Is the voltage greater than the specified value? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 431 Did you complete the replacement? Replace the TCC PCS. Refer to Control Valve Solenoid Replacement . — Go to Step 11 — Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 432: Dtc P2764
This diagnostic procedure supports the following DTC: • If the failure occurs while in a forward range, a shift to • DTC P2764 Torque Converter Clutch (TCC) Pressure WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 433 – A broken wire inside the insulation • When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 434 Go to Step 10 Go to Step 5 (68°F) 2. Using the DMM, measure resistance at terminals 11 and 78. Is the resistance reading within the specified value? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 435 TCM. ly before replacing the TCM. Replace the TCM. Refer to Control Module References for replacement, setup, and programming. Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 436: Dtc P2771
(MIL) during the second consecutive trip in which the Conditions for Setting the DTC are met. • Engine speed is greater than 200 RPM and less than WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 437 The numbers below refer to the step numbers on the diagnostic table. 2. This step tests the status of the 4WD low switch. 3. This step tests for a 4WD switch failure to ground. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 438: Automatic Transmission - Allison
Inspect the transfer case switch for proper operation or a short to ground. Refer to Go to Step 8 Go to Step 15 Circuit Testing and Wiring Repairs . Did you find a condition? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 439 In most cases, the TCM is not at fault. Investigate thoroughly before replacing the TCM. replacing the TCM. Replace the TCM. Refer to Control Module References for replacement, setup, and programming. Did you complete the replacement? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 440: Symptoms - Automatic Transmission
The Functional Test Procedure should be performed before beginning any diagnosis. If this procedure has not already been performed, refer to Functional Test Procedure. been performed, refer to Functional Test Procedure. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 441 • Refer to Excessive Flare - Engine Overspeed on Wide-Open Throttle • Erratic shifts • Harsh, soft, delayed or slipping shifts • Harsh, soft, or delayed engagement WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 442 This category contains the following topics: • Poor performance • Noise during converter operation • TCC shudder • Shudder after TCC apply • Vibration during converter operation WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 443: Functional Test
Did the vibration occur only during torque converter clutch (TCC) apply o Did the vehicle exhibit a shift speed condition, such as low or high shift s WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 444 • No PARK, REVERSE or DRIVE • No engine braking • No gear selection • Incorrect gear selection Did the vehicle exhibit any of these range performance conditions? WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 445: Transmission Fluid Checking
200°F) is reached. 7. With the service brakes applied, put the transmission in the P, PARK, position. 8. Engage the park pawl by slowly releasing the service WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 447: Line Pressure Check
4. Clean all internal and external hydraulic circuits, data against speciﬁ cations provided. cooler, and all other areas where the particles could lodge. Refer to Automatic Transmission Oil Cooler Flushing and Flow Test . WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 448: Obtaining Diagnostic Trouble Codes
TCM. Other data sent to the TCM include 600 RPM. throttle position, engine, turbine, and output speeds, and A. Select F0: Diagnostics and press ENTER. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 449: Clutch Test
10. Select F0: Diagnostic Trouble Codes (DTC). Press 8. Select F1: Transmission Output Controls. ENTER. 9. Select Shift Transmission. This allows the technician 11. Select F1: DTC (s) (Transmission). Press ENTER. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 450: Fastlearn Procedure
• F3: Special Functions in that range. If low pressure is in FIRST range only, • F1: Transmission Output Controls suspect Low and Reverse piston seal damage. • FastLearn WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 451 2 (PCS2) pressures Next, the scan tool instructs the driver to select corresponding to clutch return springs, and is also able REVERSE. Once REVERSE is selected, the TCM WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 452: Limp Home Mode
4. Start the engine and move the range selector to Principle of Operation REVERSE position. The Allison transmission incorporates control logic that 5. The transmission should engage REVERSE range. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 453 The clutches that could possibly have an indicated failure in Limp Home are the 1-2-3-4 clutch, the 3rd, 5th and reverse clutch, and the low and reverse clutch. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 454: Road Test
• The engine is performing properly. • Engine speed • Transmission ﬂ uid level is correct. • Transmission input speed, turbine • Tire pressure is correct. • Transmission output speed WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 455 A. Apply the brake pedal and ensure the parking brake B. Move the shift selector through the following is set. ranges: B. Move the shift selector through all ranges. i. PARK to REVERSE WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 456 • Note the TCC apply point. When the TCC applies there to cover the normal driving range. should be a noticeable drop in engine speed and a drop 2. Monitor the following scan tool parameters: WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 457 3. Quickly increase throttle angle to greater than 63 percent. 4. Verify the following conditions: • The TCC releases. • The transmission downshifts immediately to FOURTH range. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 458 3. Verify that there is no noticeable slip, noise or 3. Go to 8 km/h (5 mph) above the 1-2 shift point. vibration. 4. Release the throttle while moving the shift selector to FIRST. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 459: Torque Converter Diagnosis
The torque converter clutch (TCC) is applied by ﬂ uid You should be able to turn the race clockwise, pressure, which is controlled through the converter ﬂ ow WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 460 • Defective friction material on the TCC piston 7. Place your foot on the brake. 8. Place the range selector in DRIVE. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 461 • External leaks appear in the hub weld area amount of fuel. The mixture may run rich or lean • The converter hub is scored or damaged depending on where the leak occurs. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 462 • The threads in one or more of the converter bolt holes are damaged • Correct the condition with a new thread insert. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 463: Flexplate/Torque Converter Vibration Test (8.1L)
3. Remove the starter motor bolts and position the starter bolts and position the starter motor aside. Refer to motor aside. Refer to Starter Motor Replacement in Starter Motor Replacement in Engine Electrical. Engine Electrical. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 465: Noise And Vibration Analysis
RPM increases, the condition may be caused by FLUID LEAK DIAGNOSIS unsatisfactory engine performance. • Inspect the tires for the following conditions: TOOLS REQUIRED – Uneven wear Refer to Tire Diagnosis - Irregular or WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 466 2. Apply an aerosol type powder, such as foot powder, to • Plugged vent or drain-back holes the suspected leak area. • Damaged seal bore 3. Operate the vehicle for 24 km (15 mi), or until normal WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 467: Case Porosity Repair
5. Repeat the ﬂ uid leak diagnosis procedures. • Funnel AUTOMATIC TRANSMISSION OIL COOLER • Water supply - hot water recommended • Water hose at least 16 mm (5/8 in) ID WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 468 ﬂ usher tank (4) to 550-700 kPa (80-100 psi), using the shop air supply at the tank air valve (9). IMPORTANT: • Do not substitute with solutions that WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 469 OFF position, connect the water supply hose from the J 35944-A to the water supply at the faucet. 9. Turn ON the water supply at the faucet. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 470 (2) on the J 35944-A and blow out the water from the oil cooler and pipes. Continue until no water comes out of the discharge hose (5). WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 471 L (2.3 quarts) must be discharged during this 5 second 3. After every third use, clean the J 35944-A as described run time. in the instructions included with the tool. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 472 2007 W Series Chassis PAGE SECTION Service Manual Automatic Transmission – Allison 4. Dispose of any waste water/solution and transmission ﬂ uid in accordance with local regulations. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 473: Excessive Slippage And Clutch Chatter
Low and Reverse clutch slipping, leaks at piston seals, Low and Inspect the Low and Reverse clutch plates and piston seals. Replace/ Reverse clutch plates worn rebuild as necessary. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 474: Fluid Leaks From Fluid Fill Tube And/Or Vent
Main pressure plug leak Replace or torque the main pressure plug. Refer to Oil Pressure Test Plug Replacement. Pump bushing shows excessive wear Rebuild and repair the pump. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 475: Fluid Leaks From Transmission Output
Low main pressure causes main regulator valve to oscillate Refer to Low Main Line Pressure in All Ranges and Low Main Line Pressure in specific Ranges, Normal Pressure in Other Ranges . WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 476: Low Main Line Pressure In All Ranges
LOW MAIN LINE PRESSURE IN SPECIFIC RANGES, NORMAL PRESSURE IN OTHER RANGES Condition Action Seal leak Replace the seals that are causing low pressure in a particular range. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 477: Low Lubrication Pressure
Fluid/Filter Replacement. Excessive heat Inspect the cooling system for restrictions and proper capacity. Substandard fluid Use recommended fluid. Refer to Transmission General Specifications. Clutch/transmission failure Overhaul the transmission. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 478: Excessive Flare - Engine Overspeed On
Rebuild the 1-2-3-4 clutch or the Low and Reverse clutch or the 2-6 clutch. Use the diagnostic tool to measure turbine speed. Higher power engine Confirm proper engine match. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 479: Low Stall Speeds (Stall In Ranges 1-6)
Replace the solenoid assembly. Refer to Control Valve Solenoid Replacement. Low pressure Repair the transmission. Faulty solenoid - leaking Replace the solenoid. Refer to Control Valve Solenoid Replacement. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 480: Transmission Will Not Shift To Forward Or
Mechanical failure in transmission torque converter, shafts, or Repair the transmission. planetaries. Low pressure Repair the transmission. Faulty wiring in transmission control module (TCM) input/output Correct the circuit wiring. function circuits WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 481: Transmission Overheats
Replacement . A stuck stator will not allow cool down in Neutral. Cooler flow loss due to internal transmission leakage Overhaul the transmission. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 482: Transmission Does Not Shift Properly
1-2-3-4 clutch failed or not released Rebuild the 1-2-3-4 clutch Vehicle Moves Backward in Neutral 3rd, 5th and reverse clutch failed or not released Rebuild the 3rd, 5th and reverse clutch assembly. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 483: Repair Instructions
Refer to Fastener Notice in Cautions and Notices. Refer to Fastener Notice in Cautions and Notices. 3. Install the TCM cover bolts (1) to the radiator shroud WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 484: Transmission Fluid Filter Adapter Replacement
ﬁ lter adapter (1) in the converter housing or from the ﬁ lter element. 3. Clean any metal debris from the magnet. Presence of any metal pieces larger than dust may indicate WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 485 ﬁ lter with transmission ﬂ uid. 4. Install, by hand, the transmission external oil ﬁ lter (4) until the gasket on the ﬁ lter touches the converter WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 486: Transmission Fluid Cooler Hose/Pipe Connector Replacement
(2) and tighten the ﬁ ttings to 25 N·m (18 lb ft). pipe connector being replaced. 2. Connect the hose to the transmission oil cooler pipe 2. Remove the transmission oil cooler pipe connectors connectors. (1) and (2). WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 487: Replacement
ﬁ lter touches the converter housing. 3. Remove the ﬁ lter (4) by rotating in the counterclockwise direction. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 488: Filler Tube And Seal Replacement
6. Place a drain pan under the transmission to catch any dripping ﬂ uid. 7. Loosen the ﬁ ll tube from the transmission. 8. Remove the ﬁ ll tube and seal from the vehicle. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 489 7. Lower the vehicle. 8. Fill the transmission to the proper level with approved ﬂ uid. 1. Install a new ﬁ ll tube plug seal (2) into the main WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 490: Replacement
5. Use a bent tip screwdriver. 3. Remove the cooling lines from the clips. 4. Remove the two retaining rings securing the two cooling lines to the transmission. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 491 ﬁ tting until the retaining ring is out of the ﬁ tting. 8. Repeat this procedure to remove all the remaining Discard the retaining ring. cooling lines from quick connect ﬁ ttings. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 492 9. For vehicles without an auxiliary cooler, remove the 10. For vehicles with auxiliary cooling, remove the cooling cooling lines from the radiator. lines from the radiator. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 493 ﬁ ttings if there is excessive of the slots in the quick connect ﬁ tting. corrosion. • Do not reuse any of the existing retaining rings that were removed from the existing WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 494 5. Do not install the new retaining ring onto the ﬁ tting by retaining ring is positioned with all three ears through pushing the retaining ring. the three slots on the ﬁ tting. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 495 ﬁ tting slots. until a click is either heard or felt. 7. Install the NEW retaining ring (E-clip) into the remaining quick connect ﬁ ttings. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 496 ﬁ tting. 12. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect ﬁ tting. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 497 ﬁ tting. plastic cap onto the quick connect ﬁ tting. 14. Ensure that the plastic cap is fully seated against the ﬁ tting. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 498 ﬁ tting. Check the retaining ring and the tube end in order to ensure neither is bent. Replace the cooler line or the retaining ring if necessary, and reinstall the cooler line per the installation procedure. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 499 Automatic Transmission – Allison 19. For vehicles without auxiliary cooling, install the 20. For vehicles with auxiliary cooling, install the cooling cooling lines to the radiator. lines to the radiator. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 500 24. Ensure all of the protective plastic caps are positioned over all of the quick connect ﬁ ttings. 25. Lower the vehicle. 26. Check and add ﬂ uid as necessary. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 501: Transmission Heat Shield Replacement
3. Install the front heat shield (1). 5. Remove the side heat shield (3). 4. Install the front heat shield bolts (2) and tighten the bolts (2) to 17 N·m (13 lb ft). WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 502: Transmission Mount Replacement
7. Remove the transmission mount from the vehicle. 2. Support the transmission with a transmission jack. 3. Remove the transmission mount to the transmission support retaining nut or nuts. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 503 2. Install the transmission mount to the transmission or 6. Lower the vehicle. transfer case adapter mounting bolts (1) and tighten the bolts to 50 N·m (37 lb ft). WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 504: Transmission Replacement (L18) Engine)
6. Drain the transmission ﬂ uid, if necessary. 4. Remove the engine protection shield bolts and shield. 7. Remove the propeller shaft. Refer to Propeller Shaft Replacement. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 505 13. Remove the transmission mount bolts (1). 14. Remove the transmission mount. 15. Disconnect the shift cable from the selector lever ball stud (5) and remove the cable from the bracket (3). WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 506 21. Remove the fuel line retainer (1) bolts on the left side J 44257 may be used, but is not required. of the transmission. 20. Disconnect the park neutral position (PNP) switch electrical connector. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 507 Automatic Transmission – Allison 22. Remove the transmission heat shield bolt and nut (4, 23. Remove the exhaust pipe hanger bolts and reposition 5) and shield (3). the hanger. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 508 Service Manual Automatic Transmission – Allison 24. Remove the transmission heat shield bolts (2) and 25. Remove the converter housing inspection cover bolts shield (1). and cover. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 510 29. Remove the fuel line bracket nut from the converter 30. Remove the wire harness/vent tube bracket nut from housing stud. the converter housing stud and reposition the bracket. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 511 33. Plug the transmission oil cooler line ﬁ ttings in the transmission case. 34. If the vehicle is equipped with a power take off (PTO) unit , disconnect and/or remove any necessary components to facilitate transmission removal. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 512 36. Separate the transmission from the engine. shaft. 38. Carefully lower the transmission from the vehicle while simultaneously removing the ﬁ ll tube. 39. Remove the J 21366 . WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 513 50 N·m (37 lb ft). 3. Remove the J 21366 . NOTICE: Refer to Fastener Notice in Cautions and Notices. Refer to Fastener Notice in Cautions and Notices. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 515 8. Install the transmission ﬁ ll tube nuts to the converter 9. Remove the safety chain from around the housing studs and tighten the nuts to 18 N·m (13 lb ft). transmission. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 516 (Canadian P/N 10953489), or equivalent to the threads prior to installation. 12. Install the torque converter bolts (3) and tighten the bolts to 60 N·m (44 lb ft). WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 517 15. Position the hanger and install the exhaust pipe and tighten the bolts to 17 N·m (13 lb ft). hanger bolts and tighten the bolts to 12 N·m (106 lb in). WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 518 17. Install the fuel line retainer (1) bolts to the left side of 5) and tighten the bolt/nut to 17 N·m (13 lb ft). the transmission and tighten the bolts to 2.5 N·m (22 lb in). WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 519 21. Connect the turbine speed sensor (1) and input speed sensor (2) electrical connectors. 22. Install the shift cable bracket (2) and bolts to the transmission and tighten the bolts to 25 N·m (18 lb ft). WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 520 26. Install the transmission support. 27. Install the transmission support bolts and nuts. 28. Install the transmission support bracket bolts and tighten the bolts/nuts to 95 N·m (70 lb ft). WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 521 35. Tighten the engine protection shield bolts to 20 N·m Negative Cable Disconnection and Connection . (15 lb ft). 41. Fill the transmission with new transmission ﬂ uid. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 522: Emergency Removal From Park
Figure 7-4 (shown with PNP switch removed for movement of the tow or disabled vehicles. clarity). B. Using an adjustable end wrench (Crescent Wrench) WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 523 VERTICALLY mounted Actuators. The following two graphics illustrate the difference between the two: HORIZONTALLY Mounted Actuator VERTICALLY Mounted Actuator. The transmission MUST be in NEUTRAL for proper WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 524 Be sure that the M8 x 60mm, ﬂ anged head, thread 7. For both the horizontally and vertically mounted forming bolt is used here not the M8 x 55mm hex actuators, place the Round Spacer, MT1246 (supplied WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 525 Place the shift shaft adapter into the center of the actuator. Be sure that the Shift Shaft Adapter properly engages the end of elector Shaft of the transmission. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 526 Attempt to start the engine. If the installation was done correctly the engine should start. Turn OFF the engine and proceed to the next system check. – Power-up the system with the ignition switch WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 527 1. Remove the 3 screws that hold the cover plate on. Calibration Using Shift Shaft Adapter A. 5. Turn the ignition ON, and select NEUTRAL 6. Turn the Ignition OFF. The Shift Selector will stay WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 528 NEUTRAL. 13. Replace the 2 - #10-32 x _” long that were removed in A. Using a long substantial screwdriver wedged WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...
Page 529 Grasp the head of the socket head cap screw with a pair of pliers and pull the lost motion wheel outward to place the actuator into the “calibration” position. WSM082106 © 2006 Workhorse Custom Chassis — All Rights Reserved 2007 W Series...

This manual is also suitable for:

Allison 2100mh Allison lct1000