Allison Transmission Motorhome Series Operator's Manual
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Allison Transmission Motorhome Series Operator's Manual

Allison Transmission Motorhome Series Operator's Manual

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MOTORHOME SERIES
3000/4000
OPERATOR'S
MANUAL

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  • Page 1 MOTORHOME SERIES 3000/4000 OPERATOR’S MANUAL...
  • Page 2 Operator’s 2005 FEBRUARY Rev. 1 2005 SEPTEMBER Manual OM3349EN Allison Transmission VOCATIONAL MODELS Motorhome Series (MH) Transmissions 3000 and 4000 Product Families WTEC III Controls and Allison 4 Generation Controls 3000 MH 4000 MH Printed in USA Copyright © 2005 General Motors Corporation...
  • Page 3 NOTES...

  • Page 4: Table Of Contents

    KEEPING THAT ALLISON ADVANTAGE ......7 A BRIEF DESCRIPTION OF THE ALLISON MOTORHOME SERIES TRANSMISSIONS ........12 ELECTRONIC CONTROL SYSTEM .
  • Page 5 SERVICE LITERATURE ........88 ALLISON TRANSMISSION DISTRIBUTORS ..... 90...
  • Page 6 TRADEMARK USAGE The following trademarks are the property of the companies indicated: • Allison DOC™ is a trademark of General Motors Corporation. ® • DEXRON is a registered trademark of the General Motors Corporation. • TranSynd™ is a trademark of Castrol Ltd.
  • Page 7 IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings and cautions described in this manual. It is, however, important to understand that these warnings and cautions are not exhaustive. Allison Transmission could not possibly know, evaluate, and advise the service trade of all conceivable ways in which service might be done or of the possible hazardous consequences of each way.

  • Page 8: Introduction

    “stop and go” or change speeds frequently. Driving is easier, safer, and more efficient. The Motorhome Series transmissions are rugged and designed to provide long, trouble-free service. This manual will help you gain maximum benefits from your...
  • Page 9 BREATHER ASSEMBLY PADS INPUT OUTPUT SPEED SPEED SENSOR SENSOR FEEDTHROUGH HARNESS CONNECTOR COOLER PORTS NAMEPLATE NOTE: Inch Series Threads MAIN-PRESSURE TAP NOTE: Inch Series Threads TORQUE CONVERTER FEEDTHROUGH WITH LOCKUP CLUTCH HARNESS AND TORSIONAL DAMPER CONNECTOR BREATHER ASSEMBLY PADS (BOTH SIDES) FILL TUBE AND DIPSTICK (Available on...
  • Page 10 BREATHER ASSEMBLY PADS INPUT OUTPUT SPEED SPEED SENSOR SENSOR FILL TUBE AND DIPSTICK (Available on both sides) COOLER PORTS NAMEPLATE NOTE: Inch Series Threads FEEDTHROUGH MAIN-PRESSURE TAP HARNESS CONNECTOR NOTE: Inch Series Threads TORQUE CONVERTER WITH LOCKUP CLUTCH AND TORSIONAL DAMPER BREATHER ASSEMBLY PADS...
  • Page 11 BREATHER FEEDTHROUGH HARNESS CONNECTOR MOUNTING INPUT SPEED SENSOR TURBINE SPEED SENSOR OUTPUT SPEED SENSOR FILL TUBE AND DIPSTICK NAMEPLATE COOLER PORTS BREATHER MOUNTING PAD (BOTH SIDES) FEEDTHROUGH HARNESS CONNECTOR COOLER PORTS MAIN-PRESSURE TAP V06342 Figure 3. Typical 4000 MH Series Transmission (WTEC III Controls)
  • Page 12 BREATHER MOUNTING INPUT SPEED SENSOR TURBINE SPEED SENSOR OUTPUT SPEED SENSOR FILL TUBE AND DIPSTICK NAMEPLATE COOLER PORTS FEEDTHROUGH HARNESS CONNECTOR BREATHER MOUNTING PAD (BOTH SIDES) COOLER PORTS MAIN-PRESSURE TAP V06342.01.00 Figure 4. Typical 4000 MH Series Transmission (Allison 4 Generation Controls)

  • Page 13: A Brief Description Of The Allison Motorhome Series Transmissions

    Generation Controls • A torque converter with lockup and torsion damper • Three planetary gear sets Motorhome Series transmissions may contain an integral retarder or a provision to mount a Power Takeoff (PTO). ELECTRONIC CONTROL SYSTEM All Motorhome Series transmissions come standard with WTEC III Controls or Allison 4 Generation Controls.

  • Page 14: Torque Converter

    Seek help from the nearest Allison Transmission service outlet when any of the above components are present, but are not responding properly. Another feature of the Motorhome Series transmission is its ability to adapt or “learn” as it operates. Each shift is measured electronically, stored, and used by the TCM/ECU to adapt or “learn”...

  • Page 15: Planetary Gears And Clutches

    When the pump turns faster than the turbine, the torque converter is multiplying torque. When the turbine approaches the speed of the pump, the stator starts to rotate with the pump and turbine. When this occurs, torque multiplication stops and the torque converter functions as a fluid coupling. The lockup clutch is located inside the torque converter and consists of the following elements: •...

  • Page 16: Retarder

    RETARDER The self-contained retarder is at the output of the transmission and consists of a vaned rotor which rotates in a vaned cavity. The rotor is splined to and driven by the output shaft. An external accumulator holds transmission fluid until the retarder is activated.

  • Page 17: Shift Selectors

    SHIFT SELECTORS DESCRIPTION OF AVAILABLE TYPES HOLD OVERRIDE BUTTON HOLD OVERRIDE BUTTON MODE INDICATOR MODE INDICATOR (LED) (LED) MODE BUTTON MODE MODE MODE MODE BUTTON MODE ID MODE ID DIGITAL DISPLAY DIGITAL DISPLAY DISPLAY MODE/ DISPLAY MODE/ DIAGNOSTIC BUTTON DIAGNOSTIC BUTTON SIX-SPEED, SIX-SPEED, CONTOURED...

  • Page 18: Introduction

    With an Allison-equipped vehicle, it is not necessary to select the right moment to upshift or downshift during changing road and traffic conditions. The Allison Motorhome Series transmission does it for you. However, knowledge of the shift selector positions, available ranges, and when to select them, make vehicle control and your job even easier.

  • Page 19: Lever Shift Selector

    • N (Neutral) • D (Drive) • Some number of lower forward range positions Motorhome Series transmissions can be programmed to have four, five, or six forward ranges. Shift selector positions should agree with the programming of the TCM/ECU unit.
  • Page 20 Digital Display. During normal operation, if D (Drive) is selected, the digital display shows the highest forward range attainable for the shift schedule in use. Abnormal operation is indicated by the WTEC III digital display as follows: • When all segments of the digital display are illuminated for more than 12 seconds, the ECU did not complete initialization.

  • Page 21: Pushbutton Shift Selector

    LEVER SHIFT SELECTOR paragraph, MODE Button paragraph. NOTE: The oil level sensor is a standard feature on Motorhome Series transmissions. Fluid level information is displayed after pressing both the ↑ (Up) and ↓ (Down) arrow buttons simultaneously. Simultaneously press both buttons again to obtain diagnostic data.

  • Page 22: Range Selection

    RANGE SELECTION MODE MODE MODE MODE V07344 Figure 7. Typical Motorhome Series Shift Selectors (WTEC III Controls) MODE V07344.01.00 Figure 8. Typical Motorhome Series Shift Selectors (Allison 4 Generation Controls)
  • Page 23 PUSHBUTTON AND LEVER SHIFT SELECTORS WITH DIGITAL DISPLAY Description of Available Ranges (refer to Figure 7 and Figure 8) WARNING: If you leave the vehicle and the engine is running, the vehicle can move unexpectedly and you or others could be injured.
  • Page 24 PUSHBUTTON AND LEVER SHIFT SELECTORS WITH DIGITAL DISPLAY (cont’d) Description of Available Ranges (refer to Figure 7 and Figure 8) Completely stop the vehicle and let the engine return to idle before shifting from a forward range to R (Reverse) or from R (Reverse) to a forward range.
  • Page 25 PUSHBUTTON AND LEVER SHIFT SELECTORS WITH DIGITAL DISPLAY (cont’d) Description of Available Ranges (refer to Figure 7 and Figure 8) WARNING: D (Drive) may not be attained due to an active inhibitor. Always apply the service brakes when selecting D (Drive) to prevent unexpected vehicle movement and because a service inhibit may be present.
  • Page 26 PUSHBUTTON AND LEVER SHIFT SELECTORS WITH DIGITAL DISPLAY (cont’d) Description of Available Ranges (refer to Figure 7 and Figure 8) Lower ranges provide greater engine braking for going down grades (the lower the range, the greater the braking effect). Occasionally, it may be desirable to restrict automatic shifting to a lower range because of: •...

  • Page 27: Driving Tips

    DRIVING TIPS CHECK TRANS LIGHT The electronic control system is programmed to inform the operator of a problem with the transmission system and automatically take action to protect the operator, vehicle, and transmission. When the Electronic Control Unit (ECU) or the Transmission Control Module (TCM) detects a problem condition, the TCM/ECU: •...

  • Page 28: Diagnostic Codes

    service assistance. Service should be performed immediately in order to minimize the potential for damage to the transmission. When the CHECK TRANS light comes on and the ignition switch is turned off, the transmission will remain in N (Neutral) until the condition causing the CHECK TRANS light is corrected.
  • Page 29 There is no speed limitation on upshifting, but there is a limitation on downshifting and for shifts that cause a direction change such as D (Drive)-to-R (Reverse) or R (Reverse)-to-D (Drive). Manual range downshifts will not occur until a calibration output speed (preset) is reached.

  • Page 30: Using The Engine To Slow The Vehicle

    USING THE ENGINE TO SLOW THE VEHICLE WARNING: To avoid loss of control, use a combination of downshifting, braking, and other retarding devices. Downshifting to a lower transmission range increases engine braking and can help you maintain control. The transmission has a feature to prevent automatic upshifting above the lower range selected.
  • Page 31 NOTE: If your transmission has a retarder but it is not functioning, it may not have been “autodetected” during vehicle manufacture. Go immediately to your nearest Allison Transmission service outlet to have “autodetect” reset or the retarder enabled using the Allison DOC™ For PC–Service Tool.
  • Page 32 Types of Retarder Control Type Description Amount of Application Manual Separate apply Zero to Full apply pedal Hand lever * Six levels based on lever position Automatic Auto “Full On” * “Full On” when closed throttle sensed Brake Pressure Single pressure Off or “Full On”...

  • Page 33: Adapting Shifts

    NOTE: When the transmission fluid or engine water temperature (engine water is an OEM option) exceeds programmed limits, retarder capacity is automatically gradually reduced to minimize or avoid possible system overheating. Contact your vehicle manufacturer to understand how the retarder controls have been integrated into your vehicle.
  • Page 34 All segments of this procedure are to be repeated a minimum of 5 times or until shift quality variation is indistinguishable from shift to shift. 1. From Neutral, with parking brake set and service brakes applied via foot pedal, select the following sequence: Drive, Neutral, Reverse, Neutral, Drive, Reverse, Drive, Neutral.

  • Page 35: Range Preselection

    COLD WEATHER STARTS All Motorhome Series transmissions are programmed to restrict full operation until specific fluid temperatures are reached. Refer to the following table for temperature restrictions.

  • Page 36: Driving On Snow Or Ice

    Minimum Fluid Operating Temperatures CHECK Sump Fluid Temperature TRANS Light Operation –32°C (–25°F) to –7°C (19°F) Neutral, Reverse, Second –7°C (19°F) Full operation in all ranges NOTE: When sump temperature is below 10°C (50°F) and transmission ® fluid is C4 (not DEXRON or TranSynd™), follow these procedures when making directional shift changes: •...

  • Page 37: Rocking Out

    ROCKING OUT WARNING: To help avoid injury or property damage caused by sudden movement of the vehicle, do not make shifts from N (Neutral) to D (Drive) or R (Reverse) when the throttle is open. The vehicle will lurch forward or rearward and the transmission can be damaged. Avoid this condition by making shifts from N (Neutral) to a forward range or R (Reverse) only when the throttle is closed and the service brakes are applied.

  • Page 38: Parking Brake

    If the transmission overheats during normal operations, check the fluid level in the transmission. Refer to the fluid level check procedures described in the CARE AND MAINTENANCE section. CAUTION: The engine should never be operated for more than 10 seconds at full throttle with the transmission in range and the output stalled.

  • Page 39: Towing Or Pushing

    TOWING OR PUSHING CAUTION: Failure to lift the driving wheels off the road, disconnect the driveline, or remove the axle shafts before pushing or towing can cause serious transmission damage. The engine cannot be started by pushing or towing. Before pushing or towing a vehicle do one of the following: •...

  • Page 40: Turning Off The Vehicle

    cycle if the cruise control speed setting is set too close to a scheduled shift point. One of the following actions may eliminate shift cycling: • Select the secondary shift schedule by pushing the MODE button (refer to Figure 5 or Figure 6) on the shift selector. •...

  • Page 41: Power Takeoff Operation

    Be sure that the limits for PTO engagement speed and operational speed are not exceeded. Consult the vehicle manufacturer’s literature for these speed limits. Also, all Motorhome Series-equipped vehicles with PTO enable have engagement and operational speed limits programmed into the ECU to help protect PTO equipment.

  • Page 42: Care And Maintenance

    Generation Controls or WTEC III Controls oversee the operation of the transmission. Minor problems can be kept from becoming major problems if an Allison Transmission distributor or dealer is notified when one of these conditions occur: • Shifting feels odd.

  • Page 43: Importance Of Proper Fluid Level

    fluid. If fluid level is too high, the fluid can aerate. Aerated fluid can cause the transmission to shift erratically or overheat. Motorhome Series transmissions have an oil level sensor (OLS) that allows the operator to obtain an indication of fluid level from the shift selector. However, no oil level sensor diagnostics take place unless the OLS is “autodetected”...

  • Page 44: Fluid Level Check Using Pushbutton Or Lever Shift Selector

    FLUID LEVEL CHECK USING PUSHBUTTON OR LEVER SHIFT SELECTOR HOLD OVERRIDE BUTTON HOLD OVERRIDE BUTTON MODE INDICATOR MODE INDICATOR (LED) (LED) MODE BUTTON MODE MODE MODE MODE BUTTON MODE ID MODE ID DIGITAL DISPLAY DIGITAL DISPLAY DISPLAY MODE/ DISPLAY MODE/ DIAGNOSTIC BUTTON DIAGNOSTIC BUTTON SIX-SPEED,...
  • Page 45 HOLD OVERRIDE HOLD OVERRIDE BUTTON BUTTON MODE INDICATOR MODE INDICATOR (LED) (LED) MODE BUTTON MODE BUTTON MODE ID MODE ID DIGITAL DISPLAY DIGITAL DISPLAY DISPLAY MODE DISPLAY MODE DIAGNOSTIC BUTTON DIAGNOSTIC BUTTON DIGITAL DISPLAY MODE ID MODE MODE INDICATOR (LED) Push simultaneously to enter diagnostic mode and fluid...
  • Page 46 A delayed fluid level check for transmissions with WTEC III Controls is indicated by a “—” in the display window followed by a numerical countdown. The countdowns, starting at 8, indicates the time remaining in the two minutes setting period. The indication of a delayed fluid level check for Allison 4 Generation Controls is a flashing display under SELECT and a digit countdown from 8 to 1 under...
  • Page 47 —, 9, 5 Sensor failure* * Report sensor failure display to a distributor or dealer in your area (check the telephone directory for an Allison Transmission distributor or dealer). Fluid Level Fault Codes (for Allison 4 Generation Controls) Display...

  • Page 48: Manual Fluid Check Procedure

    MANUAL FLUID CHECK PROCEDURE Refer to Figure 1 through Figure 4 for the location of the fill tube and dipstick. WARNING: If you leave the vehicle and the engine is running, the vehicle can move unexpectedly and you or others could be injured. If you must leave the engine running, do not leave the vehicle until you have completed all of the following procedures: 1.
  • Page 49 NOTE: Calibrate level marking locations with respect to transmission control module split line and fill tube. Scale none. *Dimension determined by installation. **Reference dimension only. Actual dimension to be determined by installation. ***Reference drawing AS66-60. ****Reference drawing AS67-60. V07301.00.01 Figure 11. Standard Motorhome Series Transmission Dipstick Markings...

  • Page 50: Cold Check

    COLD CHECK The Cold Check determines if the transmission has enough fluid to be operated safely until a Hot Check can be made. NOTE: The correct fluid level can not be determined unless the transmission is in a level position. CAUTION: DO NOT start the engine until the presence of sufficient transmission fluid has been confirmed.

  • Page 51: Hot Check

    CAUTION: DO NOT operate the transmission for extended periods of time until a Hot Check has verified proper fluid level. Transmission damage can result from extended operation at improper fluid level conditions. CAUTION: Obtain an accurate fluid level by imposing the following conditions: •...

  • Page 52: Keeping Fluid Clean

    ® DEXRON -III license numbers on the container or consult the lubricant manufacturer. Consult your Allison Transmission dealer or distributor before using other fluid types. CAUTION: Disregarding minimum fluid temperature limits can result in transmission malfunction or reduced transmission life.

  • Page 53: Fluid And Internal Filter Change Interval Recommendations

    It is absolutely necessary that transmission fluid be clean. The fluid must be handled in clean containers to prevent foreign material from entering the transmission. FLUID AND INTERNAL FILTER CHANGE INTERVAL RECOMMENDATIONS CAUTION: Transmission fluid and filter change frequency is determined by the severity of transmission service.

  • Page 57: Transmission Fluid Contamination

    CAUTION: Transmission fluid and filters must be changed whenever there is evidence of dirt or a high temperature condition. A high temperature condition is indicated when the transmission fluid is discolored, has a strong odor, or has exceeded oil analysis limits. Fluid Analysis Transmission protection and fluid change intervals may be optimized by monitoring fluid oxidation according to the tests and limits shown in the Fluid...

  • Page 58: Transmission Fluid And Filter Change Procedure

    Metal. Metal particles in the fluid (except for the minute particles normally trapped in the oil filter) indicate internal transmission damage. If these particles are found in the sump, the transmission must be disassembled and closely inspected to find their source. Metal contamination requires complete transmission disassembly.
  • Page 59 4000 MH FILTER 3000 MH COVER LUBE MAIN LUBE MAIN DRAIN PLUG DRAIN LUBE MAIN PLUG V03532.03.00 Figure 12. Location of Filters for Service CAUTION: Do not use the bolts to draw the filter covers to the control module. Do not use an impact wrench to tighten the bolts. Using an impact wrench to tighten the bolts can strip threads and cause expensive parts replacement.
  • Page 60 Refill Transmission. The amount of refill fluid is less than the amount used for the initial fill. Fluid remains in the external circuits and transmission cavities after draining the transmission. After refill, check the fluid level. Refer to FLUID LEVEL CHECK USING PUSHBUTTON OR LEVER SHIFT SELECTOR paragraph.

  • Page 61: Introduction

    DIAGNOSTICS INTRODUCTION Continued illumination of the CHECK TRANS light during vehicle operation (not start-up) indicates the TCM/ECU has signaled a diagnostic code. Poor performance may activate a code without illuminating the CHECK TRANS light. Up to five diagnostic codes can be recorded. Diagnostic codes can be read and cleared by two methods: by using the shift selectors shown below or using the Allison DOC™...
  • Page 62 MODE MODE SHIFT ALLISON DOC™ SELECTORS V07952.00.00 Figure 13. Shift Selector/Allison DOC™ Diagnostic Tool Historical codes are codes that are retained in the TCM/ECU’s memory and will not necessarily affect the TCM/ECU decision-making process.Historical codes are useful in determining if a problem: •...
  • Page 63 If the MODE INDICATOR (LED) is illuminated, the displayed code is active. If the mode indicator (refer to Figure 7 and Figure 8) is not illuminated, the displayed code is not active. An illuminated mode indicator during normal operation signifies secondary mode operation. Diagnostic Codes—WTEC III Controls.

  • Page 64: Diagnostic Code Display Procedure

    — Allison 4 Generation Electric Controls—Press and hold the MODE button for 10 seconds to clear both active indicators and inactive codes. 2. Begin operating as normal—have the transmission checked at the earliest opportunity by an Allison Transmission distributor or dealer.
  • Page 65 MODE button for 10 seconds to clear both active indicators and inactive codes. 2. Begin operating as normal—have the transmission checked at the earliest opportunity by an Allison Transmission distributor or dealer. NOTE: If the condition that caused the code is still present, the code will again become active.

  • Page 66: Diagnostic Code Listings And Procedures (Wtec Iii Controls)

    DIAGNOSTIC CODE LISTINGS AND PROCEDURES (WTEC III CONTROLS) The following table presents information about the diagnostic codes which may occur during the operation of the transmission. For additional information, refer to TS2973EN Troubleshooting Manual for WTEC III Controls. Code Listings And Procedures (WTEC III Controls) CODES QUICK CHECKS MAIN...
  • Page 67 Code Listings And Procedures (WTEC III Controls) (cont’d) CODES QUICK CHECKS MAIN CODE CODE 14, 15, 16 Check: a. Speed sensors and connectors are tight, clean, and undamaged. Speed Sensors b. Wiring harness to sensors has no opens, shorts-between-wires, or shorts-to-ground. 12, 13, 14, Check: 15, 16...
  • Page 68 Code Listings And Procedures (WTEC III Controls) (cont’d) CODES QUICK CHECKS MAIN CODE CODE 00, 11 Check: a. TPS for proper operation, related harness for opens and shorts. Throttle/Engine Coolant Source Not b. Serial connection to engine is tight, clean, and Detected undamaged.
  • Page 69 Code Listings And Procedures (WTEC III Controls) (cont’d) CODES QUICK CHECKS MAIN CODE CODE 00, 01, 02 a. If able, recalibrate ECU; if not, replace ECU. b. Check that ECU is compatible with TransID level Hardware/Software (36 01). Not Compatible c.
  • Page 70 Code Listings And Procedures (WTEC III Controls) (cont’d) CODES QUICK CHECKS MAIN CODE CODE 01, 10, 12, Check: 21, 23, 24, a. Output and turbine speed sensor connectors are 35, 42, 43, tight, clean, and undamaged. 45, 46, 53, b. Speed sensor wiring harness has no opens, 64, 65, shorts-between-wires, or shorts-to-ground.
  • Page 71 Code Listings And Procedures (WTEC III Controls) (cont’d) CODES QUICK CHECKS MAIN CODE CODE 01, 07, 10, Check: 12, 17, 21, a. Turbine and output speed sensor connectors are 23, 24, 27, tight, clean, and undamaged. 32, 34, 35, b. Speed sensor wiring harness has no opens, 42, 43, 45, shorts-between-wires, or shorts-to-ground.
  • Page 72 Code Listings And Procedures (WTEC III Controls) (cont’d) CODES QUICK CHECKS MAIN CODE CODE 00, 11, 22, Check: 33, 44, 55, a. Turbine and output speed sensor connectors are 66, 77 tight, clean, and undamaged. b. Speed sensor wiring harness has no opens, shorts-between-wires, or shorts-to-ground.
  • Page 73 Code Listings And Procedures (WTEC III Controls) (cont’d) CODES QUICK CHECKS MAIN CODE CODE 12, 23, 32, Check: a. Retarder temperature measured with diagnostic tool is consistent with code; or determine if code is active using shift selector. b. Sensor connector is tight, clean and undamaged. Retarder c.

  • Page 74: Diagnostic Code Listings And Procedures (Allison 4 Generation Controls)

    DIAGNOSTIC CODE LISTINGS AND PROCEDURES (ALLISON 4 GENERATION CONTROLS) The following table presents information about the diagnostic codes which may occur during the operation of the transmission. For additional information, refer to TS3989EN Troubleshooting Manual for Allison 4 Generation Controls. Code Listings And Procedures (Allison 4 Generation Controls)
  • Page 75 Code Listings And Procedures (Allison 4 Generation Controls) (cont’d) P0613 1. Contact Allison Transmission Technical Assistance Center at: 1-800-252-5283. Processor P0614 1. Check: Torque a. Data link communication connectors at engine and Control Data transmission controllers are tight, clean, and Mismatch—...
  • Page 76 Code Listings And Procedures (Allison 4 Generation Controls) (cont’d) P063F 1. Check: Auto a. Data link communication connectors at engine and Configuration transmission controllers are tight, clean, and Engine undamaged. Coolant Not b. Data link communications wiring harness has no Present opens, shorts, or shorts-to-ground.
  • Page 77 Code Listings And Procedures (Allison 4 Generation Controls) (cont’d) P0703 1. Check: Brake Switch a. Brake pressure switch, wiring, and connectors to Circuit determine why brake input is not being sent to the TCM. P0708 1. Check: Transmission a. TCM connector is tight, clean, and undamaged. Range Sensor b.
  • Page 78 Code Listings And Procedures Generation Controls) (cont’d) (Allison 4 P071A 1. Check brake pressure switch, wiring, and connectors to RELS Input determine why RELS input is not being sent to the Fault TCM. P071D 1. Check input wiring, switches, and connectors to General determine why input states are different.
  • Page 79 Code Listings And Procedures (Allison 4 Generation Controls) (cont’d) P0776, P0796, 1. Check: P2714, P2723 a. Turbine and output speed sensor connectors are Pressure tight, clean, and undamaged. Control b. Speed sensor wiring harness has no opens, Solenoid shorts-between-wires, or shorts-to-ground. Controlled Clutch Stuck 2.
  • Page 80 Code Listings And Procedures (Allison 4 Generation Controls) (cont’d) P0880, P0881, 1. Check: P0882, P0883 a. Battery direct ground and power connections are TCM Power tight and clean. Input Signal b. Vehicle batteries are charged. Fault c. Vehicle charging system is not over- or under-charging.
  • Page 81 Code Listings And Procedures (Allison 4 Generation Controls) (cont’d) P0973, P0976 1. Check: Shift Solenoid a. Main transmission connector is tight, clean, and Circuit Low undamaged. b. TCM connector is tight, clean, and undamaged. c. Wiring harness has no opens, shorts-between-wires, or shorts-to-ground.
  • Page 82 Code Listings And Procedures (Allison 4 Generation Controls) (cont’d) P2637, P2641 1. Check that no unauthorized engine power upgrades Torque were made. Management 2. Check that engine software is compatible with Feedback transmission torque requirements, otherwise: Signal Fault a. Recalibrate engine controller with compatible software, or b.
  • Page 83 Code Listings And Procedures (Allison 4 Generation Controls) (cont’d) U0001 1. Check: High Speed a. High speed CAN connectors at engine and CAN Bus transmission controllers are tight, clean, and Reset Counter undamaged. Overrun b. High speed CAN wiring harness has no opens, shorts-between-wires, or shorts-to-ground.
  • Page 84 Code Listings And Procedures (Allison 4 Generation Controls) (cont’d) U0304, U0313 1. Check that the shift selector is an Allison supplied shift Incompatible selector. Gear Shift Module U0404, U0592 1. Check: Invalid Data a. Shift selector connector is tight, clean, and Received from undamaged.

  • Page 85: Abbreviations And Definitions

    Engine/transmission serial data communications link. J1939 High-speed vehicle serial data communications link. Light-Emitting Diode—Electronic device used for illumination. Motorhome Series. Original Equipment Manufacturer—Maker of vehicle or equipment. Oil Level Sensor—Electronic device (optional) on control module for indicating transmission fluid level.
  • Page 86 Personal Computer—Needed to run a version of Allison DOC™ diagnostic tool. Powered Downshift—A downshift forced by applying brakes with the throttle applied. Allison Transmission does not recommend this procedure. Personal Digital Assistant—Used to run a version of Allison DOC™ diagnostic tool.

  • Page 87: Customer Service

    The satisfaction and goodwill of the owners of Allison transmissions are of primary concern to Allison Transmission, its distributors, and their dealers. As an owner of an Allison transmission, you have service locations throughout the world that are eager to meet your parts and service needs with: •...
  • Page 88 Therefore, it is suggested that Step One be followed when experiencing a problem. Your purchase of an Allison Transmission product is greatly appreciated, and it is our sincere desire to assure complete satisfaction.

  • Page 89: Service Literature

    Parts Catalog PC2150EN PC2456EN Parts Catalog CD-ROM CD2150EN CD2456EN Principles of Operation PO2454EN PO2454EN Service Manual SM2148EN SM2457EN Troubleshooting Manual TS2973EN TS2973EN Worldwide Sales and Service SA2229EN SA2229EN Directory* * Also available on the Allison Transmission web site at www.allisontransmission.com...
  • Page 90 Parts Catalog* PC2150EN PC2456EN Parts Catalog on CD CD2150EN CD2456EN Principles of Operation PO4016EN PO4016EN Service Manual SM4013EN SM4014EN Troubleshooting Manual TS3989EN TS3989EN Worldwide Sales and Service SA2229EN SA2229EN Directory* * Also available on the Allison Transmission web site at www.allisontransmission.com...

  • Page 91: Allison Transmission Distributors

    ALLISON TRANSMISSION DISTRIBUTORS EASTERN REGION Atlantic Detroit Diesel-Allison, LLC Penn Detroit Diesel-Allison, Inc. 180 Route 17 South 8330 State Road Lodi, NJ 07644 Philadelphia, PA 19136-2986 201-489-5800 215-335-0500 Covington Detroit Diesel-Allison Western Branch Diesel, Inc. 8015 Piedmont Triad Parkway 3504 Shipwright Street...
  • Page 92 SOUTHERN REGION Caribe Detroit Diesel-Allison Stewart & Stevenson Power, Inc. 5840 Dahlia Street Division of GT Corporation Commerce City, CO 80022 Ceramic Ind. Park Campo Rico Ave., Block C 303-287-7441 Carolina, Puerto Rico 00982 787-750-5000 Detroit Diesel-Allison de Mexico S.A. Stewart &...

  • Page 93: Allison Transmission Regional Offices

    ALLISON TRANSMISSION REGIONAL OFFICES EASTERN REGION SOUTHERN REGION 19 Oaklynn Drive Av. Ejercito Nacional No. 843 PO Box 400 Colonia Granada Columbus, NJ 08022-0400 Mexico, D.F. C.P. 11520 609-298-2541 936-321-4248 CENTRAL REGION WESTERN REGION PO Box 894, Mail Code 462-470-PF06...
  • Page 94 OM3349EN 200509 www.allisontransmission.com Printed in USA 200509...

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