Allison Troubleshooting Manual Wtec Iii

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3000 AND 4000 ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL
PREFACE

Welcome to the TS2973EN Troubleshooting Manual. We make every effort to keep our service
information current and accurate. Because of the time lag involved with writing and printing processes,
the transmission TCM may report a code that has not yet been added to this document. If you encounter
a code that is not yet in this publication, please call the Allison Transmission Technical Assistance Center
at 1-800-252-5283.

Go to the Table of Contents.

Copyright© 2005 General Motors Corp.

This is the cut pages sample. Download all 443 page(s) at: ManualPlace.com
Troubleshooting 2005 OCTOBER
REV. 1 OCTOBER 2006
Manual TS2973EN

Allison Transmission
VOCATIONAL MODELS
3000 VOCATIONAL MODELS
3000 HS 3500 RDS B 300(P)(R)
3000 RDS 3500 EVS B 400(P)(R)
3000 EVS T 200
3000 MH T 300
3000 PTS
3000 TRV
3200 SP 3500 SP 3700 SP
3200 TRV
MD 3060 MD 3560 MD 3070PT
MD 3066
4000 VOCATIONAL MODELS
4000 EVS 4500 EVS 4700 EVS 4800 EVS B 500
4000 HS 4500 HS 4700 RDS
4000 MH 4500 RDS
4000 RDS 4500 SP
4000 TRV 4500 TRV
HD 4060 HD 4560 HD 4070 HD 4076 B 500P
HD 4060P HD 4560P HD 4070P B 500R
HD 4060R HD 4560R HD 4070R B 500PR
HD 4060PR HD 4560PR HD 4070PR T 425
T 450

Allison Transmission, General Motors Corporation

P.O. Box 894 Indianapolis, Indiana 46206-0894
www.allisontransmission.com

Printed in USA Copyright © 2005 General Motors Corporation

 WTEC III ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

FOREWORD—How to Use This Manual

This manual provides troubleshooting information for the 3000 and 4000 Product Families Transmissions. Service
Manuals SM2148EN and SM2457EN, plus Parts Catalogs PC2150EN and PC2456EN may be used in conjunction
with this manual.
This manual includes:
• Description of the WTEC III electronic control system.
• Description of the electronic control system components.
• Description of diagnostic codes, system responses to faults, and troubleshooting.
• Wire, terminal, and connector repair information.
Specific instructions for using many of the available or required service tools and equipment are not included in
this manual. The service tool manufacturer will furnish instructions for using the tools or equipment.
Additional information may be published from time to time in Service Information Letters (SIL) and will be
included in future revisions of this and other manuals. Please use these SILs to obtain up-to-date information
concerning Allison Transmission products.
This publication is revised periodically to include improvements, new models, special tools, and procedures. A
revision is indicated by a new date on the title page and in the lower left corner of the rear cover. Contact your
Allison Transmission service outlet for the currently applicable publication. Additional copies of this publication
may be purchased from authorized Allison Transmission service outlets. Look in your telephone directory under
the heading of Transmissions—Truck, Tractor, etc.
Take time to review the Table of Contents and the manual. Reviewing the Table of Contents will aid you in quickly
locating information.

NOTE: Allison Transmission is providing for service of wiring harnesses and wiring harness components as
follows:

• Repair parts for the internal wiring harness and for wiring harness components attached to the shift selector
will be available through the Allison Transmission Parts Distribution Center (PDC). Use the P/N from your
appropriate parts catalog or from Appendix E in this manual. Allison Transmission (AT) is responsible for
warranty on these parts.
• Repair parts for the external harnesses and external harness components must be obtained from St. Clair
Technologies Inc. (SCTI). SCTI provides parts to any Allison customer or OEM and is responsible for
warranty on these parts. SCTI recognizes AT, manufacturers, and SCTI part numbers. SCTI provides a
technical HELPLINE at 519-627-1673 (Wallaceburg). SCTI will have parts catalogs available. The SCTI
addresses and phone numbers for parts outlets are:

St. Clair Technologies, Inc. St. Clair Technologies, Inc.

920 Old Glass Road Calle Damanti S/N Col
Wallaceburg, Ontario, N8A 4L8 Guadalupe—Guaymas
Phone: 519-627-1673 Sonora, Mexico CP85440
Fax: 519-627-4227 Phone: 011-526-2222-43834
Fax: 011-526 2222-43553

• St. Clair Technologies, Inc. stocks a WTEC III external harness repair kit, P/N 29532362, as a source for
some external harness repair parts. SCTI is the source for external harness repair parts.

ii Copyright © 2005 General Motors Corp.

 WTEC III ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

IMPORTANT SAFETY NOTICE

IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings and cautions

used in this manual. These warnings and cautions advise against using specific service
procedures that can result in personal injury, equipment damage, or cause the equipment to
become unsafe. These warnings and cautions are not exhaustive. Allison Transmission could
not possibly know, evaluate, or advise the service trade of all conceivable procedures by which
service might be performed or of the possible hazardous consequences of each procedure.
Consequently, Allison Transmission has not undertaken any such broad evaluation.
Accordingly, ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT
RECOMMENDED BY ALLISON TRANSMISSION MUST first be thoroughly satisfied
that neither personal safety nor equipment safety will be jeopardized by the service
procedures used.

Also, be sure to review and observe WARNINGS, CAUTIONS, and NOTES provided by the
vehicle manufacturer and/or body builder before servicing the Allison transmission in that
vehicle.

Proper service and repair is important to the safe and reliable operation of the equipment.
The service procedures recommended by Allison Transmission and described in this manual
are effective methods for performing troubleshooting operations. Some procedures require
using specially designed tools. Use special tools when and in the manner recommended.

The WARNINGS, CAUTIONS, and NOTES in this manual apply only to the Allison
transmission and not to other vehicle systems which may interact with the transmission. Be
sure to review and observe any vehicle system information provided by the vehicle
manufacturer and/or body builder at all times the Allison transmission is being serviced.

WARNINGS, CAUTIONS, AND NOTES

Three types of headings are used in this manual to attract your attention:

Is used when an operating procedure, practice, etc., which, if not correctly followed,
WARNING!
could result in injury or loss of life.

Is used when an operating procedure, practice, etc., which, if not strictly observed, could
CAUTION: result in damage to or destruction of equipment.

NOTE: Is used when an operating procedure, practice, etc., is essential to highlight.

Copyright © 2005 General Motors Corp. iii

 WTEC III ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

TRADEMARKS USED IN THIS MANUAL

The following trademarks are the property of the companies indicated:

• Allison DOCTM is a trademark of General Motors Corporation.

• DEXRON® is a registered trademark of General Motors Corporation.

• LPS® Cleaner is a registered trademark of LPS Laboratories.

• Loctite® is a registered trademark of the Loctite Corporation.

• MagiKey® is a registered trademark of NEXIQ Technologies, Inc.

• Teflon® is a registered trademark of the DuPont Corporation.

• TranSyndTM is a trademark of Castrol Ltd.

SHIFT SELECTOR TERMS AND DISPLAY INDICATIONS

Shift selector terms and displays are represented in this manual as follows:

• Button Names — ↑, ↓, “display mode”, MODE, etc.

• Transmission Ranges—D (Drive), N (Neutral), R (Reverse), 1 (First), 2 (Second), etc.
• Displays—“o, L”; “o, K”, etc. (Display occurs one character at a time.)

iv Copyright © 2005 General Motors Corp.

 3000 AND
WTEC 4000 ELECTRONIC
III ELECTRONIC CONTROLS
CONTROLS TROUBLESHOOTING MANUAL
TROUBLESHOOTING MANUAL
TABLE OF CONTENTS

Page
Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

SAFETY INFORMATION
Important Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
Warnings, Cautions, and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii

TRADEMARKS USED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv

SHIFT SELECYOR TERMS AND DISPLAY INDICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv

SECTION 1. GENERAL DESCRIPTION

1–1. TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
1–2. ELECTRONIC CONTROL UNIT (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
1–3. SHIFT SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
A. Pushbutton Shift Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
B. Lever Shift Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
1–4. THROTTLE POSITION SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
1–5. SPEED SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
1–6. CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6
1–7. WIRING HARNESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8
A. External Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8
B. Internal Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
1–8. VEHICLE INTERFACE MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
1–9. AUTODETECT FEATURE (V8, V8A, V9A SOFTWARE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
A. Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
B. Oil Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
C. Throttle Source (V8, V8A Software—See Paragraph 1–10C For V9A) . . . . . . . . . . . . . . . . . . 1–12
D. Engine Coolant Temperature Sensor Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12
1–10. AUTODETECT FEATURE (V9A, V9B, AND V9C SOFTWARE) . . . . . . . . . . . . . . . . . . . . . . . 1–12
A. Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12
B. Oil Level Sensor (OLS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12
C. Throttle Source (Also Applies to V9 Software). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13
D. Engine Coolant Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13
1–11. TRANSID FEATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13
A. General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13
B. Transmission Changes Versus TransID Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–14
C. Compatibility Between TransID Level And ECU Calibration Level . . . . . . . . . . . . . . . . . . . . 1–16

Copyright © 2005 General Motors Corp. v

 WTEC III ELECTRONIC
3000 AND CONTROLS
4000 ELECTRONIC TROUBLESHOOTING
CONTROLS MANUAL
TROUBLESHOOTING MANUAL
T A B L E O F C O N T E N T S (C o n t ' d)

Page

SECTION 2. DEFINITIONS AND ABBREVIATIONS

2–1. CHECK TRANS LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
2–2. ALLISON TRANSMISSION DIAGNOSTIC TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
Basic Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
PC Platform. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
2–3. ABBREVIATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3

SECTION 3. BASIC KNOWLEDGE

3–1. BASIC KNOWLEDGE REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3–2. USING THE TROUBLESHOOTING MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
3–3. SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
3–4. IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS . . . . . . . . . . . . . . . . 3–2
3–5. BEGINNING THE TROUBLESHOOTING PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3

SECTION 4. WIRE TESTING PROCEDURES

4–1. TESTING FOR OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND . . . . . . . 4–1
4–2. TESTING AT TRANSMISSION CONNECTOR AND THE INTERNAL HARNESS
FOR OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND . . . . . . . . . . . . . . . . 4–3

SECTION 5. OIL LEVEL SENSOR

5–1. INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
5–2. ELECTRONIC FLUID LEVEL CHECK (SHIFT SELECTOR) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
A. Fluid Level Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
5–3. ELECTRONIC FLUID LEVEL CHECK (ALLISON DOC™ FOR PC–SERVICE TOOL) . . . . . 5–5
A. Fluid Level Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5

SECTION 6. DIAGNOSTIC CODES

6–1. DIAGNOSTIC CODE MEMORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
6–2. CODE READING AND CODE CLEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
6–3. DIAGNOSTIC CODE RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
6–4. SHIFT SELECTOR DISPLAYS RELATED TO ACTIVE CODES . . . . . . . . . . . . . . . . . . . . . . . . 6–4
6–5. DIAGNOSTIC CODE LIST AND DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
6–6. DIAGNOSTIC CODE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–16
A. Beginning the Troubleshooting Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–16
B. Solenoid Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–16
C. Diagnostic Code Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–16
D. Wire/Terminal Numbering Scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–17

vi Copyright © 2005 General Motors Corp.

 WTEC III ELECTRONIC
3000 AND CONTROLS
4000 ELECTRONIC TROUBLESHOOTING
CONTROLS MANUAL
TROUBLESHOOTING MANUAL
T A B L E O F C O N T E N T S (C o n t ' d)

Page

SECTION 7. INPUT AND OUTPUT FUNCTIONS

7–1. INPUT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
7–2. OUTPUT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3

SECTION 8. GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS

APPENDICES
A. IDENTIFICATION OF POTENTIAL CIRCUIT PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1
B. MEASURING CLUTCH AND RETARDER PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–1
C. SOLENOID AND CLUTCH CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C–1
D. WIRE/CONNECTOR CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–1
E. CONNECTOR PART NUMBERS, TERMINAL PART NUMBERS,
TOOL PART NUMBERS, AND REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–1
F. THROTTLE POSITION SENSOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F–1
G. WELDING ON VEHICLE/VEHICLE INTERFACE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . G–1
H. HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H–1
J. 3000 AND 4000 PRODUCT FAMILIES WIRING SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . J–1
K. TRANSID 1 TEMPERATURE SENSOR AND SOLENOID RESISTANCE CHARTS . . . . . . . . K–1
L. EXTERNALLY-GENERATED ELECTRONIC INTERFERENCE . . . . . . . . . . . . . . . . . . . . . . . . L–1
M. DIAGNOSTIC TREE—HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M–1
N. DIAGNOSTIC TOOL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N–1
P. INPUT/OUTPUT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–1
Q. TRANSID 2 AND 3 THERMISTOR TROUBLESHOOTING INFORMATION . . . . . . . . . . . . . . Q–1
R. SAE J1939 COMMUNICATION LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R–1

Copyright © 2005 General Motors Corp. vii

 WTEC III ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

NOTES

viii Copyright © 2005 General Motors Corp.

 WTEC III ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL
SECTION 1—GENERAL DESCRIPTION

1–1. TRANSMISSION
The World Transmission Electronic Controls (WTEC III) system features closed-loop clutch control to provide
superior shift quality over a wide range of operating conditions. The 3000 and 4000 Product Families transmissions
configurations can be programmed to have up to six forward ranges, neutral, and one reverse range. The MD 3070,
3700 SP, HD 4070/4076, 4700 RDS, 4700/4800 EVS, 4700/4800 SP have up to seven forward ranges and one
reverse.

Figure 1–1 is a block diagram of the basic system inputs and outputs.

SHIFT SELECTOR
RANGE AND
MODE SWITCH DISPLAY

SPEED SENSORS OIL LEVEL SENSOR

THROTTLE POSITION SENSOR SOLENOIDS
RETARDER MODULATION
ECU
C3 PRESSURE SWITCH
VEHICLE/ENGINE TEMPERATURE SENSOR
COMMUNICATION LINKS (SUMP/RETARDER)

VIM

INPUTS OUTPUTS V03469

Figure 1–1. Electronic Control Unit Block Diagram

Figure 1–2 shows WTEC III electronic control components.

WTEC III Electronic Controls consist of the following elements:

• Remote 12/24V Max Feature Sealed Electronic Control Unit (ECU)
• Remote Pushbutton or Lever Shift Selector
• Optional Secondary Shift Selector
• Throttle Position Sensor (TPS) (or electronic engine throttle data or PWM signal)
• Engine, Turbine, and Output Speed Sensors
• Control Module (Electro-Hydraulic Valve Body)
• Wiring Harnesses
• Vehicle Interface Module (VIM)
• Autodetect Feature
• TransID Feature
• Optional Retarder Controls
• Optional Engine Coolant Temperature Input.

NOTE: • All external harnesses are OEM supplied

• The VIM is an OEM option

Copyright © 2005 General Motors Corp. 1–1

 WTEC III ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL
GENERAL DESCRIPTION

ELECTRONIC VEHICLE (V)

CONTROL
UNIT HARNESS

Y
A
R
G
(ECU) TRANSMISSION (T) 1
HARNESS

K
C
UE

LA
B
BL

“T” “V”
CONNECTOR CONNECTOR
BL
UE (BLUE) (GRAY) TPS
CONNECTOR
ALLISON DOC™ (OPTIONAL)
FOR PC SELECTOR (S) 1
4
HARNESS
“S” VIW
CONNECTOR VEHICLE CONNECTOR
(BLACK) INTERFACE
MODULE 3
(VIM)

17
DIAGNOSTIC
TOOL
CONNECTOR 25
J 1939
COMPACT 17 CONNECTOR 5
PUSHBUTTON DEUTSCH 9-PIN (OPTIONAL)
DIAGNOSTIC TOOL 6 VIM
SELECTOR RETARDER ACCUMULATOR CONNECTOR
CONNECTOR
3 CONNECTOR
19
E
D
O
M

R
N
D
SCI (J 1587)
CONNECTOR
(OPTIONAL) VIW
CONNECTOR
17
DEUTSCH
DIAGNOSTIC TOOL 7
REMOTE LEVER CONNECTOR SENSOR HARNESS
SELECTOR (OPTIONAL) CONNECTOR (OPTIONAL)
OUTPUT
8 SPEED SENSOR
RETARDER
MODULATION 18 CONNECTOR
REQUEST (RMR)
CONNECTOR 9
RETARDER TEMP. SENSOR CONNECTOR
16
THROTTLE POSITION 4
SHIFT SENSOR (TPS) 14
SELECTOR 15
CONNECTOR
CONNECTOR
RMR TURBINE 13
CONNECTOR SPEED SENSOR ENGINE
REMOTE (OPTIONAL) CONNECTOR SPEED
PUSHBUTTON THROTTLE (4000 PRODUCT SENSOR
SELECTOR POSITION FAMILY) CONNECTOR
SENSOR (TPS)
T
C
LE
SE

RETARDER “H” SOLENOID 13

DE
O
M
R

CONNECTOR
N

Bulkhead Connector (Optional)

D

(4000 PRODUCT FAMILY)

STRIP PUSHBUTTON
SHIFT SELECTORS
(EUROPEAN
OEM)
RETARDER TEMPERATURE 11
SENSOR CONNECTOR
(4000 PRODUCT FAMILY) PRE-TRANSID & TID 1
1 10
2 R
N
3 D TRANSMISSION
D FEEDTHROUGH
N
NOTE: Illustration is not to scale. Actual harness HARNESS
R configuration may differ from this illustration. CONNECTOR
V07347.04.00
.

Figure 1–2. WTEC III Electronic Control Components

1–2 Copyright © 2005 General Motors Corp.

 WTEC III ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL
GENERAL DESCRIPTION

1–2. ELECTRONIC CONTROL UNIT (ECU)

The ECU (Figure 1–3) contains the microcomputer which is the brain of the control system. The ECU receives and
processes information defining:
• Shift selector
• Throttle position
• Sump/retarder temperature
• Engine speed
• Turbine speed
• Transmission output speed.
The ECU uses the information to:
• Control transmission solenoids and valves
• Supply system status
• Provide diagnostic information.
Each ECU has a date code stamped on the label which is attached to the outer case of the ECU. This is the date
when the ECU passed final testing. This date is commonly used to denote the change configuration level of the
ECU. It is normal for the ECU date displayed electronically to be a few days prior to the date shown on the label.

NOTE: ECU wiring harness connector retainers are individually

keyed and color-coded to ensure that the proper
Y
A
R
G

connector is attachedto the correct ECU socket.

The color of the connector retainer should
K
C

UE
LA
B

BL

match the color of the connector strain relief

(see Appendix E, Paragraph 1–1).
UE
BL
ECU
V07346.00.01

Figure 1–3. Electronic Control Unit (ECU)

1–3. SHIFT SELECTOR

Pushbutton and lever shift selectors for the WTEC III Series are remote mounted from the ECU and connected to
the ECU by a wiring harness. All shift selectors except the strip-type pushbutton have a single digit LED display
and a mode indicator (LED). During normal transmission operation, illumination of the LED mode indicator shows
that a secondary or special operating condition has been selected by pressing the MODE button. During diagnostic
display mode, illumination of the LED indicator shows that the displayed diagnostic code is active. Display
brightness is regulated by the same vehicle potentiometer that controls dash light display brightness. More
information on both types of shift selectors is continued below.
A. Pushbutton Shift Selector (Figure 1–4)
There are three full-function pushbutton shift selectors and a strip pushbutton shift selector. Strip
pushbutton shift selectors are used by European OEMs. A full-function shift selector has a MODE
button and diagnostic display capability through the single digit LED display. The strip pushbutton
shift selector does not have a MODE button, diagnostic capability, or adjustable illumination. The
full-function pushbutton shift selector has six (6) pushbuttons which are R (Reverse), N (Neutral),
D (Drive), ↓ (Down), ↑ (Up), and MODE. Manual forward range downshifts and upshifts are made
by pressing the ↓ (Down) or ↑ (Up) arrow buttons after selecting D (Drive). The N (Neutral) button
has a raised lip to aid in finding it by touch. The MODE button is pressed to select a secondary or
special operating condition, such as ECONOMY shift schedule. Diagnostic and oil level (if sensor is
present) information is obtained by pressing the ↓ (Down) and ↑ (Up) arrow buttons at the same time.

Copyright © 2005 General Motors Corp. 1–3

 WTEC III ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL
GENERAL DESCRIPTION

The strip pushbutton shift selector has either three or six range selection positions as shown in Figure
1–4. When a strip pushbutton shift selector is used, diagnostic information must be obtained by using
the Allison DOC™ For PC–Service Tool, or a customer-furnished remote display.

DISPLAY DISPLAY
MODE ID MODE ID D N R
MODE INDICATOR
R MODE
MODE INDICATOR R MODE (LED)
N (LED) N 1 2 3 D N R
D MODE D MODE
BUTTON BUTTON
STRIP PUSHBUTTON
REGULAR PUSHBUTTON COMPACT SHIFT SELECTORS
CONTOURED VERSION
SELECTORS V07178

Figure 1–4. Pushbutton Shift Selectors

B. Lever Shift Selector (Figure 1–5)

The lever shift selector can have as many as six forward range positions (seven for the 7-speed
models), as well as R (Reverse) and N (Neutral). There is a hold override button which must be
pressed and held in order to move between certain selector positions. The hold override button must
be pressed when shifting between R, N, and D. The hold override button is released when the desired
selector position is reached. The selector lever can be moved freely between D and the numbered
forward ranges without pressing the hold override button. The lever selector can be chosen with the
lever on the left side or on the right side and with the R (Reverse) position toward the front or toward
the rear of the selector. Diagnostic and oil level (if sensor is present) information is obtained from the
LED display by pressing the DISPLAY MODE/DIAGNOSTIC button.

HOLD OVERRIDE BUTTON HOLD OVERRIDE BUTTON

MODE INDICATOR MODE INDICATOR
(LED) (LED)
R
1 R MODE
MODE MODE
N
2 N
D
3 D
4
MODE BUTTON 5
MODE BUTTON 5
4
5 4 3
D MODE ID 3 MODE ID 2
N 2 1
R 1
DIGITAL DISPLAY DIGITAL DISPLAY
DISPLAY MODE/ DISPLAY MODE/
DIAGNOSTIC BUTTON DIAGNOSTIC BUTTON
SIX-SPEED, LEFT-HAND SIX-SPEED, RIGHT-HAND
LEVER SELECTOR LEVER SELECTOR CONTOURED VERSION
WITH REVERSE TO REAR WITH REVERSE TO FRONT V07177

Figure 1–5. Typical Lever Shift Selector

1–4 Copyright © 2005 General Motors Corp.

 WTEC III ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL
GENERAL DESCRIPTION

1–4. THROTTLE POSITION SENSOR (Figure 1–6)

The Throttle Position Sensor (TPS) can be mounted to the engine, chassis, or transmission. The TPS contains a pull
actuation cable and a potentiometer. One end of the cable is attached to the engine fuel lever and the other, inside a
protective housing, to the TPS potentiometer. Output voltage from the TPS is directed to the ECU through the
external harness. The voltage signal indicates the throttle position and, in combination with other input data,
determines shift timing.

A B
C

THROTTLE SENSOR

V00628

Figure 1–6. Throttle Position Sensor (Without Mounting Brackets)

1–5. SPEED SENSORS (Figure 1–7)

The following three sensors provide information to the ECU:
• Engine speed−signal is generated by ribs on the torque converter pump.
• Turbine speed−signal is generated by the rotating-clutch housing spline contours.
• Output speed−signal is generated by a toothed member attached to the output shaft (except for the
3000 Product Family 7-speed models, where the toothed member is the transfer case idler gear).
The speed ratios between the various speed sensors allow the ECU to determine if the transmission is in the
selected range. Speed sensor information is also used to control the timing of clutch apply pressures, resulting in
the smoothest shifts possible. Hydraulic problems are detected by comparing the speed sensor information for the
current range to that range’s speed sensor information stored in the ECU memory.

Copyright © 2005 General Motors Corp. 1–5

 WTEC III ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL
GENERAL DESCRIPTION

MD/HD/B 300/B 400 HD/B 500 MD/B 300/B 400 MD/B 300/B 400 MD 3070PT MD/HD/B
ENGINE TURBINE TURBINE (EXCEPT 7-SPEED) OUTPUT OUTPUT
(EXTERNAL) (EXTERNAL) (INTERNAL) RETARDER OUTPUT (INTERNAL) (EXTERNAL)
(EXTERNAL)
FORMER (BEFORE APPROXIMATELY JANUARY 1, 2006

MD/HD/B HD/B 500 MD/B 300/B 400 MD/B 300/B 400 MD 3070PT 7-SPEED MD/HD/B
ENGINE TURBINE TURBINE (EXCEPT 7-SPEED) OUTPUT OUTPUT
(EXTERNAL) (EXTERNAL) (INTERNAL) RETARDER OUTPUT (INTERNAL HD) (EXTERNAL)
(EXTERNAL) RETARDER
CURRENT (AFTER APPROXIMATELY JANUARY 1, 2006)

SENSORS V09818.00.00

Figure 1–7. Speed Sensors

1–6. CONTROL MODULE (Figure 1–8)

Pulse width modulated solenoids are used in the valve bodies. For valve locations, refer to SIL 27-WT-93.
The WTEC III Series transmission control module contains a channel plate on which is mounted a:
• Main valve body assembly.
• Stationary-clutch valve body assembly.
• Rotating-clutch valve body assembly.
The main valve body assembly contains:
• G solenoid and the C1 and C2 latch valves controlled by the solenoid.
• Main and lube regulator valves.
• Control main and converter regulator valves.
• Converter flow valve and exhaust backfill valves.
The stationary-clutch valve body assembly contains:
• C solenoid (C3)
• D solenoid (C4)
• E solenoid (C5)
• Solenoid regulator valves controlled by the solenoids
• C3 accumulator relay valve

1–6 Copyright © 2005 General Motors Corp.

 WTEC III ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL
GENERAL DESCRIPTION

The rotating-clutch valve body assembly contains:

• A solenoid (C1)
• B solenoid (C2)
• F solenoid (lockup)
• Solenoid regulator valves controlled by the solenoids
• C3 pressure switch
The low valve body assembly (3000 and 4000 Product Families 7-speed) contains N and J solenoids.

3000 PRODUCT FAMILY CONTROL MODULE 3000 PRODUCT FAMILY 7-SPEED 4000 PRODUCT FAMILY CONTROL MODULE
(EXCEPT 7-SPEED MODELS) V07349.00.00

Figure 1–8. WTEC III Control Modules

A temperature sensor (thermistor) is located in the internal wiring harness. Changes in sump fluid temperature are
indicated by changes in sensor resistance which changes the signal sent to the ECU. Refer to Figure 6–8 in
Section 6, Code 24.

The oil level sensor (OLS) is a float type device mounted on the control module channel plate. The OLS senses
transmission fluid level by electronically measuring the buoyancy forces on the float. The sensor operates on
5 VDC supplied by the ECU. The oil level sensor is standard on 3000 and 4000 Product Families transmissions.
An OLS is required on all models with a shallow sump but is optional on other models. The oil level sensor is not
available on the 3000 Product Family 7-speed models.

The C3 pressure switch is mounted on the rotating-clutch valve body assembly and indicates when pressure exists
in the C3 clutch-apply passage. An accumulator/relay valve is in-line ahead of the C3 pressure switch and prevents
high frequency hydraulic pulses generated by the C3 solenoid from cycling the C3 pressure switch.

Also mounted on the control module is the turbine speed sensor for the 3000 Product Family transmissions. The
turbine speed sensor is directed at the rotating-clutch housing. The turbine speed sensor on the 4000 Product
Family transmissions is located on the outside of the main housing.

Copyright © 2005 General Motors Corp. 1–7

 WTEC III ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL
GENERAL DESCRIPTION

1–7. WIRING HARNESSES

A. External Wiring Harness (Figure 1–9)

The ECU uses three connectors labeled Black, Blue, and Gray, which are used to receive input from
the following:

Transmission TPS Diagnostic tool connector

Engine Vehicle interface module (VIM) Retarder
Turbine Retarder control module Retarder temperature sensor
Output speed sensor Shift selector Accumulator

Many harnesses will include a bulkhead fitting to separate cab and chassis components. Also, many
different styles and materials for harnesses are likely to be encountered.

NOTE: Allison Transmission is providing for service of wiring harnesses and wiring harness components as
follows:

• Repair parts for the internal wiring harness and for wiring harness components attached to the
shift selector will be available through the Allison Transmission Parts Distribution Center (PDC).
Use the P/N from your appropriate parts catalog or from Appendix E in this manual. Allison
Transmission is responsible for warranty on these parts.
• Repair parts for the external harnesses and external harness components must be obtained from St.
Clair Technologies Inc. (SCTI). SCTI provides parts to any Allison customer or OEM and is
responsible for warranty on these parts. SCTI recognizes Allison Transmission, manufacturers,
and SCTI part numbers. SCTI provides a technical HELPLINE at 519-627-1673 (Wallaceburg).
SCTI will have parts catalogs available. The SCTI addresses and phone numbers for parts outlets
are:

St. Clair Technologies, Inc. St. Clair Technologies, Inc.

920 Old Glass Road Calle Damanti S/N Col
Wallaceburg, Ontario, Canada N8A 4L8 Guadalupe—Guaymas
Phone: 519-627-1673 Sonora, Mexico CP85440
Fax: 519-627-4227 Phone: 011-526 2222-43834
Fax: 011-526-2222-43553

• St. Clair Technologies, Inc. stocks a WTEC III external harness repair kit, P/N 29532362, as a
source for some external harness repair parts. SCTI is the source for external harness repair parts.

1–8 Copyright © 2005 General Motors Corp.

 WTEC III ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL
GENERAL DESCRIPTION

VEHICLE (V)
HARNESS
TRANSMISSION (T)
HARNESS
“V”
“T” CONNECTOR
CONNECTOR (GRAY)
(BLUE) TPS
CONNECTOR
(OPTIONAL)
SELECTOR (S)
HARNESS
VIW
“S” CONNECTOR
CONNECTOR
(BLACK)

VIM
CONNECTOR
DIAGNOSTIC
TOOL ENGINE
CONNECTOR SPEED
J 1939 SENSOR
CONNECTOR RETARDER
CONNECTOR
DEUTSCH 9-PIN (OPTIONAL) ACCUMULATOR
DIAGNOSTIC TOOL CONNECTOR
CONNECTOR RETARDER
“H” SOLENOID
CONNECTOR TRANSFER
SCI (J 1587) (4000 PRODUCT
CONNECTOR CASE
FAMILY) CONNECTOR
(OPTIONAL) VIW (3000 PRODUCT FAMILY
CONNECTOR 7–SPEED)

DEUTSCH RETARDER RETARDER

DIAGNOSTIC TOOL “H” SOLENOID CONNECTOR
6–PIN CONNECTOR CONNECTOR (3000 PRODUCT FAMILY)
(OPTIONAL) (3000 PRODUCT FAMILY) PRE-TRANSID & TID 1
TID 2
SENSOR HARNESS
CONNECTOR
RETARDER (OPTIONAL)
MODULATION RETARDER
REQUEST (RMR) TEMPERATURE SENSOR
CONNECTOR CONNECTOR OUTPUT
(4000 PRODUCT FAMILY) SPEED SENSOR
PRE-TRANSID & TID 1 CONNECTOR

RETARDER TEMPERATURE
RMR SENSOR CONNECTOR
CONNECTOR (3000 PRODUCT FAMILY)
(OPTIONAL) TID 2
SHIFT
SELECTOR
CONNECTOR
THROTTLE POSITION
TURBINE SENSOR (TPS)
SPEED SENSOR CONNECTOR
CONNECTOR
(4000 PRODUCT FAMILY)
Bulkhead Connector (Optional)

TRANSMISSION
FEEDTHROUGH
HARNESS
CONNECTOR

NOTE: Illustration is not to scale. Actual harness configuration may differ from this illustration.
V07086.04.00

Figure 1–9. WTEC III External Wiring Harnesses

Copyright © 2005 General Motors Corp. 1–9

 WTEC III ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL
GENERAL DESCRIPTION

B. Internal Wiring Harness (Figure 1–10)

The internal wiring harness provides connection between the external harness, the pulse width
modulated solenoids, oil level sensor, C3 pressure switch, and the temperature sensor.

TURBINE SPEED SENSOR C2 SOLENOID (B) OIL LEVEL SENSOR

3000 PRODUCT FAMILY LU SOLENOID (F) 4000 PRODUCT FAMILY
(Omitted in 4000 Product Family) (Before S/N 6610048466)
C1 SOLENOID (A)

OIL LEVEL SENSOR C3 PRESSURE

3000 PRODUCT FAMILY SWITCH
(Starting with S/N 6510220479)
FEEDTHROUGH HARNESS
STANDOFF
(3000 and 4000
OIL LEVEL SENSOR Product Families
3000 PRODUCT FAMILY are different heights)
(Before S/N 6510220479)
TEMPERATURE SENSOR –
LO SIGNAL SOLENOID (N) TRANSID 1
3000 AND 4000 PRODUCT
FAMILIES 7-SPEED FORWARD TEMPERATURE SENSOR –
SOLENOID (G) TRANSID 2
C4 SOLENOID (D)
C6 SOLENOID (J) OIL LEVEL SENSOR
C5 SOLENOID (E) 4000 PRODUCT FAMILY
3000 AND 4000 PRODUCT
FAMILIES 7-SPEED C3 SOLENOID (C) (Starting with S/N 6610048466) V07381.02.00

Figure 1–10. WTEC III Internal Wiring Harness

1–8. VEHICLE INTERFACE MODULE (Figure 1–11)

The vehicle interface module (VIM) provides relays, fuses, and connection points for interface with
the output side of the vehicle electrical system. VIMs are available for both 12V and 24V electrical
systems. The VIM for 12V systems uses all 12V relays. The VIM for 24V systems has all 24V relays.
Refer to the Parts Catalog for the transmission assembly number that you are servicing for detailed
parts information. Refer to Pages D–30 and D–31 for VIM wire number and terminal information.

Some OEMs may provide their own equivalent for the VIM which performs the same functions as the
VIM shown in Figure 1–11.

V00631.02

Figure 1–11. Vehicle Interface Module (VIM)

1–10 Copyright © 2005 General Motors Corp.

Allison Troubleshooting Manual Wtec Iii
Full download: http://manualplace.com/download/allison-troubleshooting-manual-wtec-iii/
WTEC III ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL
GENERAL DESCRIPTION

1–9. AUTODETECT FEATURE (V8, V8A, V9 SOFTWARE)

Autodetect is active on the first 24 engine starts or a larger calibration number of engine starts, depending upon the
component or sensor being detected (details follow in A through D below). Autodetect takes place within the first
30 seconds of each engine start monitored. Autodetect searches for the presence of the following transmission
components or data inputs:

Retarder Present, Not Present

Oil level sensor (OLS) Present, Not Present
Throttle Analog, J1939, J1587
Engine coolant temperature Analog, J1939, J1587

Even after auotdetect has been completed, it can be reset to monitor an additional group of engine starts. Reset may
be necessary if a device known to be present is not detected or if an autodetectable component or sensor was added
after the initial vehicle build. Reset is accomplished by using Allison DOC™ For PC–Service Tool. Select “RESET
AUTODETECT INFORMATION.” Allison DOC™ For PC–Service Tool can also be used to override autodetect
and manually enter the component or sensor to be recognized by the ECU by changing appropriate “customer
modifiable constants”.
The four items above are the only customer modifiable constants (CMCs) that are autodetected. Other CMCs can
be changed at any time and are not related to autodetect. Consult Allison publication GN3433EN, User Guide, for
detailed instructions related to WTEC III “customer modified constants.” Additional details for each of the four
autodetectable features are given below.

A. Retarder
Autodetect searches for the presence of the H (retarder) solenoid during the first 24 engine ignition
cycles. The H solenoid must be present on the 24th engine start or the retarder is not detected and
will not function on subsequent engine starts.

If the retarder is present but not detected by autodetect, the retarder will not function. Be
sure to test for proper retarder function immediately after the 24th engine start. If the
WARNING retarder is not functioning, test H solenoid for open, short-to-ground, or short-to-battery
condition. Use Allison DOC™ For PC–Service Tool to reset autodetect or to manually
select the presence of the retarder after the H solenoid circuit is repaired.

B. Oil Level Sensor (OLS)

NOTE: If an OLS is known to be present, but has not been detected, a possible cause is that the transmission
fluid level is too low. Determine the fluid level before beginning OLS troubleshooting.

No oil level sensor diagnostics take place until the OLS is detected. Frequently test for the presence of
oil level diagnostics if the transmission is known to contain an OLS. If an OLS is not detected during
the first 24 engine starts, autodetect continues for a larger calibration number of engine starts.
Autodetect stops when an OLS is detected or when the calibration number of starts is reached. When
the larger calibration number of engine starts is reached, the ECU concludes that no OLS is present. If
an OLS is known to be present, but has not been detected, troubleshooting the OLS circuit is required.
After the OLS circuit is repaired, reset autodetect or manually select the OLS function using Allison
DOC™ For PC–Service Tool.

Copyright © 2005 General Motors Corp. 1–11

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