Revisions to this document are noted #2009, Rev.

A
by a stripe in the left hand margin June, 2010
Product Code(s): 70, 71
Page 1 of 135

SUBJECT: Allison 4th Generation Controls for EP 40/50 Systems

MODELS AFFECTED: EP 40/50 Systems

Introduction:
In April 2010, Allison Transmission, Inc. 4th Generation (4th Gen) controls were released for the EP 40/50 product
family. OEMs that build new vehicles with Model Year 2010 engines must use 4th Gen controls. The intention of
this Service Information Letter (SIL) is to describe the new parts, features, and Diagnostic Trouble Codes (DTC)
corresponding with the release.

The implementation of 4th Gen controls includes several controller hardware changes. The 4th Gen EP 40/50 Control
System will continue to use two controllers, a Transmission Control Module (TCM) and a Vehicle Control Module
(VCM). The EP 40/50 System will use the new A54 4th Gen controllers, P/N 29549402. The A54 controllers are the
only 4th Gen controllers used with the EP 40/50 System. Along with new controllers, the 4th Gen EP 40/50 Systems
will also use a 4th Gen shift selector. The figures below illustrate the differences in all of these components.

NOTE: Due to connector and wiring differences, the current 4th Gen components are not interchangeable
with the former control components. They should be serviced as two separate systems. Allison
Transmission, Inc. will maintain the Pre 4th Gen controllers for service.

TCM/VCM 80 Way Connector:

The TCM and VCM will connect to the vehicle wiring harness using the same 80 way connector used by current
Allison products with 4th Gen controls. This 80 way connector is manufactured by AFL Automotive (EPC). It is
available in a straight backshell or 90 degree wire dress configuration, as specified by the vehicle OEM. A bolt
retains the connector to the TCM/VCM. The torque specification for the bolt is 2–3 N·m (18–28 lb in.). The Allison
4th Gen Controls TCM/VCM require a new mating connector terminal. When replacing these terminals, a Molex
terminal crimp tool, P/N 63811 6000 Premium Grade Tool or P/N 64016–0133 Service Grade Tool is available.

JG / SL5855EN 60235

Copyright © 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 2 of 135

Figure 1. Connector Identification

Terminal Crimp Tool P/N 63811­6000 Premium Grade Tool

1. Refer to Troubleshooting Manual TS3989EN (Appendix E) for complete details of connector and terminal
service.
2. Carefully strip the insulation from the wire to leave 4.70–5.60 mm (0.185–0.220 inch) of bare wire (core)
exposed.

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 3 of 135

3. Pull out the wire stop blade of the crimping tool so it is clear of the terminal crimp area. Place the terminal all
the way into the appropriate wire size opening of the Terminal Crimp Tool P/N 63811­6000 Premium Grade
Tool or P/N 64016–0133 Service Grade Tool until it contacts the stop and is properly oriented. Squeeze the
handle enough to keep the terminal in place in the tool but not enough to compress the crimp wings.
4. Push in the wire stop blade until it touches the terminal. Insert the wire core into the terminal, with the
core held against the wire stop blade.
5. Hold the wire and terminal against the stops until the terminal is fully crimped. Squeeze the crimper handle
until the ratchet releases.
6. Pull out the wire stop blade and remove the crimped terminal and wire.

NOTE: If cavities do not have a terminal/wire lead or grommet cover pin (or if grommet cover pin is
damaged) install cavity plug P/N 12034413 into corresponding cavity in grommet seal in connector body.

7. Repeat as necessary.
8. Slide the grommet retainer containing the grommet seal along the wires and snap it into place on the
connector body.
9. When all terminals have been inserted, be sure the green interfacial seal is properly located on the connector
body and not damaged. Install the red spacer into the connector body. Push it into the connector body
until it is fully seated against the connector body.

NOTE: If the red spacer will not seat properly on the connector body, be sure all terminals are fully seated.

Figure 2. Terminal Crimp Tool P/N 63811­6000 Premium Grade Tool

Pushbutton Shift Selectors (PBSS):

The EP 40/50 System will use the same PBSS currently used by other Allison 4th Gen products. The 4th Gen shift
selectors have a two digit display and a seven wire connector. For the EP 40/50 Systems, only the left side of the

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 4 of 135

display will be used to display range attained (Forward, Neutral, or Reverse) while in the normal operation mode.
Both sides of the display will be used while in the fluid level and diagnostic modes. Allison 4th Gen shift selectors
are J1939­based and no longer use serial and parallel data lines as the primary means of communication with the
TCM. The 4th Gen PBSS exchanges digital messages with the Allison 4th Gen TCM via the vehicle’s Controller
Area Network (CAN) backbone. If CAN communication is lost, the shift selector can provide directional commands
to the TCM on an analog “back up” wire. It generates a pulse width modulated signal to communicate range
requests (Forward, Neutral, or Reverse). Allison 4th Gen controls shift selectors support the same functionality as
the Pre­4th Gen shift selectors, including selected range, oil level, and diagnostic displays. The procedures for
PBSS oil level checks and diagnostic code displays are different with the 4th Gen PBSS. These procedures are
similar to other Allison products with 4th Gen controls and without prognostics.

NOTE: Refer to Figure 6 for a display of the 4th Gen PBSS buttons.

Normal Operation Mode:

During normal operation Forward, Neutral, or Reverse ranges can be selected by using the D (Forward), N
(Neutral), or R (Reverse) buttons on the PBSS. Once a range has been attained F (Forward), N (Neutral), or R
(Reverse) will be displayed on the left side of the PBSS display. While in forward range, pressing the Down ↓ arrow
button increases the level of regen. Once the level of regen has been increased, L will be displayed on the left side
of the PBSS display in the place of F. Pressing the Up ↑ arrow button will return the system to the normal regen
level and F will once again be displayed on the left side of the PBSS display.

Fluid Level Mode:

All EV Drive Units are equipped with an Oil Level Sensor (OLS). The oil level can be checked using the PBSS
shift selector after certain criteria are met:
• Engine at idle (625­750 rpm)
• Sump fluid at operating temperature of 68º­176ºF (20º­80ºC)
• EV Drive Unit output shaft stopped
• EV Drive Unit is in neutral range
• OLS is functioning properly

NOTE: The vehicle should be parked on level ground prior to starting any oil level check.

To enter the fluid level mode and display fluid level information using the PBSS, simultaneously press and hold the
PBSS Up ↑ and Down ↓ arrows for approximately five seconds. While in fluid level mode, both sides of the display
will be used. A number of responses are possible once the PBSS has entered fluid level mode. These displays will
indicate the fluid level or which conditions required to display fluid level are not met.

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 5 of 135

Table 1. Invalid for Display Codes

Display Sequence Interpretation of Display
oL, ­ ­, 50 Engine rpm too low, below 625 rpm
oL, ­ ­, 59 Engine rpm too high, above 750 rpm
oL, ­ ­, 65 Neutral—not selected
oL, ­ ­, 70 Sump fluid temperature too low
oL, ­ ­, 79 Sump fluid temperature too high
oL, ­ ­, 89 Output shaft rotation
oL, ­ ­, 95 Sensor failure

Table 2. Fluid Level Information

Display Sequence Display Meaning
oL, oK Fluid level is correct
oL, Lo, 01 Fluid level is 1 quart low
oL, HI, 01 Fluid level is 1 quart high

NOTE: The drive unit fluid level may be too low or too high by more than one quart. If so, the third
set of digits will increase incrementally (02, 03, 04). Correct the fluid level per the display and then
re­check the fluid level.

To exit the fluid level mode, press the N (Neutral) button once. To continue to the diagnostic mode, simultaneously
press the Up ↑ and Down ↓ arrows once.

Diagnostic Mode:
Diagnostic Trouble Codes (DTCs) are stored in the TCM. The PBSS can be used to display up to nine codes
(d1­d9). These nine codes will be the highest priority (i.e. active codes) or the codes most recently set. As codes
are added, the oldest non­active code is dropped from the list. If all codes are active, the code with the lowest
priority is dropped from the list. The diagnostic mode of the PBSS allows these codes to be displayed on the
PBSS, beginning with the most recent code. When using the shift selector to retrieve trouble codes, if the mode
indicator (LED) is illuminated, the displayed code is active. If the mode indicator is not illuminated, the displayed
code is inactive. Prior to entering diagnostic mode the vehicle should be stopped in a safe location, with the parking
brake applied, the ignition in the ON position, and N (Neutral) selected.

To enter the PBSS diagnostic mode, simultaneously press and hold the Up ↑ and Down ↓ arrow buttons
for approximately five seconds. This will allow you to enter the fluid level mode. Once in fluid level mode
simultaneously press the Up ↑ and Down ↓ arrow buttons again one time. The diagnostic codes stored in the
PBSS will now be displayed using both sides of the PBSS display. Diagnostic codes are displayed as follows:

In this example DTC 25­11 Transmission Output Speed Edge Count Mismatch is the code that has set most
recently.
1. Code list position (e.g. d1)
2. Main code (e.g. 25)

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 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 6 of 135

3. Sub code (e.g. 11)

The PBSS will cycle through these three displays until you move onto the next code or exit the diagnostic mode. To
view the next diagnostic code (d2, d3, d4…) momentarily press the MODE button. Each time the MODE button is
pressed the PBSS will move onto the next diagnostic code position. If less than nine codes are stored in the PBSS
memory, the empty code positions will display dX, ­ ­, ­ ­. To clear the codes from the PBSS, press and hold the
MODE button for approximately ten seconds until the display shows “**”.

NOTE: If the condition that caused the code is still present, the code will again become active.

To exit the diagnostic mode, press the N (Neutral button) or simultaneously press the Up ↑ and Down ↓ arrows once.

Additional PBSS operational information is available in the 4th Gen EP 40/50 Operators Manual.

NOTE: The service indicator wrench icon on the 4th Gen shift selector will not be used with the EP 40/50
products. The EP 40/50 products do not currently have any prognostic capabilities. This feature is a
carryover from the other Allison Transmission, Inc. products using these same shift selectors. The service
indicator wrench should only light for a moment at initial TCM wakeup.

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 7 of 135

(VCM/TCM) – P/N 29545503

Figure 3. Pre­4th Generation TCM/VCM

(VCM/TCM) – P/N 29549402

Figure 4. 4th Generation TCM/VCM

NOTE: The A54 12/24V 4th Gen controller is the only 4th Gen controller that is compatible with the EP
40/50 System. If there is an attempt to load a SID into the wrong controller, TCM Reflash will display an
error message.

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 8 of 135

(Shift Selector) – P/N 29538360

Figure 5. Pre­4th Generation Shift Selector

NOTE: The SERVICE ICON (wrench) shown in Figure 6, is not used with 4th Gen controls.

(COMPACT) – P/N 29546168 (STANDARD) – P/N 29546210 (COMMON) – P/N 29546211

Figure 6. 4th Generation Shift Selector

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 9 of 135

New Features:
Check System and Stop System lamps signals available on CAN:
• Pre­4th Gen controls required discrete wire outputs to the dash
• With 4th Gen controls these signals will be available as CAN messages or discrete wire outputs

EP 40/50 System Cooling Fan Control:

• Pre­4th Gen controls required a temperature sensor input from the cooler return line by the OEM to turn the
drive unit cooling fans on/off
• With 4th Gen controls the temperature sensor input is no longer needed because cooling fan requests can
be sent via CAN messaging

Special Tools:
New:
J­50111 EP 40/50 (4th Gen) Power Adapter Harness (TCM/VCM/DPIM/ESS) for off­vehicle component
reprogramming with 4th Gen controllers.

NOTE: Allison DOC® for PC (AED) is available as an online upgrade for compatibility with 4th Gen
controls, DPIM2 and ESS2. See SIL 17­TR­09 for additional information.

Existing tools that should be utilized for EP 40/50 4th Gen diagnostics and repair:
J­47275 4th Gen TCM Breakout Harness; 1000, 2000, 3000, and 4000 breakout box harness for TCM/VCM
wire troubleshooting.

Terminal Crimp Tool P/N 63811­6000 Premium Grade Tool or P/N 64016–0133 Service Grade Tool is used for 4th
Gen 80­way connector terminal repair. See SIL 19­TR­07 for additional tool and ordering information.

Spare Parts Information:

Pre­4th Gen EP 40/50 System controllers (TCM/VCM) and shift selectors are being maintained as service parts.

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 10 of 135

Appendix A. 4th Gen DTCs

NOTE: Should you encounter any Diagnostic Trouble Codes in a 4th Gen vehicle that are not included in
this SIL, refer to TS3715EN, and use the wire conversion tables in Appendix C.

Table 3. Diagnostic Trouble Code (DTC) List

Failure Page
DTC Code Description Light Restrictive Mode
Record Number
DTC 23­14 (PBSS PWM Input Fault (No Range Info
Check System Disable Special Mode Yes 12
from PWM))
DTC 23­15 (PBSS CAN Fault (No Range Info from
Check System Disable Special Mode Yes 16
CAN))
Disable Special Mode,
DTC 23­18 (PBSS Communication Fault (No Range
Check System Inhibit Neutral to Range Yes 20
Info from CAN or PWM))
Shifts
DTC 41­12 (Clutch 1 Block Solenoid Open) None Disable Clutch Adaptive Yes 24
DTC 41­16 (Clutch 2 Block Solenoid Open) None Disable Clutch Adaptive Yes 29
DTC 42­12 (Clutch 1 Block Solenoid Short to Power) None Disable Clutch Adaptive Yes 34
DTC 42­16 (Clutch 2 Block Solenoid Short to Power) None Disable Clutch Adaptive Yes 38
DTC 43­12 (Clutch 1 Block Solenoid Short to Ground) None Disable Clutch Adaptive Yes 42
DTC 43­16 (Clutch 2 Block Solenoid Short to Ground) None Disable Clutch Adaptive Yes 46
DTC 45­61 (Clutch 1 Solenoid Failed Open) Check System Disable Clutch Adaptive Yes 50
DTC 45­62 (Clutch 1 Solenoid Failed Short to Ground) Check System Disable Clutch Adaptive Yes 55
DTC 45­63 (Clutch 1 Solenoid Failed Short to Power) Check System Disable Clutch Adaptive Yes 59
DTC 45­64 (Clutch 2 Solenoid Failed Open) Check System Disable Clutch Adaptive Yes 63
DTC 45­65 (Clutch 2 Solenoid Failed Short to Ground) Check System Disable Clutch Adaptive Yes 68
DTC 45­66 (Clutch 2 Solenoid Failed Short to Power) Check System Disable Clutch Adaptive Yes 72
DTC 45­67 (Main Boost Solenoid Failed Open) Check System Disable Clutch Adaptive Yes 76
DTC 45­68 (Main Boost Solenoid Failed Short to Disable Clutch Adaptive,
Ground) Check System Limit output torque Yes 81
DTC 45­69 (Main Boost Solenoid Failed Short to
Power) Check System Disable Clutch Adaptive Yes 85
DTC 45­71 (Solenoid High Side Driver 1 Open) Check System Disable Clutch Adaptive Yes 89
DTC 45­72 (Solenoid High Side Driver 1 Short to
Ground) Check System Disable Clutch Adaptive Yes 93
DTC 45­73 (Solenoid High Side Driver 1 Short to
Power) None Disable Clutch Adaptive Yes 97
DTC 45­74 (Solenoid High Side Driver 2 Open) Check System Disable Clutch Adaptive Yes 104

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 11 of 135

Table 3. Diagnostic Trouble Code (DTC) List (cont’d)

Failure Page
DTC Code Description Light Restrictive Mode
Record Number
DTC 45­75 (Solenoid High Side Driver 2 Short to
Ground) Check System Disable Clutch Adaptive Yes 108
DTC 45­76 (Solenoid High Side Driver 2 Short to
Power) None Disable Clutch Adaptive Yes 112
DTC 66­40 (CAN Link Lost with Fan Drive Controller) None None Yes 118
DTC 67­18 (Fan Drive Controller CAN Data Error/Fault
or Unavailable) None None Yes 121
DTC 67­19 (PBSS CAN Data Error/Fault or
Unavailable) None None Yes 122
DTC 70­23 (Controller Hardware Watchdog Timeout
TCM) Check System None Yes 123
DTC 70­24 (Controller Hardware Watchdog Timeout
VCM) Check System None Yes 124

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 12 of 135

DTC 23­14 PBSS PWM Input Fault (No Range Info from PWM)

Overview:
Allison 4th Generation Controls shift selectors communicate with the Transmission Control Module (TCM) by
exchanging standardized digital messages over the SAE J1939 Controller Area Network (CAN). The shift
selectors are also equipped with a single wire backup to the J1939 CAN data link. Allison 4th Generation shift
selectors transmit directional information (Forward, Neutral, and Reverse) in the form of an analog pulse­width
modulated (PWM) signal via wire 334 to the TCM. The shift selector switches an internal driver ON and OFF to
vary the duty cycle of the voltage on wire 334. When the driver in the shift selector is ON, the voltage on wire
334 is pulled to ground. When the driver is OFF, the driver’s output is open and the voltage on wire 334 is high.
Since duty cycle is measured when voltage is high, the driver’s OFF­time determines the duty cycle. For example,
if wire 334 duty cycle is 15 percent, the shift selector driver is ON (pulled low) 85 percent of the time and OFF
(open) 15 percent of the time.

Actions Taken When DTC Sets:

When DTC 23­14 is active, the following conditions will occur:
• Check System light illuminates

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 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 13 of 135

DTC 23­14 PBSS PWM Input Fault (No Range Info from PWM) (cont’d)

• Disable special mode

– HUSH mode will be disabled (if equipped)
• Continue running using primary CAN data

Causes:
• Open or short on wire 334 between Push Button Shift Selector (PBSS) and TCM
• Internal Shift Selector fault
• Internal TCM fault
• Loss of power, ground, or wake­up to the PBSS

Tool Requirements:
• Allison DOC® For PC (AED)
• J­39700 Universal Electronic Breakout Box
• J­47275 Breakout Harness 4th Gen TCM/VCM
• J­46712 Breakout Harness Drive Unit/ESS
• J­46708 Multimeter
• J­39197 Jumper WIre Kit

Table 4. PWM Signal Characteristics

Shift Selector
977 Hz 10 Hz
Unknown 15% ± 2%
Park 30% ± 2%
Reverse 45% ± 2%
Neutral 60% ± 2%
Forward 75% ± 2%
Error 90% ± 2%

Step Action Value(s) Yes No

1 Are codes 23­15 and/or 23­18 set along with Troubleshoot Go to Step 2
this code? these codes first.
2 1. Install Allison DOC® For PC (AED). 9–18V Go to Step 3 Resolve voltage
2. Start the engine. problem. Go to
3. Record the DTC failure record data. Step 13
4. Monitor TCM ignition voltage.
Is the voltage within the specified values?
3 Is code 23­14 active? Go to Step 5 Go to Step 4

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 14 of 135

DTC 23­14 PBSS PWM Input Fault (No Range Info from PWM) (cont’d)

Step Action Value(s) Yes No

4 1. Clear the DTC. Go to Step 5 System OK
2. Attempt to duplicate the conditions in the
failure record (mode, temperature, etc.)
Does code 23­14 return?
5 1. Turn OFF the ignition. Go to Step 10 Go to Step 6
2. Disconnect the TCM 80­way connector.
3. Install the OEM­side 80­way connector
to the J­47275, TCM Breakout Harness
Adapter. Leave the TCM disconnected.
4. Disconnect the 16­way PBSS connector.
5. At J­47275­1, TCM Overlay, test for
wire­to­wire shorts between pin 34 and all
other pins in the 80­way connector, and
shorts­to­ground on pin 34. Wiggle the
harness while making the wiring checks.
Were any shorts­to­ground or shorts to other
wires found?
6 1. Turn ON the ignition. Go to Step 10 Go to Step 7
2. Leave the TCM disconnected.
3. Leave the 16­way PBSS connector
disconnected.
4. At J­47275­1, TCM Overlay, test for
shorts­to­power on pin 34.
Were any shorts­to­power found?
7 1. Turn the ignition OFF. Less than 4 Go to Step 8 Go to Step 10
2. Reconnect the TCM and OEM 80­way Ohms
connectors.
3. Leave the 16­way PBSS connector
disconnected.
4. Using J­39197, Jumper Wire Kit, measure
resistance between pin 5 of the PBSS and
chassis ground.
Is the resistance within the specified range?
8 1. Leave the ignition OFF. 4.5 – 5.0V Go to Step 11 Go to Step 9
2. Disconnect the shift selector.
3. Turn ON the ignition. Leave the engine
OFF.
4. Using J­39197, Jumper Wire Kit, measure
the voltage on pin 11 in the 16­way PBSS
connector.
Is voltage within specified values?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 15 of 135

DTC 23­14 PBSS PWM Input Fault (No Range Info from PWM) (cont’d)

Step Action Value(s) Yes No

9 1. Turn the igntion OFF. 4.5 – 5.0V Go to Step 10 Go to Step 12
2. Disconnect the TCM 80­way connector.
3. Install J­47275, TCM Breakout Harness
Adapter between the OEM and TCM
80­way connector.
4. Turn ON the ignition. Leave the engine
OFF.
5. At J­47275­1, TCM Overlay, measure for
voltage on pin 34.
Is voltage within specified values?
10 NOTE: The vehicle OEM has responsibility for Go to Step 13
all external wiring harness repairs. Harness
repairs performed by Allison Transmission
distributors and dealers are not covered by
Allison Transmission warranty.

Coordinate with the vehicle OEM to repair or

replace the vehicle wiring.
Is the repair complete?
11 Replace the shift selector. Go to Step 13
Is the replacement complete?
12 NOTE: In most cases, the TCM is not at fault. Go to Step 13
Investigate thoroughly before replacing the
TCM.

Replace the TCM.

Is the replacement complete?
13 In order to verify the repair: Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under normal driving Go to Step 1
conditions.
Did the DTC return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 16 of 135

DTC 23­15 PBSS CAN Fault (No Range Info from CAN)

Overview:
The Push Button Shift Selector (PBSS) sends range selection data to the TCM via CAN communication. The
PBSS also sends the range selection data to the TCM via a redundant PWM signal. PBSS TC1 fault means that
no valid range could be determined from the TC1 message or that the TC1 message has timed out. CAN Link
Lost with the PBSS or invalid CAN data.

Actions Taken When DTC Sets:

When DTC 23­15 is active, the following conditions will occur:

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 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 17 of 135

DTC 23­15 PBSS CAN Fault (No Range Info from CAN) (cont’d)

• Check System light illuminates

• Continue running using secondary PWM data
• Disable special mode
– HUSH mode will be disabled (if equipped)

Causes:
• Loss of CAN wiring integrity
• Internal shift selector fault
• Internal TCM fault
• Loss of power, ground, or wake­up to the PBSS

Tool Requirements:
• Allison DOC® For PC (AED)
• J­39700 Universal Electronic Breakout Box
• J­47275 Breakout Harness 4th Gen TCM/VCM
• J­46712 Breakout Harness Drive Unit/ESS
• J­46708 Multimeter
• J­39197 Jumper Wire Kit

Step Action Value(s) Yes No

1 1. Install Allison DOC® For PC (AED). 9–18V Go to Step 2 Resolve voltage
2. Start the engine. problem. Go to
3. Record the DTC failure record data. Step 13
4. Monitor TCM ignition voltage.
Is the voltage within the specified values?
2 Is code 23­15 active? Go to Step 4 Go to Step 3
3 1. Clear the DTC. Go to Step 4 System OK
2. Attempt to duplicate the conditions in the
failure record (mode, temperature, etc.)
Does code 23­15 return?
4 1. Turn the ignition OFF. Less than 4 Go to Step 5 Go to Step 10
2. Disconnect the 16­way PBSS connector. Ohms
3. Using J­39197, Jumper Wire Kit, measure
resistance between pin 5 in the 16­way
PBSS connector and chassis ground.
Was the resistance within specificaiton?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 18 of 135

DTC 23­15 PBSS CAN Fault (No Range Info from CAN) (cont’d)

Step Action Value(s) Yes No

5 1. Turn the ignition ON. 10.5­32V Go to Step 6 Go to Step 10
2. Using J­39197, Jumper Wire Kit, measure
battery supply voltage at pin 13 of the
16­way PBSS connector.
Is the voltage within the specified range?
6 1. Leave the ignition ON. 9­32V Go to Step 8 Go to Step 7
2. Using J­39197, Jumper Wire Kit, measure
shift selector wakeup voltage at pin 12 of
the 16­way PBSS.
Is the voltage within the specified range?
7 1. Turn the ignition OFF. 9­32V Go to Step 10 Go to Step 12
2. Disconnect the TCM 80­way connector.
3. Install J­47275, TCM Breakout Harness
Adapter between the OEM and TCM
80­way connector.
4. Turn the ignition ON.
5. At J­47275­1, TCM Overlay, test for shift
selector wakeup voltage at pin 50.
Is the voltage within the specified range?
8 1. Turn the ignition OFF. Go to Step 10 Go to Step 9
2. Disconnect the shift selector.
3. At J­47275­1, TCM Overlay, test for
wire­to­wire shorts, shorts­to­ground, and
opens at pins 28 (CAN Hi) and 8 (CAN Lo).

NOTE: Pin 28 (CAN Hi) and pin 8 (CAN Lo)

can be checked for an open by measuring
resistance between the two pins. Resistance
should be 60 Ohms

NOTE: If the TCM internal resistor is used,

CAN Hi will be pin 48 and CAN Lo will be
pin 68. In this case, test pins 48 and 68 for
wire­to­wire shorts, shorts­to­ground and
opens.
Were any opens, shorts­to­ground, or shorts
to other wires found?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 19 of 135

DTC 23­15 PBSS CAN Fault (No Range Info from CAN) (cont’d)

Step Action Value(s) Yes No

9 1. Leave the igntion OFF. Go to Step 10 Go to Step 11
2. Leave the shift selector disconnected.
3. At J­47275­1, TCM Overlay, test for
wire­to­wire shorts and opens at pin 49
(CAN shield).

NOTE: Pin 49 (CAN shield) can be checked for

an open by measuring resistance to ground.
Resistance should be less than 4 Ohms.

NOTE: If the TCM internal resistor is used,

the vehicle OEM will connect wire 307 and
wire 348 together in the external harness. In
this case, test pin 7 for wire­to­wire shorts,
shorts­to­ground and opens.
Were any opens, shorts­to­ground, or shorts
to other wires found?
10 NOTE: The vehicle OEM has responsibility Go to Step 13
for all external wiring harness repair. Harness
repairs performed by Allison Transmission
distributors and dealers are not covered by
Allison Transmission warranty.

Coordinate with the vehicle OEM to repair or

replace the vehicle wiring.
Is the repair complete?
11 Replace the shift selector. Go to Step 13
Is the replacement complete?
12 NOTE: In most cases, the TCM is not at fault. Go to Step 13
Investigate thoroughly before replacing the
TCM.

Replace the TCM.

Is the replacement complete?
13 In order to verify the repair: Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under normal driving Go to Step 1
conditions.
Did the DTC return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 20 of 135

DTC 23­18 PBSS Communication Fault (No Range

Info from CAN or PWM)

Overview:
The Push Button Shift Selector (PBSS) sends range selection data to the TCM via CAN communication. The
PBSS also sends the range selection data to the TCM via a redundant Pulse Width Modulated (PWM) signal.
PBSS Communication fault means that no valid range could be determined from either the CAN signal or
the PWM backup signal.

This code will set when DTC 23­14 and DTC 23­15 are active.

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 21 of 135

DTC 23­18 PBSS Communication Fault (No Range Info from

CAN or PWM) (cont’d)

Actions Taken When DTC Sets:

When DTC 23­18 is active, the following conditions will occur:
• Check System light illuminates
• Disable special mode
– HUSH mode will be disabled (if equipped)
• Inhibit N (Neutral) to Range Shifts

Causes:
• Loss of CAN wiring integrity and wire 334 integrity
• Internal shift selector fault
• Internal TCM fault
• Loss of power, ground, or wake­up to the PBSS

Tool Requirements:
• Allison DOC® For PC (AED)
• J­39700 Universal Electronic Breakout Box
• J­47275 Breakout Harness 4th Gen TCM/VCM
• J­46712 Breakout Harness Drive Unit/ESS
• J­46708 Multimeter
• J­39197 Jumper Wire Kit

Step Action Value(s) Yes No

1 1. Install Allison DOC® For PC (AED). 9–18V Go to Step 2 Resolve voltage
2. Start the engine. problem. Go to
3. Record the DTC failure record data. Step 15
4. Monitor TCM ignition voltage.
Is the voltage within the specified values?
2 Is code 23­18 active? Go to Step 4 Go to Step 3
3 1. Clear the DTC. Go to Step 4 System OK
2. Attempt to duplicate the conditions in the
failure record (mode, temperature, etc.)
Does code 23­18 return?
4 1. Turn OFF the ignition. Less than 4 Go to Step 5 Go to Step 12
2. Disconnect the 16­way PBSS connector. Ohms
3. Using J­39197, Jumper Wire Kit, measure
resistance between pin 5 in the 16­way
PBSS connector and chassis ground.
Was the resistance within specification?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 22 of 135

DTC 23­18 PBSS Communication Fault (No Range Info from

CAN or PWM) (cont’d)

Step Action Value(s) Yes No

5 1. Turn ON the ignition. 10.5­32V Go to Step 6 Go to Step 12
2. Using J­39197, Jumper Wire Kit, measure
battery supply voltage at pin 13 of the
16­way PBSS connector.
Is the voltage within the specified range?
6 1. Leave ON the ignition. 9­32V Go to Step 8 Go to Step 7
2. Using J­39197, Jumper Wire Kit, measure
shift selector wakeup voltage at pin 12 of
the 16­way PBSS.
Is the voltage within the specified range?
7 1. Turn OFF the ignition. 9­32V Go to Step 12 Go to Step 14
2. Disconnect the TCM 80­way connector.
3. Install J­47275, TCM Breakhout Harness
Adapter between the OEM and TCM
80­way connector.
4. Turn ON the ignition.
5. At J­47275­1, TCM Overlay, test for shift
selector wakeup voltage at pin 50.
Is the voltage within the specified range?
8 1. Turn OFF the ignition. Go to Step 12 Go to Step 9
2. Disconnect the TCM from the J­47275,
TCM Breakout Harness Apdapter. Leave
the OEM side connected.
3. Leave the 16­way PBSS connector
disconnected.
4. At J­472751, TCM Overlay, test for
wire­to­wire shorts between pin 34 and all
other pins in the 80­way connector, and
shorts­to­ground on pin 34. Wiggle the
harness while making the wiring checks.
Were any shorts­to­ground or shorts to other
wires found?
9 1. Leave the TCM disconnected. Go to Step 12 Go to Step 10
2. Leave the 16­way PBSS connector
disconnected.
3. Turn ON the ignition.
4. At J­472751, TCM Overlay, test for
shorts­to­power on pin 34.
Were any shorts­to­power found?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 23 of 135

DTC 23­18 PBSS Communication Fault (No Range Info from

CAN or PWM) (cont’d)

Step Action Value(s) Yes No

10 1. Turn OFF the ignition. 4.5 – 5.0V Go to Step 13 Go to Step 11
2. Reconnect the TCM 80­way connector
to the J­47275, TCM Breakout Harness
Adapter. Leave the OEM side connected.
3. Leave the 16­way PBSS connector
disconnected.
4. Turn ON the ignition. Leave the engine
OFF.
5. Using J­39197, Jumper Wire Kit, measure
the voltage on pin 11 in the 16­way PBSS
connector.
Is voltage within specified values?
11 1. Leave ON the ignition. Leave the engine 4.5 – 5.0V Go to Step 12 Go to Step 14
OFF.
2. At J­47275­1, TCM Overlay, measure for
voltage on pin 34.
Is voltage within specified values?
12 NOTE: The vehicle OEM has responsibility Go to Step 15
for all external wiring harness repair. Harness
repairs performed by Allison Transmission
distributors and dealers are not covered by
Allison Transmission warranty.

Coordinate with the vehicle OEM to repair or

replace the vehicle wiring.
Is the repair complete?
13 Replace the shift selector. Go to Step 15
Is the replacement complete?
14 NOTE: In most cases, the TCM is not at fault. Go to Step 15
Investigate thoroughly before replacing the
TCM.

Replace the TCM.

Is the replacement complete?
15 In order to verify the repair: Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under normal driving Go to Step 1
conditions.
Did the DTC return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 24 of 135

DTC 41­12 Clutch 1 Block Solenoid Open

Overview:
A Clutch 1 (C1) Block Solenoid failed open fault occurs when the TCM detects that pin 52 is not connected to a
load or that pin 52 is connected to a load through high resistance. When either of these conditions is sensed by
the TCM, this code is set indicating an open in the C1 Block Solenoid circuit. This code will clear when the TCM
no longer detects an open fault condition.

Actions Taken When DTC Sets:

When DTC 41­12 is active, the following conditions will occur:

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 25 of 135

DTC 41­12 Clutch 1 Block Solenoid Open (cont’d)

• Disable Clutch Adaptive

– TCM will not adapt clutch logic

Causes:
• Open in wire 352 or wire 371 between TCM and Drive Unit
• High resistance in wire 352 or wire 371 between TCM and Drive Unit
• Faulty Drive Unit internal wiring harness
• Faulty C1 Block Solenoid
• Faulty TCM

Tool Requirements:
• Allison DOC® For PC (AED)
• J­39700 Universal Electronic Breakout Box
• J­47275 Breakout Harness 4th Gen TCM/VCM
• J­46712 Breakout Harness Drive Unit/ESS
• J­46708 Multimeter

Step Action Value(s) Yes No

1 1. Install AllisonDOC® For PC (AED). 9–18V Go to Step 2 Resolve voltage
2. Start the engine. problem. Go to
3. Record the DTC failure record data. Step 11
4. Monitor TCM ignition voltage.
Is the voltage within the specified values?
2 1. Clear the DTC. Go to Step 3 System OK
2. Attempt to duplicate the conditions in the
failure record (mode, temperature, etc.)

NOTE: This DTC is intended to detect an open

condition in the C1 Block Solenoid electrical
circuit.
Does code 41–12 return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 26 of 135

DTC 41­12 Clutch 1 Block Solenoid Open (cont’d)

Step Action Value(s) Yes No

3 1. Turn OFF the ignition. Go to Step 5 Go to Step 4
2. Install J­47275, TCM Breakout Harness
Adapter between the OEM and TCM
80­way connector.
3. Install J­46712, Breakout Harness
between the OEM and Drive Unit 31­way
connector.
4. Turn ON the ignition, leave engine OFF.
5. Using Allison DOC®, enter solenoid test
mode and command C1 Block Solenoid
ON.
6. Determine the voltage drop in the high side
of the C1 Block Solenoid circuit as follows:
• At J­47275­1, TCM Overlay,
measure voltage between pin 71
and an isolated ground.
• At J­46712­1, Drive Unit Overlay,
measure voltage between pin A and
an isolated ground.
• Subtract the two voltage
measurements to obtain the
voltage drop in the circuit.

NOTE: A voltage drop of more than 0.5V

across either circuit indicates an excessive
voltage loss in the OEM harness.
Did the high side voltage drop exceed 0.5
VDC?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 27 of 135

DTC 41­12 Clutch 1 Block Solenoid Open (cont’d)

Step Action Value(s) Yes No

4 1. Leave the C1 Block Solenoid commanded Go to Step 5 Go to Step 6
ON.
2. Determine the voltage drop in the low side
of the C1 Block Solenoid circuit as follows:
• At J­47275­1, TCM Overlay,
measure voltage between pin 52
and an isolated ground.
• At J­46712­1, Drive Unit Overlay,
measure voltage between pin B and
an isolated ground.
• Subtract the two voltage
measurements to obtain the
voltage drop in the circuit.

NOTE: A voltage drop of more than 0.5V

across either circuit indicates an excessive
voltage loss in the OEM harness.
Did the low side voltage drop exceed 0.5 VDC?
5 NOTE: The vehicle OEM has responsibility Go to Step 11
for all external wiring harness repair. Harness
repairs performed by Allison Transmission
distributors and dealers are not covered by
Allison Transmission warranty.

Coordinate with the vehicle OEM to repair or

replace the chassis harness.
Is the repair complete?
6 1. Turn OFF the ignition. Refer to Go to Step 10 Go to Step 7
2. Disconnect the OEM­side of the 31­way Appendix B
drive unit connector from the J­46712,
Drive Unit Breakout Harness. Leave the
Drive Unit side of the J­46712 connected.
3. Measure the resistance between pins A
and B at J­46712­1, Drive Unit Overlay.
Is the resistance within the specified value?
7 1. Remove the Drive Unit oil pan. Refer to Go to Step 8 Go to Step 9
2. Disconnect the C1 Block Solenoid from Appendix B
the Drive Unit internal wiring harness.
3. Using a digital volt/ohmmeter (DVOM),
measure the resistance of the C1 Block
Solenoid.
Is the resistance within the specified value?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 28 of 135

DTC 41­12 Clutch 1 Block Solenoid Open (cont’d)

Step Action Value(s) Yes No

8 Replace the Drive Unit internal wiring harness Go to Step 11
(refer to Service Manual).
Is the replacement complete?
9 Replace the C1 Block Solenoid (refer to Go to Step 11
Service Manual).
Is the replacement complete?
10 NOTE: In most cases, the TCM is not at fault. Go to Step 11
Investigate thoroughly before replacing the
TCM.

Replace the TCM.

Is the replacement complete?
11 In order to verify the repair: Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under normal driving Go to Step 1
conditions.
Did the DTC return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 29 of 135

DTC 41­16 Clutch 2 Block Solenoid Open

Overview:
A Clutch 2 (C2) Block Solenoid failed open fault occurs when the TCM detects that pin 33 is not connected to a
load or that pin 33 is connected to a load through high resistance. When either of these conditions is sensed by
the TCM, this code is set indicating an open in the C2 Block Solenoid circuit. This code will clear when the TCM
no longer detects an open fault condition.

Actions Taken When DTC Sets:

When DTC 41­16 is active, the following conditions will occur:

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 30 of 135

DTC 41­16 Clutch 2 Block Solenoid Open (cont’d)

• Disable Clutch Adaptive

– TCM will not adapt clutch logic

Causes:
• Open in wire 333 or wire 371 between TCM and Drive Unit
• High resistance in wire 333 or wire 371between TCM and Drive Unit
• Faulty Drive Unit internal wiring harness
• Faulty C2 Block Solenoid
• Faulty TCM

Tool Requirements:
• Allison DOC® For PC (AED)
• J­39700 Universal Electronic Breakout Box
• J­47275 Breakout Harness 4th Gen TCM/VCM
• J­46712 Breakout Harness Drive Unit/ESS
• J­46708 Multimeter

Step Action Value(s) Yes No

1 1. Install AllisonDOC® For PC (AED). 9–18V Go to Step 2 Resolve voltage
2. Start the engine. problem. Go to
3. Record the DTC failure record data. Step 11
4. Monitor TCM ignition voltage.
Is the voltage within the specified values?
2 1. Clear the DTC. Go to Step 3 System OK
2. Attempt to duplicate the conditions in the
failure record (mode, temperature, etc.)

NOTE: This DTC is intended to detect an open

condition in the C2 Block Solenoid electrical
circuit.
Does code 41–16 return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 31 of 135

DTC 41­16 Clutch 2 Block Solenoid Open (cont’d)

Step Action Value(s) Yes No

3 1. Turn OFF the ignition. Go to Step 5 Go to Step 4
2. Install J­47275, TCM Breakout Harness
Adapter between the OEM and TCM
80­way connector.
3. Install J­46712, Breakout Harness
between the OEM and Drive Unit 31­way
connector.
4. Turn ON the ignition, leave engine OFF.
5. Using Allison DOC®, enter solenoid test
mode and command C2 Block Solenoid
ON.
6. Determine the voltage drop in the high side
of the C2 Block Solenoid circuit as follows:
• At J­47275­1, TCM Overlay,
measure voltage between pin 71
and an isolated ground.
• At J­46712­1, Drive Unit Overlay,
measure voltage between pin Q and
an isolated ground.
• Subtract the two voltage
measurements to obtain the
voltage drop in the circuit.

NOTE: A voltage drop of more than 0.5V

across either circuit indicates an excessive
voltage loss in the OEM harness.
Did the high side voltage drop exceed 0.5
VDC?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 32 of 135

DTC 41­16 Clutch 2 Block Solenoid Open (cont’d)

Step Action Value(s) Yes No

4 1. Leave the C2 Block Solenoid commanded Go to Step 5 Go to Step 6
ON.
2. Determine the voltage drop in the low side
of the C2 Block Solenoid circuit as follows:
• At J­47275­1, TCM Overlay,
measure voltage between pin 33
and an isolated ground.
• At J­46712­1, Drive Unit Overlay,
measure voltage between pin R and
an isolated ground.
• Subtract the two voltage
measurements to obtain the
voltage drop in the circuit.

NOTE: A voltage drop of more than 0.5V

across either circuit indicates an excessive
voltage loss in the OEM harness.
Did the low side voltage drop exceed 0.5 VDC?
5 NOTE: The vehicle OEM has responsibility Go to Step 11
for all external wiring harness repair. Harness
repairs performed by Allison Transmission
distributors and dealers are not covered by
Allison Transmission warranty.

Coordinate with the vehicle OEM to repair or

replace the chassis harness.
Is the repair complete?
6 1. Turn OFF the ignition. Refer to Go to Step 10 Go to Step 7
2. Disconnect the OEM­side of the 31­way Appendix B
drive unit connector from the J­46712,
Drive Unit Breakout Harness. Leave the
Drive Unit side of the J­46712 connected.
3. Measure the resistance between pins Q
and R at J­46712­1, Drive Unit Overlay.
Is the resistance within the specified value?
7 1. Remove the Drive Unit oil pan. Refer to Go to Step 8 Go to Step 9
2. Disconnect the C2 Block Solenoid from Appendix B
the internal wiring harness.
3. Using a digital volt/ohmmeter (DVOM),
measure the resistance of the C2 Block
Solenoid.
Is the resistance within the specified value?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 33 of 135

DTC 41­16 Clutch 2 Block Solenoid Open (cont’d)

Step Action Value(s) Yes No

8 Replace the Drive Unit internal wiring harness Go to Step 11
(refer to Service Manual).
Is the replacement complete?
9 Replace the C2 Block Solenoid (refer to Go to Step 11
Service Manual).
Is the replacement complete?
10 NOTE: In most cases, the TCM is not at fault. Go to Step 11
Investigate thoroughly before replacing the
TCM.

Replace the TCM.

Is the replacement complete?
11 In order to verify the repair: Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under normal driving Go to Step 1
conditions.
Did the DTC return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 34 of 135

DTC 42­12 Clutch 1 Block Solenoid Short to Power

Overview:
A Clutch 1 (C1) Block Solenoid short to power fault occurs when the TCM detects that pin 52 is shorted to power
through low or no resistance. When this short to power condition is sensed by the TCM, code 42­12 is set. This
code will clear when the TCM no longer detects a short to power condition.

Actions Taken When DTC Sets:

When DTC 42­12 is active, the following conditions will occur:

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 35 of 135

DTC 42­12 Clutch 1 Block Solenoid Short to Power (cont’d)

• Disable Clutch Adaptive

– TCM will not adapt clutch logic

Causes:
• Short to power in wire 352 between TCM and Drive Unit
• Short to power in Drive Unit internal wiring harness
• Faulty TCM

Tool Requirements:
• Allison DOC® For PC (AED)
• J­39700 Universal Electronic Breakout Box
• J­47275 Breakout Harness 4th Gen TCM/VCM
• J­46712 Breakout Harness Drive Unit/ESS
• J­46708 Multimeter

Step Action Value(s) Yes No

1 1. Install AllisonDOC® For PC (AED). 9–18V Go to Step 2 Resolve voltage
2. Start the engine. problem. Go to
3. Record the DTC failure record data. Step 9
4. Monitor TCM ignition voltage.
Is the voltage within the specified values?
2 1. Clear the DTC. Go to Step 3 System OK
2. Attempt to duplicate the conditions in the
failure record (mode, temperature, etc.)

NOTE: This DTC is intended to detect a

short­to­battery condition in the C1 Block
Solenoid electrical circuit.
Does code 42­12 return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 36 of 135

DTC 42­12 Clutch 1 Block Solenoid Short to Power (cont’d)

Step Action Value(s) Yes No

3 1. Turn OFF the ignition. Go to Step 5 Go to Step 4
2. Disconnect the TCM 80­way connector.
3. Install the OEM­side 80­way connector
to the J­47275, TCM Breakout Harness
Adapter. Leave the TCM disconnected.
4. Disconnect the Drive Unit 31­way
connector.
5. Turn ON the ignition.
6. At J­47275­1, TCM Overlay, test for
shorts­to­power at pin 52.

NOTE: The voltage at pin 52 should be 0 Volts

with the TCM disconnected.
Were any shorts­to­power found?
4 1. Turn OFF the ignition. Go to Step 5 Go to Step 6
2. At J­47275­1, TCM Overlay, test for shorts
to other wires between pin 52 and all other
pins in the 80­way connector.
Were any shorts to other wires found?
5 NOTE: The vehicle OEM has responsibility Go to Step 9
for all external wiring harness repair. Harness
repairs performed by Allison Transmission
distributors and dealers are not covered by
Allison Transmission warranty.

Coordinate with the vehicle OEM to repair or

replace the chassis harness.
Is the repair complete?
6 1. Leave the ignition OFF. Go to Step 7 Go to Step 8
2. Install J­46712, Breakout Harness, to the
Drive Unit 31­way connector. Leave the
OEM harness disconnected.
3. At J­46712­1, Drive Unit Overlay, test for
shorts to other wires between pin B and all
other pins in the 31­way connector.

NOTE: The resistance value between pins A

and B should read normal solenoid resistance.
Were any shorts to other wires found?
7 Replace the Drive Unit internal wiring harness Go to Step 9
(refer to Service Manual).
Is the replacement complete?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 37 of 135

DTC 42­12 Clutch 1 Block Solenoid Short to Power (cont’d)

Step Action Value(s) Yes No

8 NOTE: In most cases, the TCM is not at fault. Go to Step 9
Investigate thoroughly before replacing the
TCM.

Replace the TCM.

Is the replacement complete?
9 In order to verify the repair: Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under normal driving Go to Step 1
conditions.
Did the DTC return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 38 of 135

DTC 42­16 Clutch 2 Block Solenoid Short to Power

Overview:
A Clutch 2 (C2) Block Solenoid short to power fault occurs when the TCM detects that pin 33 is shorted to power
through low or no resistance. When this short to power condition is sensed by the TCM, code 42­16 is set. This
code will clear when the TCM no longer detects a short to power condition.

Actions Taken When DTC Sets:

When DTC 42­16 is active, the following conditions will occur:

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 39 of 135

DTC 42­16 Clutch 2 Block Solenoid Short to Power (cont’d)

• Disable Clutch Adaptive

– TCM will not adapt clutch logic

Causes:
• Short to power in wire 333 between TCM and Drive Unit
• Short to power in Drive Unit internal wiring harness
• Faulty TCM

Tool Requirements:
• Allison DOC® For PC (AED)
• J­39700 Universal Electronic Breakout Box
• J­47275 Breakout Harness 4th Gen TCM/VCM
• J­46712 Breakout Harness Drive Unit/ESS
• J­46708 Multimeter

Step Action Value(s) Yes No

1 1. Install AllisonDOC® For PC (AED). 9–18V Go to Step 2 Resolve voltage
2. Start the engine. problem. Go to
3. Record the DTC failure record data. Step 9
4. Monitor TCM ignition voltage.
Is the voltage within the specified values?
2 1. Clear the DTC. Go to Step 3 System OK
2. Attempt to duplicate the conditions in the
failure record (mode, temperature, etc.)

NOTE: This DTC is intended to detect a

short­to­battery condition in the C2 Block
Solenoid electrical circuit.
Does code 42­16 return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 40 of 135

DTC 42­16 Clutch 2 Block Solenoid Short to Power (cont’d)

Step Action Value(s) Yes No

3 1. Turn OFF the ignition. Go to Step 5 Go to Step 4
2. Disconnect the TCM 80­way connector.
3. Install the OEM­side 80­way connector
to the J­47275, TCM Breakout Harness
Adapter. Leave the TCM disconnected.
4. Disconnect the Drive Unit 31­way
connector.
5. Turn ON the ignition.
6. At J­47275­1, TCM Overlay, test for
shorts­to­power at pin 33.

NOTE: The voltage at pin 33 should be 0 Volts

with the TCM disconnected.
Were any shorts­to­power found?
4 1. Turn OFF the ignition. Go to Step 5 Go to Step 6
2. At J­47275­1, TCM Overlay, test for shorts
to other wires between pin 33 and all other
pins in the 80­way connector.
Were any shorts to other wires found?
5 NOTE: The vehicle OEM has responsibility Go to Step 9
for all external wiring harness repair. Harness
repairs performed by Allison Transmission
distributors and dealers are not covered by
Allison Transmission warranty.

Coordinate with the vehicle OEM to repair or

replace the chassis harness.
Is the repair complete?
6 1. Leave the ignition OFF. Go to Step 7 Go to Step 8
2. Install J­46712, Breakout Harness, to the
Drive Unit 31­way connector. Leave the
OEM harness disconnected.
3. At J­46712­1, Drive Unit Overlay, test for
shorts to other wires between pin R and all
other pins in the 31­way connector.

NOTE: The resistance value between pins Q

and R should read normal solenoid resistance.
Were any shorts to other wires found?
7 Replace the Drive Unit internal wiring harness Go to Step 9
(refer to Service Manual).
Is the replacement complete?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 41 of 135

DTC 42­16 Clutch 2 Block Solenoid Short to Power (cont’d)

Step Action Value(s) Yes No

8 NOTE: In most cases, the TCM is not at fault. Go to Step 9
Investigate thoroughly before replacing the
TCM.

Replace the TCM.

Is the replacement complete?
9 In order to verify the repair: Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under normal driving Go to Step 1
conditions.
Did the DTC return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 42 of 135

DTC 43­12 Clutch 1 Block Solenoid Short to Ground

Overview:
A Clutch 1 (C1) Block Solenoid short to ground fault occurs when the TCM detects that pin 52 is shorted to ground
through low or no resistance. When this short to ground condition is sensed by the TCM, code 43­12 is set. This
code will clear when the TCM no longer detects a short to ground condition.

Actions Taken When DTC Sets:

When DTC 43­12 is active, the following conditions will occur:

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 43 of 135

DTC 43­12 Clutch 1 Block Solenoid Short to Ground (cont’d)

• Disable Clutch Adaptive

– TCM will not adapt clutch logic

Causes:
• Short to ground in wire 352 between TCM and Drive Unit
• Short to ground in Drive Unit internal wiring harness
• Faulty C1 Block Solenoid
• Faulty TCM

Tool Requirements:
• Allison DOC® For PC (AED)
• J­39700 Universal Electronic Breakout Box
• J­47275 Breakout Harness 4th Gen TCM/VCM
• J­46712 Breakout Harness Drive Unit/ESS
• J­46708 Multimeter

Step Action Value(s) Yes No

1 1. Install AllisonDOC® For PC (AED). 9–18V Go to Step 2 Resolve voltage
2. Start the engine. problem. Go to
3. Record the DTC failure record data. Step 10
4. Monitor TCM ignition voltage.
Is the voltage within the specified values?
2 1. Clear the DTC. Go to Step 3 System OK
2. Attempt to duplicate the conditions in the
failure record (mode, temperature, etc.)

NOTE: This DTC is intended to detect a

short­to­ground condition in the C1 Block
Solenoid electrical circuit.
Does code 43–12 return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 44 of 135

DTC 43­12 Clutch 1 Block Solenoid Short to Ground (cont’d)

Step Action Value(s) Yes No

3 1. Turn OFF the ignition. Go to Step 4 Go to Step 5
2. Disconnect the TCM 80­way connector.
3. Install the OEM­side 80­way connector
to the J­47275, TCM Breakout Harness
Adapter. Leave the TCM disconnected.
4. Disconnect the Drive Unit 31­way
connector.
5. At J­47275­1, TCM Overlay, test for shorts
to other wires between pin 52 and all
other pins in the 80­way connector, and
shorts­to­ground between pin 52 and
chassis ground.
Were any shorts to other wires or
shorts­to­ground found?
4 NOTE: The vehicle OEM has responsibility Go to Step 10
for all external wiring harness repair. Harness
repairs performed by Allison Transmission
distributors and dealers are not covered by
Allison Transmission warranty.

Coordinate with the vehicle OEM to repair or

replace the chassis harness.
Is the repair complete?
5 1. Leave the ignition OFF. Go to Step 6 Go to Step 9
2. Install J­46712, Breakout Harness to the
Drive Unit 31­way connector. Leave the
OEM harness disconnected.
3. At J­46712­1, Drive Unit Overlay, test for
shorts to other wires between pin B and
all other pins in the 31­way connector
and shorts­to ground between pin B and
chassis ground.

NOTE: The resistance value between pins A

and B should read normal solenoid resistance.
Were any shorts to other wires or
shorts­to­ground found?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 45 of 135

DTC 43­12 Clutch 1 Block Solenoid Short to Ground (cont’d)

Step Action Value(s) Yes No

6 1. Remove the Drive Unit oil pan. Go to Step 7 Go to Step 8
2. Disconnect the C1 Block Solenoid.
3. At J­46712­1, Drive Unit Overlay, test for
shorts to other wires between pin B and
all other pins in the 31­way connector
and shorts­to­ground between pin B and
chassis ground.
Were any shorts to other wires or
shorts­to­ground found?
7 Replace the Drive Unit internal wiring harness Go to Step 10
(refer to Service Manual).
Is the replacement complete?
8 Replace C1 Block Solenoid (refer to Service Go to Step 10
Manual).
Is the replacement complete?
9 NOTE: In most cases, the TCM is not at fault. Go to Step 10
Investigate thoroughly before replacing the
TCM.

Replace the TCM.

Is the replacement complete?
10 In order to verify the repair: Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under normal driving Go to Step 1
conditions.
Did the DTC return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 46 of 135

DTC 43­16 Clutch 2 Block Solenoid Short to Ground

Overview:
A Clutch 2 (C2) Block Solenoid short to ground fault occurs when the TCM detects that pin 33 is shorted to ground
through low or no resistance. When this short to ground condition is sensed by the TCM, code 43­16 is set. This
code will clear when the TCM no longer detects a short to ground condition.

Actions Taken When DTC Sets:

When DTC 43­16 is active, the following conditions will occur:

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 47 of 135

DTC 43­16 Clutch 2 Block Solenoid Short to Ground (cont’d)

• Disable Clutch Adaptive

– TCM will not adapt clutch logic

Causes:
• Short to ground in wire 333 between TCM and Drive Unit
• Short to ground in Drive Unit internal wiring harness
• Faulty C2 Block Solenoid
• Faulty TCM

Tool Requirements:
• Allison DOC® For PC (AED)
• J­39700 Universal Electronic Breakout Box
• J­47275 Breakout Harness 4th Gen TCM/VCM
• J­46712 Breakout Harness Drive Unit/ESS
• J­46708 Multimeter

Step Action Value(s) Yes No

1 1. Install AllisonDOC® For PC (AED). 9–18V Go to Step 2 Resolve voltage
2. Start the engine. problem. Go to
3. Record the DTC failure record data. Step 10
4. Monitor TCM ignition voltage.
Is the voltage within the specified values?
2 1. Clear the DTC. Go to Step 3 System OK
2. Attempt to duplicate the conditions in the
failure record (mode, temperature, etc.)

NOTE: This DTC is intended to detect a

short­to­ground condition in the C2 Block
Solenoid electrical circuit.
Does code 43­16 return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 48 of 135

DTC 43­16 Clutch 2 Block Solenoid Short to Ground (cont’d)

Step Action Value(s) Yes No

3 1. Turn OFF the ignition. Go to Step 4 Go to Step 5
2. Disconnect the TCM 80­way connector.
3. Install the OEM­side 80­way connector
to the J­47275, TCM Breakout Harness
Adapter. Leave the TCM disconnected.
4. Disconnect the Drive Unit 31­way
connector.
5. At J­47275­1, TCM Overlay, test for shorts
to other wires between pin 33 and all
other pins in the 80­way connector, and
shorts­to­ground between pin 33 and
chassis ground.
Were any shorts to other wires or
shorts­to­ground found?
4 NOTE: The vehicle OEM has responsibility Go to Step 10
for all external wiring harness repair. Harness
repairs performed by Allison Transmission
distributors and dealers are not covered by
Allison Transmission warranty.

Coordinate with the vehicle OEM to repair or

replace the chassis harness.
Is the repair complete?
5 1. Leave the ignition OFF. Go to Step 6 Go to Step 9
2. Install J­46712, Breakout Harness to the
Drive Unit 31­way connector. Leave the
OEM harness disconnected.
3. At J­46712­1, Drive Unit Overlay, test for
shorts to other wires between pin R and
all other pins in the 31­way connector
and shorts­to­ground between pin R and
chassis ground.

NOTE: The resistance value between pins Q

and R should read normal solenoid resistance.
Were any shorts to other wires or
shorts­to­ground found?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 49 of 135

DTC 43­16 Clutch 2 Block Solenoid Short to Ground (cont’d)

Step Action Value(s) Yes No

6 1. Remove the Drive Unit oil pan. Go to Step 7 Go to Step 8
2. Disconnect the C2 Block Solenoid.
3. At J­46712­1, Drive Unit Overlay, test for
shorts to other wires between pin R and
all other pins in the 31­way connector
and shorts­to­ground between pin R and
chassis ground.
Were any shorts to other wires or
shorts­to­ground found?
7 Replace the Drive Unit internal wiring harness Go to Step 10
(refer to Service Manual).
Is the replacement complete?
8 Replace the C2 Block Solenoid (refer to Go to Step 10
Service Manual).
Is the replacement complete?
9 NOTE: In most cases, the TCM is not at fault. Go to Step 10
Investigate thoroughly before replacing the
TCM.

Replace the TCM.

Is the replacement complete?
10 In order to verify the repair: Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under normal driving Go to Step 1
conditions.
Did the DTC return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 50 of 135

DTC 45­61 Clutch 1 Solenoid Failed Open

Overview:
A Clutch 1 (C1) Solenoid (C1 Trim Solenoid) failed open fault occurs when the TCM detects that pin 55 is not
connected to a load or that pin 55 is connected to a load through high resistance. When either of these conditions
is sensed by the TCM, this code is set indicating an open in the C1 (Trim) Solenoid Circuit. This code will clear
when the TCM no longer detects an open fault condition.

Actions Taken When DTC Sets:

When DTC 45­61 is active, the following conditions will occur:

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 51 of 135

DTC 45­61 Clutch 1 Solenoid Failed Open (cont’d)

• Check System light illuminates

• Disable Clutch Adaptive
– TCM will not adapt clutch logic

Causes:
• Open in wire 355 or wire 311 between TCM and Drive Unit
• High resistance in wire 355 or 311 between TCM and Drive Unit
• Faulty Drive Unit internal wiring harness
• Faulty C1 (Trim) Solenoid
• Faulty TCM

Tool Requirements:
• Allison DOC® For PC (AED)
• J­39700 Universal Electronic Breakout Box
• J­47275 Breakout Harness 4th Gen TCM/VCM
• J­46712 Breakout Harness Drive Unit/ESS
• J­46708 Multimeter

Step Action Value(s) Yes No

1 1. Install Allison DOC® For PC (AED). 9–18V Go to Step 2 Resolve voltage
2. Start the engine. problem. Go to
3. Record the DTC failure record data. Step 11
4. Monitor TCM ignition voltage.
Is the voltage within the specified values?
2 1. Clear the DTC. Go to Step 3 System OK
2. Attempt to duplicate the conditions in the
failure record (mode, temperature, etc.)

NOTE: This DTC is intended to detect an open

condition in the C1 (Trim) Solenoid electrical
circuit.
Does code 45–61 return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 52 of 135

DTC 45­61 Clutch 1 Solenoid Failed Open (cont’d)

Step Action Value(s) Yes No

3 1. Turn OFF the ignition. Go to Step 5 Go to Step 4
2. Install J­47275, TCM Breakout Harness
Adapter between the OEM and TCM
80­way connector.
3. Install J­46712, Breakout Harness
between the OEM and Drive Unit 31­way
connector.
4. Turn ON the ignition, leave engine OFF.
5. Using Allison DOC®, enter solenoid test
mode and command C1 (Trim) Solenoid
ON.
6. Determine the voltage drop in the high side
of the C1 (Trim) Solenoid circuit as follows:
• At J­47275­1, TCM Overlay,
measure voltage between pin 11
and an isolated ground.
• At J­46712­1, Drive Unit Overlay,
measure voltage between pin S and
an isolated ground.
• Subtract the two voltage
measurements to obtain the
voltage drop in the circuit.

NOTE: A voltage drop of more than 0.5V

across either circuit indicates an excessive
voltage loss in the OEM harness.
Did the high side voltage drop exceed 0.5
VDC?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 53 of 135

DTC 45­61 Clutch 1 Solenoid Failed Open (cont’d)

Step Action Value(s) Yes No

4 1. Leave the C1 (Trim) Solenoid commanded Go to Step 5 Go to Step 6
ON.
2. Determine the voltage drop in the low side
of the C1 (Trim) Solenoid circuit as follows:
• At J­47275­1, TCM Overlay,
measure voltage between pin 55
and an isolated ground.
• At J­46712­1 Drive Unit Overlay,
measure voltage between pin T and
an isolated ground.
• Subtract the two voltage
measurements to obtain the
voltage drop in the circuit.

NOTE: A voltage drop of more than 0.5V

across either circuit indicates an excessive
voltage loss in the OEM harness.
Did the low side voltage drop exceed 0.5 VDC?
5 NOTE: The vehicle OEM has responsibility Go to Step 11
for all external wiring harness repair. Harness
repairs performed by Allison Transmission
distributors and dealers are not covered by
Allison Transmission warranty.

Coordinate with the vehicle OEM to repair or

replace the chassis harness.
Is the repair complete?
6 1. Turn OFF the ignition. Refer to Go to Step 10 Go to Step 7
2. Disconnect the OEM­side of the 31­way Appendix B
drive unit connector from the J­46712,
Drive Unit Breakout Harness. Leave the
Drive Unit side of the J­46712 connected.
3. Measure the resistance between pins S
and T at J­46712­1, Drive Unit Overlay.
Is the resistance within the specified value?
7 1. Remove the Drive Unit oil pan. Go to Step 8 Go to Step 9
2. Disconnect the C1 (Trim) Solenoid from
the internal wiring harness.
3. Using a digital volt/ohmmeter (DVOM),
measure the resistance of the C1 (Trim)
Solenoid.
Is the resistance within the specified value?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 54 of 135

DTC 45­61 Clutch 1 Solenoid Failed Open (cont’d)

Step Action Value(s) Yes No

8 Replace the Drive Unit internal wiring harness Go to Step 11
(refer to Service Manual).
Is the replacement complete?
9 Replace the C1 (Trim) Solenoid (refer to Go to Step 11
Service Manual).
Is the replacement complete?
10 NOTE: In most cases, the TCM is not at fault. Go to Step 11
Investigate thoroughly before replacing the
TCM.

Replace the TCM.

Is the replacement complete?
11 In order to verify the repair: Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under normal driving Go to Step 1
conditions.
Did the DTC return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 55 of 135

DTC 45­62 Clutch 1 Solenoid Failed Short to Ground

Overview:
A Clutch 1 (C1) Solenoid (C1 Trim Solenoid) short to ground fault occurs when the TCM detects that pin 55 is
shorted to ground through low or no resistance. When this short to ground condition is sensed by the TCM, code
45­62 is set. This code will clear when the TCM no longer detects a short to ground condition.

Actions Taken When DTC Sets:

When DTC 45­62 is active, the following conditions will occur:
• Check System light illuminates

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 56 of 135

DTC 45­62 Clutch 1 Solenoid Failed Short to Ground (cont’d)

• Disable Clutch Adaptive

– TCM will not adapt clutch logic

Causes:
• Short to ground in wire 355 between TCM and Drive Unit
• Short to ground in Drive Unit internal wiring harness
• Faulty C1 (Trim) Solenoid
• Faulty TCM

Tool Requirements:
• Allison DOC® For PC (AED)
• J­39700 Universal Electronic Breakout Box
• J­47275 Breakout Harness 4th Gen TCM/VCM
• J­46712 Breakout Harness Drive Unit/ESS
• J­46708 Multimeter

Step Action Value(s) Yes No

1 1. Install AllisonDOC® For PC (AED). 9–18V Go to Step 2 Resolve voltage
2. Start the engine. problem. Go to
3. Record the DTC failure record data. Step 10
4. Monitor TCM ignition voltage.
Is the voltage within the specified values?
2 1. Clear the DTC. Go to Step 3 System OK
2. Attempt to duplicate the conditions in the
failure record (mode, temperature, etc.)

NOTE: This DTC is intended to detect a

short­to­ground condition in the C1 (Trim)
Solenoid electrical circuit.
Does code 45–62 return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 57 of 135

DTC 45­62 Clutch 1 Solenoid Failed Short to Ground (cont’d)

Step Action Value(s) Yes No

3 1. Turn OFF the ignition. Go to Step 4 Go to Step 5
2. Disconnect the TCM 80­way connector.
3. Install the OEM­side 80­way connector
to the J­47275, TCM Breakout Harness
Adapter. Leave the TCM disconnected.
4. Disconnect the Drive Unit 31­way
connector.
5. At J­47275­1, TCM Overlay, test for shorts
to other wires between pin 55 and all
other pins in the 80­way connector, and
shorts­to­ground between pin 55 and
chassis ground.
Were any shorts to other wires or
shorts­to­ground found?
4 NOTE: The vehicle OEM has responsibility Go to Step 10
for all external wiring harness repair. Harness
repairs performed by Allison Transmission
distributors and dealers are not covered by
Allison Transmission warranty.

Coordinate with the vehicle OEM to repair or

replace the chassis harness.
Is the repair complete?
5 1. Leave the ignition OFF. Go to Step 6 Go to Step 9
2. Install J­46712, Breakout Harness to the
Drive Unit 31­way connector. Leave the
OEM harness disconnected.
3. At J­46712­1, Drive Unit Overlay, test for
shorts to other wires between pin T and
all other pins in the 31­way connector,
and shorts­to­ground between pin T and
chassis ground.

NOTE: The resistance value between pins S

and T should read normal solenoid resistance.
Were any shorts to other wires or
shorts­to­ground found?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 58 of 135

DTC 45­62 Clutch 1 Solenoid Failed Short to Ground (cont’d)

Step Action Value(s) Yes No

6 1. Remove the Drive Unit oil pan. Go to Step 7 Go to Step 8
2. Disconnect the C1 (Trim) Solenoid.
3. At J­46712­1, Drive Unit Overlay, test for
shorts to other wires between pin T and
all other pins in the 31­way connector,
and shorts­to­ground between pin T and
chassis ground.
Were any shorts to other wires or
shorts­to­ground found?
7 Replace the Drive Unit internal wiring harness Go to Step 10
(refer to Service Manual).
Is the replacement complete?
8 Replace the C1 (Trim) Solenoid (refer to Go to Step 10
Service Manual).
Is the replacement complete?
9 NOTE: In most cases, the TCM is not at fault. Go to Step 10
Investigate thoroughly before replacing the
TCM.

Replace the TCM.

Is the replacement complete?
10 In order to verify the repair: Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under normal driving Go to Step 1
conditions.
Did the DTC return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 59 of 135

DTC 45­63 Clutch 1 Solenoid Failed Short to Power

Overview:
A Clutch 1 (C1) Solenoid (C1 Trim Solenoid) short to power fault occurs when the TCM detects that pin 55 is
shorted to power through low or no resistance. When this short to power condition is sensed by the TCM, code
45­63 is set. This code will clear when the TCM no longer detects a short to power condition.

Actions Taken When DTC Sets:

When DTC 45­63 is active, the following conditions will occur:
• Check System light illuminates

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 60 of 135

DTC 45­63 Clutch 1 Solenoid Failed Short to Power (cont’d)

• Disable Clutch Adaptive

– TCM will not adapt clutch logic

Causes:
• Short to power in wire 355 between TCM and Drive Unit
• Short to power in Drive Unit internal wiring harness
• Faulty TCM

Tool Requirements:
• Allison DOC® For PC (AED)
• J­39700 Universal Electronic Breakout Box
• J­47275 Breakout Harness 4th Gen TCM/VCM
• J­46712 Breakout Harness Drive Unit/ESS
• J­46708 Multimeter

Step Action Value(s) Yes No

1 1. Install AllisonDOC® For PC (AED). 9–18V Go to Step 2 Resolve voltage
2. Start the engine. problem. Go to
3. Record the DTC failure record data. Step 9
4. Monitor TCM ignition voltage.
Is the voltage within the specified values?
2 1. Clear the DTC. Go to Step 3 System OK
2. Attempt to duplicate the conditions in the
failure record (mode, temperature, etc.)

NOTE: This DTC is intended to detect a

short­to­battery condition in the C1 (Trim)
Solenoid electrical circuit.
Does code 45–63 return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 61 of 135

DTC 45­63 Clutch 1 Solenoid Failed Short to Power (cont’d)

Step Action Value(s) Yes No

3 1. Turn OFF the ignition. Go to Step 5 Go to Step 4
2. Disconnect the TCM 80­way connector.
3. Install the OEM­side 80­way connector
to the J­47275, TCM Breakout Harness
Adapter. Leave the TCM disconnected.
4. Disconnect the Drive Unit 31­way
connector.
5. Turn ON the ignition.
6. At J­47275­1, TCM Overlay, test for
shorts­to­power at pin 55.

NOTE: The voltage at pin 55 should be 0 Volts

with the TCM disconnected.
Were any shorts­to­power found?
4 1. Turn OFF the ignition. Go to Step 5 Go to Step 6
2. At J­47275­1, TCM Overlay, test for shorts
to other wires between pin 55 and all other
pins in the 80­way connector.
Were any shorts to other wires found?
5 NOTE: The vehicle OEM has responsibility Go to Step 9
for all external wiring harness repair. Harness
repairs performed by Allison Transmission
distributors and dealers are not covered by
Allison Transmission warranty.

Coordinate with the vehicle OEM to repair or

replace the chassis harness.
Is the repair complete?
6 1. Leave the ignition OFF. Go to Step 7 Go to Step 8
2. Install J­46712, Breakout Harness, to the
Drive Unit 31­way connector. Leave the
OEM harness disconnected.
3. At J­46712­1, Drive Unit Overlay, test for
shorts to other wires between pin T and all
other pins in the 31­way connector.

NOTE: The resistance value between pins S

and T should read normal solenoid resistance.
Were any shorts to other wires found?
7 Replace the Drive Unit internal wiring harness Go to Step 9
(refer to Service Manual).
Is the replacement complete?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 62 of 135

DTC 45­63 Clutch 1 Solenoid Failed Short to Power (cont’d)

Step Action Value(s) Yes No

8 NOTE: In most cases, the TCM is not at fault. Go to Step 9
Investigate thoroughly before replacing the
TCM.

Replace the TCM.

Is the replacement complete?
9 In order to verify the repair: Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under normal driving Go to Step 1
conditions.
Did the DTC return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 63 of 135

DTC 45­64 Clutch 2 Solenoid Failed Open

Overview:
A Clutch 2 (C2) Solenoid (C2 Trim Solenoid) failed open fault occurs when the TCM detects that pin 74 is not
connected to a load or that pin 74 is connected to a load through high resistance. When either of these conditions
is detected by the TCM, this code is is set indicating an open in the C2 (Trim) Solenoid Circuit. This code will clear
when the TCM no longer detects an open fault condition.

Actions Taken When DTC Sets:

When DTC 45­64 is active, the following conditions will occur:

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 64 of 135

DTC 45­64 Clutch 2 Solenoid Failed Open (cont’d)

• Check System light illuminates

• Disable Clutch Adaptive
– TCM will not adapt clutch logic

Causes:
• Open in wire 371 or wire 374 between TCM and Drive Unit
• High resistance in wire 371 or wire 374 between TCM and Drive Unit
• Faulty Drive Unit internal wiring harness
• Faulty C2 (Trim) Solenoid
• Faulty TCM

Tool Requirements:
• Allison DOC® For PC (AED)
• J­39700 Universal Electronic Breakout Box
• J­47275 Breakout Harness 4th Gen TCM/VCM
• J­46712 Breakout Harness Drive Unit/ESS
• J­46708 Multimeter

Step Action Value(s) Yes No

1 1. Install Allison DOC® For PC (AED). 9–18V Go to Step 2 Resolve voltage
2. Start the engine. problem. Go to
3. Record the DTC failure record data. Step 11
4. Monitor TCM ignition voltage.
Is the voltage within the specified values?
2 1. Clear the DTC. Go to Step 3 System OK
2. Attempt to duplicate the conditions in the
failure record (mode, temperature, etc.)

NOTE: This DTC is intended to detect an open

condition in the C2 (Trim) Solenoid electrical
circuit.
Does code 45–64 return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 65 of 135

DTC 45­64 Clutch 2 Solenoid Failed Open (cont’d)

Step Action Value(s) Yes No

3 1. Turn OFF the ignition. Go to Step 5 Go to Step 4
2. Install J­47275, TCM Breakout Harness
Adapter between the OEM and TCM
80­way connector.
3. Install J­46712, Breakout Harness
between the OEM and Drive Unit 31­way
connector.
4. Turn ON the ignition, leave engine OFF.
5. Using Allison DOC®, enter solenoid test
mode and command C2 (Trim) Solenoid
ON.
6. Determine the voltage drop in the high side
of the C2 (Trim) Solenoid circuit as follows:
• At J­47275­1, TCM Overlay,
measure voltage between pin 11
and an isolated ground.
• At J­46712­1, Drive Unit Overlay,
measure voltage between pin U and
an isolated ground.
• Subtract the two voltage
measurements to obtain the
voltage drop in the circuit.

NOTE: A voltage drop of more than 0.5V

across either circuit indicates an excessive
voltage loss in the OEM harness.
Did the high side voltage drop exceed 0.5
VDC?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 66 of 135

DTC 45­64 Clutch 2 Solenoid Failed Open (cont’d)

Step Action Value(s) Yes No

4 1. Leave the C2 (Trim) Solenoid commanded Go to Step 5 Go to Step 6
ON.
2. Determine the voltage drop in the low side
of the C2 (Trim) Solenoid circuit as follows:
• At J­47275­1, TCM Overlay,
measure voltage between pin 74
and an isolated ground.
• At J­46712­1, Drive Unit Overlay,
measure voltage between pin V and
an isolated ground.
• Subtract the two voltage
measurements to obtain the
voltage drop in the circuit.

NOTE: A voltage drop of more than 0.5V

across either circuit indicates an excessive
voltage loss in the OEM harness.
Did the low side voltage drop exceed 0.5 VDC?
5 NOTE: The vehicle OEM has responsibility Go to Step 11
for all external wiring harness repair. Harness
repairs performed by Allison Transmission
distributors and dealers are not covered by
Allison Transmission warranty.

Coordinate with the vehicle OEM to repair or

replace the chassis harness.
Is the repair complete?
6 1. Turn OFF the ignition. Refer to Go to Step 10 Go to Step 7
2. Disconnect the OEM­side of the 31­way Appendix B
drive unit connector from the J­46712,
Drive Unit Breakout Harness. Leave the
Drive Unit side of the J­46712 connected.
3. Measure the resistance between pins U
and V at J­46712­1, Drive Unit Overlay.
Is the resistance within the specified value?
7 1. Remove the Drive Unit oil pan. Refer to Go to Step 8 Go to Step 9
2. Disconnect the C2 (Trim) Solenoid from Appendix B
the internal wiring harness.
3. Using a digital volt/ohmmeter (DVOM),
measure the resistance of the C2 (Trim)
Solenoid.
Is the resistance within the specified value?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 67 of 135

DTC 45­64 Clutch 2 Solenoid Failed Open (cont’d)

Step Action Value(s) Yes No

8 Replace the Drive Unit internal wiring harness Go to Step 11
(refer to Service Manual).
Is the replacement complete?
9 Replace the C2 (Trim) Solenoid (refer to Go to Step 11
Service Manual).
Is the replacement complete?
10 NOTE: In most cases, the TCM is not at fault. Go to Step 11
Investigate thoroughly before replacing the
TCM.

Replace the TCM.

Is the replacement complete?
11 In order to verify the repair: Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under normal driving Go to Step 1
conditions.
Did the DTC return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 68 of 135

DTC 45­65 Clutch 2 Solenoid Failed Short to Ground

Overview:
A Clutch 2 (C2) Solenoid (C2 Trim Solenoid) short to ground fault occurs when the TCM detects that pin 74 is
shorted to ground through low or no resistance. When this short to ground condition is sensed by the TCM, code
45­65 is set. This code will clear when the TCM no longer detects a short to ground condition.

Actions Taken When DTC Sets:

When DTC 45­65 is active, the following conditions will occur:
• Check System light illuminates

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 69 of 135

DTC 45­65 Clutch 2 Solenoid Failed Short to Ground (cont’d)

• Disable Clutch Adaptive

– TCM will not adapt clutch logic

Causes:
• Short to ground in wire 374 between TCM and Drive Unit
• Short to ground in Drive Unit internal wiring harness
• Faulty C2 (Trim) Solenoid
• Faulty TCM

Tool Requirements:
• Allison DOC® For PC (AED)
• J­39700 Universal Electronic Breakout Box
• J­47275 Breakout Harness 4th Gen TCM/VCM
• J­46712 Breakout Harness Drive Unit/ESS
• J­46708 Multimeter

Step Action Value(s) Yes No

1 1. Install AllisonDOC® For PC (AED). 9–18V Go to Step 2 Resolve voltage
2. Start the engine. problem. Go to
3. Record the DTC failure record data. Step 10
4. Monitor TCM ignition voltage.
Is the voltage within the specified values?
2 1. Clear the DTC. Go to Step 3 System OK
2. Attempt to duplicate the conditions in the
failure record (mode, temperature, etc.)

NOTE: This DTC is intended to detect a

short­to­ground condition in the C2 (Trim)
Solenoid electrical circuit.
Does code 45–65 return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 70 of 135

DTC 45­65 Clutch 2 Solenoid Failed Short to Ground (cont’d)

Step Action Value(s) Yes No

3 1. Turn OFF the ignition. Go to Step 4 Go to Step 5
2. Disconnect the TCM 80­way connector.
3. Install the OEM­side 80­way connector
to the J­47275, TCM Breakout Harness
Adapter. Leave the TCM disconnected.
4. Disconnect the Drive Unit 31­way
connector.
5. At J­47275­1, TCM Overlay, test for shorts
to other wires between pin 74 and all
other pins in the 80­way connector, and
shorts­to­ground between pin 74 and
chassis ground.
Were any shorts to other wires or
shorts­to­ground found?
4 NOTE: The vehicle OEM has responsibility Go to Step 10
for all external wiring harness repair. Harness
repairs performed by Allison Transmission
distributors and dealers are not covered by
Allison Transmission warranty.

Coordinate with the vehicle OEM to repair or

replace the chassis harness.
Is the repair complete?
5 1. Leave the ignition OFF. Go to Step 6 Go to Step 9
2. Install J­46712, Breakout Harness to the
Drive Unit 31­way connector. Leave the
OEM harness disconnected.
3. At J­46712­1, Drive Unit Overlay, test for
shorts to other wires between pin V and
all other pins in the 31­way connector,
and shorts­to ground between pin V and
chassis ground.

NOTE: The resistance value between pins U

and V should read normal solenoid resistance.
Were any shorts to other wires or
shorts­to­ground found?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 71 of 135

DTC 45­65 Clutch 2 Solenoid Failed Short to Ground (cont’d)

Step Action Value(s) Yes No

6 1. Remove the Drive Unit oil pan. Go to Step 7 Go to Step 8
2. Disconnect the C2 (Trim) Solenoid.
3. At J­46712­1, Drive Unit Overlay, test for
shorts to other wires between pin V and
all other pins in the 31­way connector,
and shorts­to­ground between pin V and
chassis ground.
Were any shorts to other wires or
shorts­to­ground found?
7 Replace the Drive Unit internal wiring harness Go to Step 10
(refer to Service Manual).
Is the replacement complete?
8 Replace the C2 (Trim) Solenoid (refer to Go to Step 10
Service Manual).
Is the replacement complete?
9 NOTE: In most cases, the TCM is not at fault. Go to Step 10
Investigate thoroughly before replacing the
TCM.

Replace the TCM.

Is the replacement complete?
10 In order to verify the repair: Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under normal driving Go to Step 1
conditions.
Did the DTC return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 72 of 135

DTC 45­66 Clutch 2 Solenoid Failed Short to Power

Overview:
A Clutch 2 (C2) Solenoid (C2 Trim Solenoid) short to power fault occurs when the TCM detects that pin 74 is
shorted to power through low or no resistance. When this short to power condition is sensed by the TCM, code
45­66 is set. This code will clear when the TCM no longer detects a short to power condition.

Actions Taken When DTC Sets:

When DTC 45­66 is active, the following conditions will occur:
• Check System light illuminates

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 73 of 135

DTC 45­66 Clutch 2 Solenoid Failed Short to Power (cont’d)

• Disable Clutch Adaptive

– TCM will not adapt clutch logic

Causes:
• Short to power in wire 374 between TCM and Drive Unit
• Short to power in Drive Unit internal wiring harness
• Faulty TCM

Tool Requirements:
• Allison DOC® For PC (AED)
• J­39700 Universal Electronic Breakout Box
• J­47275 Breakout Harness 4th Gen TCM/VCM
• J­46712 Breakout Harness Drive Unit/ESS
• J­46708 Multimeter

Step Action Value(s) Yes No

1 1. Install AllisonDOC® For PC (AED). 9–18V Go to Step 2 Resolve voltage
2. Start the engine. problem. Go to
3. Record the DTC failure record data. Step 9
4. Monitor TCM ignition voltage.
Is the voltage within the specified values?
2 1. Clear the DTC. Go to Step 3 System OK
2. Attempt to duplicate the conditions in the
failure record (mode, temperature, etc.)

NOTE: This DTC is intended to detect a

short­to­battery condition in the C2 (Trim)
Solenoid electrical circuit.
Does code 45–66 return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 74 of 135

DTC 45­66 Clutch 2 Solenoid Failed Short to Power (cont’d)

Step Action Value(s) Yes No

3 1. Turn OFF the ignition. Go to Step 5 Go to Step 4
2. Disconnect the TCM 80­way connector.
3. Install the OEM­side 80­way connector
to the J­47275, TCM Breakout Harness
Adapter. Leave the TCM disconnected.
4. Disconnect the Drive Unit 31­way
connector.
5. Turn ON the ignition.
6. At J­47275­1, TCM Overlay, test for
shorts­to­power at pin 74.

NOTE: The voltage at pin 74 should be 0 Volts

with the TCM disconnected.
Were any shorts­to­power found?
4 1. Turn OFF the ignition. Go to Step 5 Go to Step 6
2. At J­47275­1, TCM Overlay, test for shorts
to other wires between pin 74 and all other
pins in the 80­way connector.
Were any shorts to other wires found?
5 NOTE: The vehicle OEM has responsibility Go to Step 9
for all external wiring harness repair. Harness
repairs performed by Allison Transmission
distributors and dealers are not covered by
Allison Transmission warranty.

Coordinate with the vehicle OEM to repair or

replace the chassis harness.
Is the repair complete?
6 1. Leave the ignition OFF. Go to Step 7 Go to Step 8
2. Install J­46712, Breakout Harness, to the
Drive Unit 31­way connector. Leave the
OEM harness disconnected.
3. At J­46712­1, Drive Unit Overlay, test for
shorts to other wires between pin V and all
other pins in the 31­way connector.

NOTE: The resistance value between pins U

and V should read normal solenoid resistance.
Were any shorts to other wires found?
7 Replace the Drive Unit internal wiring harness Go to Step 9
(refer to Service Manual).
Is the replacement complete?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 75 of 135

DTC 45­66 Clutch 2 Solenoid Failed Short to Power (cont’d)

Step Action Value(s) Yes No

8 NOTE: In most cases, the TCM is not at fault. Go to Step 9
Investigate thoroughly before replacing the
TCM.

Replace the TCM.

Is the replacement complete?
9 In order to verify the repair: Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under normal driving Go to Step 1
conditions.
Did the DTC return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 76 of 135

DTC 45­67 Main Boost Solenoid Failed Open

Overview:
A Main Boost Solenoid failed open fault occurs when the TCM detects that pin 78 is not connected to a load or
that pin 78 is connected to a load through high resistance. When either of these conditions is detected by the
TCM, this code is set indicating an open in the Main Boost Solenoid circuit. This code will clear when the TCM
no longer detects an open fault condition.

Actions Taken When DTC Sets:

When DTC 45­67 is active, the following conditions will occur:

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 77 of 135

DTC 45­67 Main Boost Solenoid Failed Open (cont’d)

• Check System light illuminates

• Disable Clutch Adaptive
– TCM will not adapt clutch logic

Causes:
• Open in wire 311 or wire 378 between TCM and Drive Unit
• High Resistance in wire 311 or wire 378 between TCM and Drive Unit
• Faulty Drive Unit internal wiring harness
• Faulty Main Boost Solenoid
• Faulty TCM

Tool Requirements:
• Allison DOC® For PC (AED)
• J­39700 Universal Electronic Breakout Box
• J­47275 Breakout Harness 4th Gen TCM/VCM
• J­46712 Breakout Harness Drive Unit/ESS
• J­46708 Multimeter

Step Action Value(s) Yes No

1 1. Install Allison DOC® For PC (AED). 9–18V Go to Step 2 Resolve voltage
2. Start the engine. problem. Go to
3. Record the DTC failure record data. Step 11
4. Monitor TCM ignition voltage.
Is the voltage within the specified values?
2 1. Clear the DTC. Go to Step 3 System OK
2. Attempt to duplicate the conditions in the
failure record (mode, temperature, etc.)

NOTE: This DTC is intended to detect an open

condition in the Main Boost Solenoid electrical
circuit.
Does code 45­67 return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 78 of 135

DTC 45­67 Main Boost Solenoid Failed Open (cont’d)

Step Action Value(s) Yes No

3 1. Turn OFF the ignition. Go to Step 5 Go to Step 4
2. Install J­47275, TCM Breakout Harness
Adapter between the OEM and TCM
80­way connector.
3. Install J­46712, Breakout Harness
between the OEM and Drive Unit 31­way
connector.
4. Turn ON the ignition, leave engine OFF.
5. Using Allison DOC®, enter solenoid test
mode and command the Main Boost
Solenoid ON.
6. Determine the voltage drop in the high
side of the Main Boost Solenoid circuit as
follows:
• At J­47275­1, TCM Overlay,
measure voltage between pin 11
and an isolated ground.
• At J­46712­1, Drive Unit Overlay,
measure voltage between pin f and
an isolated ground.
• Subtract the two voltage
measurements to obtain the
voltage drop in the circuit.

NOTE: A voltage drop of more than 0.5V

across either circuit indicates an excessive
voltage loss in the OEM harness.
Did the high side voltage drop exceed 0.5
VDC?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 79 of 135

DTC 45­67 Main Boost Solenoid Failed Open (cont’d)

Step Action Value(s) Yes No

4 1. Leave the Main Boost Solenoid Go to Step 5 Go to Step 6
commanded ON.
2. Determine the voltage drop in the low
side of the Main Boost Solenoid circuit as
follows:
• At J­47275­1, TCM Overlay,
measure voltage between pin 78
and an isolated ground.
• At J­46712­1, Drive Unit Overlay,
measure voltage between pin g and
an isolated ground.
• Subtract the two voltage
measurements to obtain the
voltage drop in the circuit.

NOTE: A voltage drop of more than 0.5V

across either circuit indicates an excessive
voltage loss in the OEM harness.
Did the low side voltage drop exceed 0.5 VDC?
5 NOTE: The vehicle OEM has responsibility Go to Step 11
for all external wiring harness repair. Harness
repairs performed by Allison Transmission
distributors and dealers are not covered by
Allison Transmission warranty.

Coordinate with the vehicle OEM to repair or

replace the chassis harness.
Is the repair complete?
6 1. Turn OFF the ignition. Refer to Go to Step 10 Go to Step 7
2. Disconnect the OEM­side of the 31­way Appendix B
drive unit connector from the J­46712,
Drive Unit Breakout Harness. Leave the
Drive Unit side of the J­46712 connected.
3. Measure the resistance between pins f
and g at J­46712­1, Drive Unit Overlay.
Is the resistance within the specified value?
7 1. Remove the Drive Unit oil pan. Refer to Go to Step 8 Go to Step 9
2. Disconnect the Main Boost Solenoid from Appendix B
the internal wiring harness.
3. Using a digital volt/ohmmeter (DVOM),
measure the resistance of the Main Boost
Solenoid.
Is the resistance within the specified value?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 80 of 135

DTC 45­67 Main Boost Solenoid Failed Open (cont’d)

Step Action Value(s) Yes No

8 Replace the Drive Unit internal wiring harness Go to Step 11
(refer to Service Manual).
Is the replacement complete?
9 Replace the Main Boost Solenoid (refer to Go to Step 11
Service Manual).
Is the replacement complete?
10 NOTE: In most cases, the TCM is not at fault. Go to Step 11
Investigate thoroughly before replacing the
TCM.

Replace the TCM.

Is the replacement complete?
11 In order to verify the repair: Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under normal driving Go to Step 1
conditions.
Did the DTC return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 81 of 135

DTC 45­68 Main Boost Solenoid Failed Short to Ground

Overview:
A Main Boost Solenoid short to ground fault occurs when the the TCM detects that pin 78 is shorted to ground
through low or no resistance. When this short to ground condition is sensed by the TCM, code 45­68 is set. This
code will clear when the TCM no longer detects a short to ground condition.

Actions Taken When DTC Sets:

When DTC 45­68 is active, the following conditions will occur:
• Check System light illuminates

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 82 of 135

DTC 45­68 Main Boost Solenoid Failed Short to Ground (cont’d)

• Disable Clutch Adaptive

– TCM will not adapt clutch logic
• Limit output torque
– Limit output torque in attempt to not slip clutches

Causes:
• Short to ground in wire 378 between TCM and Drive Unit
• Short to ground in Drive Unit internal wiring harness
• Main Boost Solenoid internal short to ground
• Faulty TCM

Tool Requirements:
• Allison DOC® For PC (AED)
• J­39700 Universal Electronic Breakout Box
• J­47275 Breakout Harness 4th Gen TCM/VCM
• J­46712 Breakout Harness Drive Unit/ESS
• J­46708 Multimeter

Step Action Value(s) Yes No

1 1. Install Allison DOC® For PC (AED). 9–18V Go to Step 2 Resolve voltage
2. Start the engine. problem. Go to
3. Record the DTC failure record data. Step 10
4. Monitor TCM ignition voltage.
Is the voltage within the specified values?
2 1. Clear the DTC. Go to Step 3 System OK
2. Attempt to duplicate the conditions in the
failure record (mode, temperature, etc.)

NOTE: This DTC is intended to detect a

short­to­ground condition in the Main Boost
Solenoid electrical circuit.
Does code 45­68 return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 83 of 135

DTC 45­68 Main Boost Solenoid Failed Short to Ground (cont’d)

Step Action Value(s) Yes No

3 1. Turn OFF the ignition. Go to Step 4 Go to Step 5
2. Disconnect the TCM 80­way connector.
3. Install the OEM­side 80­way connector
to the J­47275, TCM Breakout Harness
Adapter. Leave the TCM disconnected.
4. Disconnect the Drive Unit 31­way
connector.
5. At J­47275­1, TCM Overlay, test for shorts
to other wires between pin 78 and all
other pins in the 80­way connector, and
shorts­to­ground between pin 78 and
chassis ground.
Were any shorts to other wires or
shorts­to­ground found?
4 NOTE: The vehicle OEM has responsibility Go to Step 10
for all external wiring harness repair. Harness
repairs performed by Allison Transmission
distributors and dealers are not covered by
Allison Transmission warranty.

Coordinate with the vehicle OEM to repair or

replace the chassis harness.
Is the repair complete?
5 1. Leave the ignition OFF. Go to Step 6 Go to Step 9
2. Install J­46712, Breakout Harness to the
Drive Unit 31­way connector. Leave the
OEM harness disconnected.
3. At J­46712­1, Drive Unit Overlay, test for
shorts to other wires between pin g and
all other pins in the 31­way connector,
and shorts­to­ground between pin g and
chassis ground.

NOTE: The resistance value between pins f

and g should read normal solenoid resistance.
Were any shorts to other wires or
shorts­to­ground found?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 84 of 135

DTC 45­68 Main Boost Solenoid Failed Short to Ground (cont’d)

Step Action Value(s) Yes No

6 1. Remove the Drive Unit oil pan. Go to Step 7 Go to Step 8
2. Disconnect the Main Boost Solenoid.
3. At J­46712­1, Drive Unit Overlay, test for
shorts to other wires between pin g and
all other pins in the 31­way connector
and shorts­to­ground between pin g and
chassis ground.
Were any shorts to other wires or
shorts­to­ground found?
7 Replace the Drive Unit internal wiring harness Go to Step 10
(refer to Service Manual).
Is the replacement complete?
8 Replace the Main Boost Solenoid (refer to Go to Step 10
Service Manual).
Is the replacement complete?
9 NOTE: In most cases, the TCM is not at fault. Go to Step 10
Investigate thoroughly before replacing the
TCM.

Replace the TCM.

Is the replacement complete?
10 In order to verify the repair: Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under normal driving Go to Step 1
conditions.
Did the DTC return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 85 of 135

DTC 45­69 Main Boost Solenoid Failed Short to Power

Overview:
A Main Boost Solenoid short to power fault occurs when the TCM detects that pin 78 is shorted to power through
low or no resistance. When this short to power condition is sensed by the TCM, code 45­69 is set. This code will
clear when the TCM no longer detects a short to power condition.

Actions Taken When DTC Sets:

When DTC 45­69 is active, the following conditions will occur:
• Check System light illuminates

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 86 of 135

DTC 45­69 Main Boost Solenoid Failed Short to Power (cont’d)

• Disable Clutch Adaptive

– TCM will not adapt clutch logic

Causes:
• Short to power in wire 378 between TCM and Drive Unit
• Short to power in Drive Unit internal wiring harness
• Faulty TCM

Tool Requirements:
• Allison DOC® For PC (AED)
• J­39700 Universal Electronic Breakout Box
• J­47275 Breakout Harness 4th Gen TCM/VCM
• J­46712 Breakout Harness Drive Unit/ESS
• J­46708 Multimeter

Step Action Value(s) Yes No

1 1. Install AllisonDOC® For PC (AED). 9–18V Go to Step 2 Resolve voltage
2. Start the engine. problem. Go to
3. Record the DTC failure record data. Step 9
4. Monitor TCM ignition voltage.
Is the voltage within the specified values?
2 1. Clear the DTC. Go to Step 3 System OK
2. Attempt to duplicate the conditions in the
failure record (mode, temperature, etc.)

NOTE: This DTC is intended to detect a

short­to­battery condition in the Main Boost
Solenoid electrical circuit.
Does code 45–69 return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 87 of 135

DTC 45­69 Main Boost Solenoid Failed Short to Power (cont’d)

Step Action Value(s) Yes No

3 1. Turn OFF the ignition. Go to Step 5 Go to Step 4
2. Disconnect the TCM 80­way connector.
3. Install the OEM­side 80­way connector
to the J­47275, TCM Breakout Harness
Adapter. Leave the TCM disconnected.
4. Disconnect the Drive Unit 31­way
connector.
5. Turn ON the ignition.
6. At J­47275­1, TCM Overlay, test for
shorts­to­power at pin 78.

NOTE: The voltage at pin 78 should be 0 Volts

with the TCM disconnected.
Were any shorts­to­power found?
4 1. Turn OFF the ignition. Go to Step 5 Go to Step 6
2. At J­47275­1, TCM Overlay, test for shorts
to other wires between pin 78 and all other
pins in the 80­way connector.
Were any shorts to other wires found?
5 NOTE: The vehicle OEM has responsibility Go to Step 9
for all external wiring harness repair. Harness
repairs performed by Allison Transmission
distributors and dealers are not covered by
Allison Transmission warranty.

Coordinate with the vehicle OEM to repair or

replace the chassis harness.
Is the repair complete?
6 1. Leave the ignition OFF. Go to Step 7 Go to Step 8
2. Install J­46712, Breakout Harness, to the
Drive Unit 31­way connector. Leave the
OEM harness disconnected.
3. At J­46712­1, Drive Unit Overlay, test for
shorts to other wires between pin g and all
other pins in the 31­way connector.

NOTE: The resistance value between pins f

and g should read normal solenoid resistance.
Were any shorts to other wires found?
7 Replace the Drive Unit internal wiring harness Go to Step 9
(refer to Service Manual).
Is the replacement complete?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 88 of 135

DTC 45­69 Main Boost Solenoid Failed Short to Power (cont’d)

Step Action Value(s) Yes No

8 NOTE: In most cases, the TCM is not at fault. Go to Step 9
Investigate thoroughly before replacing the
TCM.

Replace the TCM.

Is the replacement complete?
9 In order to verify the repair: Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under normal driving Go to Step 1
conditions.
Did the DTC return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 89 of 135

DTC 45­71 Solenoid High Side Driver 1 Open

Overview:
A High Side Driver 1 (HSD1) open fault occurs when the TCM detects that pin 11 is not connected to a load or that
pin 11 is connected to a load through high resistance. When either of these conditions is detected by the TCM,
this code is is set indicating an open in the HSD1 circuit. This code will clear when the TCM no longer detects
an open fault condition.

Actions Taken When DTC Sets:

When DTC 45­71 is active, the following conditions will occur:

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 90 of 135

DTC 45­71 Solenoid High Side Driver 1 Open (cont’d)

• Check System light illuminates

• Disable Clutch Adaptive
– TCM will not adapt clutch logic

Causes:
• Open in wire 311 between TCM and Drive Unit
• Open in two or more of the following wires between TCM and Drive Unit: 355, 374, and 378
• High resistance in wire 311 between TCM and Drive Unit
• High resistance in two or more of the following wires between TCM and Drive Unit: 355, 374, and 378
• Faulty Drive Unit internal wiring harness
• Two or more open solenoids on the HSD1 circuit
• Faulty TCM

Tool Requirements:
• Allison DOC® For PC (AED)
• J­39700 Universal Electronic Breakout Box
• J­47275 Breakout Harness 4th Gen TCM/VCM
• J­46712 Breakout Harness Drive Unit/ESS
• J­46708 Multimeter
• J­19197 Jumper Wire Kit

Step Action Value(s) Yes No

1 1. Install AllisonDOC® For PC (AED). 9–18V Go to Step 2 Resolve voltage
2. Start the engine. problem. Go to
3. Record the DTC failure record data. Step 10
4. Monitor TCM ignition voltage.
Is the voltage within the specified values?
2 1. Clear the DTC. Go to Step 3 System OK
2. Attempt to duplicate the conditions in the
failure record (mode, temperature, etc.)

NOTE: This DTC is intended to detect an open

condition in the HSD1 electrical circuit.
Does code 45­71 return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 91 of 135

DTC 45­71 Solenoid High Side Driver 1 Open (cont’d)

Step Action Value(s) Yes No

3 1. Turn OFF the ignition. Less than 4 Go to Step 4 Go to Step 5
2. Install J­47275, TCM Breakout Harness, Ohms
to the OEM­side of the TCM 80­way
connector. Leave the TCM disconnected.
3. Disconnect the Drive Unit 31­way
connector.
4. Using J­39197, Jumper Wire Kit, jump
the following three sets of pins on the
OEM­side of the Drive Unit 31­way
connector: U to V, f to g, and S to T.
5. At J­47275­1, TCM Overlay, measure the
resistance between the following sets of
pins:
• 11 and 55
• 11 and 74
• 11 and 78

NOTE: Resistance measurements of more

than 4 Ohms indicates excessive resistance
in the OEM harness.
Were any of the three resistance readings
greater than the specified value?
4 NOTE: The vehicle OEM has responsibility Go to Step 10
for all external wiring harness repair. Harness
repairs performed by Allison Transmission
distributors and dealers are not covered by
Allison Transmission warranty.

Coordinate with the vehicle OEM to repair or

replace the chassis harness.
Is the repair complete?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 92 of 135

DTC 45­71 Solenoid High Side Driver 1 Open (cont’d)

Step Action Value(s) Yes No

5 1. Turn OFF the ignition. Refer to Go to Step 9 Go to Step 6
2. Disconnect the 31­way Drive Unit Appendix B
connector.
3. Install J­46712, Drive Unit Breakout
Harness, to the Drive Unit 31­way
connector. Leave the OEM harness
disconnected.
4. At J­46712­1, Drive Unit Overlay, measure
the resistance between the following sets
of pins:
• V and U
• g and f
• S and T
Is the resistance within the specified value?
6 1. Remove the Drive Unit oil pan. Refer to Go to Step 7 Go to Step 8
2. Disconnect the C1, C2 and Main Boost Appendix B
solenoids from the internal wiring harness.
3. Using a digital volt/ohmmeter (DVOM),
measure the resistance of each solenoid.
Is the resistance within the specified value?
7 Replace the Drive Unit internal wiring harness Go to Step 10
(refer to Service Manual).
Is the replacement complete?
8 Replace the solenoid(s) with the resistance Go to Step 10
value not within the specified range (refer to
Service Manual).
Is the replacement complete?
9 NOTE: In most cases, the TCM is not at fault. Go to Step 10
Investigate thoroughly before replacing the
TCM.

Replace the TCM.

Is the replacement complete?
10 In order to verify the repair: Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under normal driving Go to Step 1
conditions.
Did the DTC return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 93 of 135

DTC 45­72 Solenoid High Side Driver 1 Short to Ground

Overview:
A High Side Driver 1 (HSD1) short to ground fault occurs when the TCM detects that pin 11 is shorted to ground
through low or no resistance. When this short to ground condition is sensed by the TCM, code 45­72 is set. This
code will clear when the TCM no longer detects a short to ground condition.

Actions Taken When DTC Sets:

When DTC 45­72 is active, the following conditions will occur:

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 94 of 135

DTC 45­72 Solenoid High Side Driver 1 Short to Ground (cont’d)

• Check System light illuminates

• Disable Clutch Adaptive
– TCM will not adapt clutch logic

Causes:
• Short to ground in wire 311 between TCM and Drive Unit
• Short to ground in two or more of the following wires between TCM and Drive Unit: 355, 374, and/or 378
• Short to ground in Drive Unit internal wiring harness
• Two or more of the following solenoids faulty: C1, C2 or Main Boost solenoids
• Faulty TCM

Tool Requirements:
• Allison DOC® For PC (AED)
• J­39700 Universal Electronic Breakout Box
• J­47275 Breakout Harness 4th Gen TCM/VCM
• J­46712 Breakout Harness Drive Unit/ESS
• J­46708 Multimeter

Step Action Value(s) Yes No

1 1. Install Allison DOC® For PC (AED). 9–18V Go to Step 2 Resolve voltage
2. Start the engine. problem. Go to
3. Record the DTC failure record data. Step 10
4. Monitor TCM ignition voltage.
Is the voltage within the specified values?
2 1. Clear the DTC. Go to Step 3 System OK
2. Attempt to duplicate the conditions in the
failure record (mode, temperature, etc.)

NOTE: This DTC is intended to detect

a short­to­ground condition in the HSD1
electrical circuit.
Does code 45­72 return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 95 of 135

DTC 45­72 Solenoid High Side Driver 1 Short to Ground (cont’d)

Step Action Value(s) Yes No

3 1. Turn OFF the ignition. Go to Step 4 Go to Step 5
2. Disconnect the TCM 80­way connector.
3. Install the OEM­side 80­way connector
to the J­47275, TCM Breakout Harness
Adapter. Leave the TCM disconnected.
4. Disconnect the Drive Unit 31­way
connector.
5. At J­47275­1, TCM Overlay, test for shorts
to other wires between pin 11 and all
other pins in the 80­way connector, and
shorts­to­ground between pin 11 and
chassis ground.
Were any shorts to other wires or
shorts­to­ground found?
4 NOTE: The vehicle OEM has responsibility Go to Step 10
for all external wiring harness repair. Harness
repairs performed by Allison Transmission
distributors and dealers are not covered by
Allison Transmission warranty.

Coordinate with the vehicle OEM to repair or

replace the chassis harness.
Is the repair complete?
5 1. Leave the ignition OFF. Go to Step 6 Go to Step 9
2. Install J­46712, Breakout Harness to the
Drive Unit 31­way connector. Leave the
OEM harness disconnected.
3. At J­46712­1, Drive Unit Overlay, test for
shorts to other wires at pins U, f, and S.
Also, test for shorts­to­ground at pins U,
f, and S.

NOTE: The resistance value between pins U

and V, pins f and g, and pins S and T, should
read normal solenoid resistance.
Were any shorts to other wires or
shorts­to­ground found?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 96 of 135

DTC 45­72 Solenoid High Side Driver 1 Short to Ground (cont’d)

Step Action Value(s) Yes No

6 1. Remove the Drive Unit oil pan. Go to Step 7 Go to Step 8
2. Disconnect the C1, C2 and Main Boost
Solenoids.
3. At J­46712­1, Drive Unit Overlay, test for
shorts to other wires at pins U, f, and S.
Also, test for shorts­to­ground at pins U,
f, and S.
Were any shorts to other wires or
shorts­to­ground found?
7 Replace the Drive Unit internal wiring harness Go to Step 10
(refer to Service Manual).
Is the replacement complete?
8 Replace the solenoid(s) with the resistance Go to Step 10
value not within the specified range or any
solenoid(s) that indicated a short to ground in
Step 5 before they were disconnected, (refer
to Service Manual).

NOTE: If you are unsure which solenoid is

faulty, measure each solenoid terminal for a
short­to­ground and replace any solenoids that
indicate a short­to­ground.
Is the replacement complete?
9 NOTE: In most cases, the TCM is not at fault. Go to Step 10
Investigate thoroughly before replacing the
TCM.

Replace the TCM.

Is the replacement complete?
10 In order to verify the repair: Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under normal driving Go to Step 1
conditions.
Did the DTC return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 97 of 135

DTC 45­73 Solenoid High Side Driver 1 Short to Power

Overview:
A High Side Driver 1 (HSD1) short to power fault occurs when the TCM detects that pin 11 is shorted to power
through low or no resistance. When this short to power condition is sensed by the TCM, code 45­73 is set. This
code will clear when the TCM no longer detects a short to power condition.

Actions Taken When DTC Sets:

When DTC 45­73 is active, the following conditions will occur:

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 98 of 135

DTC 45­73 Solenoid High Side Driver 1 Short to Power (cont’d)

• Disable Clutch Adaptive

– TCM will not adapt clutch logic

Causes:
• Short to power in wire 311 between TCM and Drive Unit
• Short to power in any of the following wires: 355, 374, and/or 378
• Short to power in Drive Unit internal wiring harness
• Faulty TCM

Tool Requirements:
• Allison DOC® For PC (AED)
• J­39700 Universal Electronic Breakout Box
• J­47275 Breakout Harness 4th Gen TCM/VCM
• J­46712 Breakout Harness Drive Unit/ESS
• J­46708 Multimeter

Step Action Value(s) Yes No

1 1. Install AllisonDOC® For PC (AED). 9–18V Go to Step 2 Resolve voltage
2. Start the engine. problem. Go to
3. Record the DTC failure record data. Step 12
4. Monitor TCM ignition voltage.
Is the voltage within the specified values?
2 1. Clear the DTC. Go to Step 3 System OK
2. Cycle the key OFF/ON.

NOTE: During the ignition cycle, the ignition

must remain in the OFF position until the shift
selector is no longer illuminated or Allison
DOC® for PC (AED), if connected, goes
OFFLINE.
3. Attempt to duplicate the conditions in the
failure record (mode, temperature, etc.)

NOTE: This DTC is intended to detect

a short­to­battery condition in the HSD1
electrical circuit.
Does code 45­73 return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 99 of 135

DTC 45­73 Solenoid High Side Driver 1 Short to Power (cont’d)

Step Action Value(s) Yes No

3 1. Turn OFF the ignition. Less than 0.5 Go to Step 8 Go to Step 4
2. Install J­47275, TCM Breakout Harness VDC
Adapter, between the OEM and TCM
80­way connector.
3. Install J­46712, Breakout Harness,
between the OEM and Drive Unit 31­way
connector.
4. Turn ON the ignition, leave engine OFF.
5. Using Allison DOC®, enter solenoid test
mode and command C2 solenoid ON.
6. Determine the voltage drop in the high
side of the C2 circuit as follows:
• At J­47275­1, TCM Overlay,
measure voltage between pin 11
and an isolated ground.
• At J­46712­1, Drive Unit Overlay,
measure voltage between pin U and
ground. It will be necessary to use
J­39700, Universal Breakout Box,
at J­46712, TCM Breakout Harness
Adapter, and J­47275, Breakout
Harness.
• Subtract the two voltage
measurements to obtain the
voltage drop in the circuit.

Repeat for the low side, pins V – 74.

NOTE: A voltage drop of more than 0.5V

across either circuit indicates an excessive
voltage loss in the OEM harness.
Did the high side voltage drop exceed 0.5
VDC?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 100 of 135

DTC 45­73 Solenoid High Side Driver 1 Short to Power (cont’d)

Step Action Value(s) Yes No

4 1. Leave the ignition ON. Less than 0.5 Go to Step 8 Go to Step 5
2. Using Allison DOC®, turn C2 solenoid OFF VDC
and command Main Boost Solenoid ON.
3. Determine the voltage drop in the high
side of the Main Boost circuit as follows:
• At J­47275­1, TCM Overlay,
measure voltage between pin 11
and an isolated ground.
• At J­46712­1, Drive Unit Overlay,
measure voltage between pin f and
ground. It will be necessary to use
J­39700, Universal Breakout Box,
at J­46712, TCM Breakout Harness
Adapter, and J­47275, Breakout
Harness.
• Subtract the two voltage
measurements to obtain the
voltage drop in the circuit.
Repeat for the low side, pins g –
78.

NOTE: A voltage drop of more than 0.5V

across either circuit indicates an excessive
voltage loss in the OEM harness.
Did the high side voltage drop exceed 0.5
VDC?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 101 of 135

DTC 45­73 Solenoid High Side Driver 1 Short to Power (cont’d)

Step Action Value(s) Yes No

5 1. Leave the ignition ON. Less than 0.5 Go to Step 8 Go to Step 6
2. Using Allison DOC®, turn Main Boost VDC
Solenoid OFF and command C1 Solenoid
ON.
3. Determine the voltage drop in the high
side of the C1 circuit as follows:
• At J­47275­1, TCM Overlay,
measure voltage between pin 11
and an isolated ground.
• At J­46712­1, Drive Unit Overlay,
measure voltage between pin S and
ground. It will be necessary to use
J­39700, Universal Breakout Box,
at J­46712, TCM Breakout Harness
Adapter, and J­47275, Breakout
Harness.
• Subtract the two voltage
measurements to obtain the
voltage drop in the circuit.

Repeat for the low side, pins T – 55.

NOTE: A voltage drop of more than 0.5V

across either circuit indicates an excessive
voltage loss in the OEM harness.
Did the high side voltage drop exceed 0.5
VDC?
6 1. Turn OFF the ignition. Go to Step 8 Go to Step 7
2. Disconnect the J­47275, TCM Breakout
Harness Adapter, from the TCM. Leave
the OEM 80­way connector connected.
3. Disconnect the OEM 31­way connector
from J­46712, Breakout Harness.
4. Turn ON the ignition.
5. At J­47275­1, TCM Overlay, test for
shorts­to­power at pins 11, 55, 74, and 78.

NOTE: The voltage at pins 11, 55, 74, and 78

should be 0 Volts with the TCM disconnected.
Were any shorts­to­power found?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 102 of 135

DTC 45­73 Solenoid High Side Driver 1 Short to Power (cont’d)

Step Action Value(s) Yes No

7 1. Turn OFF the ignition. Go to Step 8 Go to Step 9
2. At J­467275­1, TCM Overlay, test for
shorts to other wires at pins 11, 55, 74 and
78. Also, test for shorts­to­ground at pins
11, 55, 74 and 78.
Were any shorts to other wires or
shorts­to­ground found?
8 NOTE: The vehicle OEM has responsibility Go to Step 12
for all external wiring harness repair. Harness
repairs performed by Allison Transmission
distributors and dealers are not covered by
Allison Transmission warranty.

Coordinate with the vehicle OEM to repair or

replace the chassis harness.
Is the repair complete?
9 1. Leave the ignition OFF. Go to Step 10 Go to Step 11
2. If not performed in Step 6 above,
disconnect the OEM 31­way connector
from J­46712, Breakout Harness. Leave
the Drive Unit 31­way connector connected
to the breakout box.
3. At J­46712­1, Drive Unit Overlay, test for
shorts to other wires at pins U, f, and S.
Also, test for shorts­to­ground at pins U,
f, and S.

NOTE: The resistance value between pins S

and T, pins U and V, and pins f and g, should
read normal solenoid resistance.
Were any shorts to other wires or
shorts­to­ground found?
10 Replace the Drive Unit internal wiring harness Go to Step 12
(refer to Service Manual).
Is the replacement complete?
11 NOTE: In most cases, the TCM is not at fault. Go to Step 12
Investigate thoroughly before replacing the
TCM.

Replace the TCM.

Is the replacement complete?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 103 of 135

DTC 45­73 Solenoid High Side Driver 1 Short to Power (cont’d)

Step Action Value(s) Yes No

12 In order to verify the repair: Begin the System OK
1. Clear the DTC. diagnosis again.
2. Cycle the key OFF/ON. Go to Step 1

NOTE: During the ignition cycle, the ignition

must remain in the OFF position until the shift
selector is no longer illuminated or Allison
DOC® for PC (AED), if connected, goes
OFFLINE.
3. Operate the vehicle under normal driving
conditions.
Did the DTC return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 104 of 135

DTC 45­74 Solenoid High Side Driver 2 Open

Overview:
A High Side Driver 2 (HSD2) open fault occurs when the TCM detects that pin 71 is not connected to a load or
that pin 71 is connected to a load through high resistance. When either of these conditions is detected by the
TCM, this code is is set indicating an open in the HSD2 circuit. This code will clear when the TCM no longer
detects an open fault condition.

Actions Taken When DTC Sets:

When DTC 45­74 is active, the following conditions will occur:

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 105 of 135

DTC 45­74 Solenoid High Side Driver 2 Open (cont’d)

• Check System light illuminates

• Disable Clutch Adaptive
– TCM will not adapt clutch logic

Causes:
• Open in wire 371 between TCM and Drive Unit
• Open in both of the following wires between TCM and Drive Unit: 333 and 352
• High resistance in wire 371 between TCM and Drive Unit
• High resistance in both of the following wires between TCM and Drive Unit: 333 and 352
• Faulty Drive Unit internal wiring harness
• Both solenoids open in the HSD2 circuit
• Faulty TCM

Tool Requirements:
• Allison DOC® For PC (AED)
• J­39700 Universal Electronic Breakout Box
• J­47275 Breakout Harness 4th Gen TCM/VCM
• J­46712 Breakout Harness Drive Unit/ESS
• J­46708 Multimeter
• J­39197 Jumper Wire Kit

Step Action Value(s) Yes No

1 1. Install AllisonDOC® For PC (AED). 9–18V Go to Step 2 Resolve voltage
2. Start the engine. problem. Go to
3. Record the DTC failure record data. Step 10
4. Monitor TCM ignition voltage.
Is the voltage within the specified values?
2 1. Clear the DTC. Go to Step 3 System OK
2. Attempt to duplicate the conditions in the
failure record (mode, temperature, etc.)

NOTE: This DTC is intended to detect an open

condition in the HSD2 electrical circuit.
Does code 45­74 return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 106 of 135

DTC 45­74 Solenoid High Side Driver 2 Open (cont’d)

Step Action Value(s) Yes No

3 1. Turn OFF the ignition. Less than 4 Go to Step 4 Go to Step 5
2. Install J­47275, TCM Breakout Harness, Ohms
to the OEM­side of the TCM 80­way
connector. Leave the TCM disconnected.
3. Disconnect the Drive Unit 31­way
connector.
4. Using J­39197, Jumper Wire Kit, jump the
following two sets of pins on the OEM­side
of the Drive Unit 31­way connector: A to B
and Q to R.
5. At J­47275­1, TCM Overlay, measure the
resistance between the following sets of
pins:
• 71 and 33
• 71 and 52

NOTE: Resistance measurements of more

than 4 Ohms indicates excessive resistance
in the OEM harness.
Were either of the two resistance readings
greater than the specified value?
4 NOTE: The vehicle OEM has responsibility Go to Step 10
for all external wiring harness repair. Harness
repairs performed by Allison Transmission
distributors and dealers are not covered by
Allison Transmission warranty.

Coordinate with the vehicle OEM to repair or

replace the chassis harness.
Is the repair complete?
5 1. Turn OFF the ignition. Refer to Go to Step 9 Go to Step 6
2. Disconnect the 31­way Drive Unit Appendix B
connector.
3. Install J­46712, Drive Unit Breakout
Harness, to the Drive Unit 31­way
connector. Leave the OEM harness
disconnected.
4. At J­46712­1, Drive Unit Overlay, measure
the resistance between the following sets
of pins:
• A and B
• Q and R
Is the resistance within the specified value?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 107 of 135

DTC 45­74 Solenoid High Side Driver 2 Open (cont’d)

Step Action Value(s) Yes No

6 1. Remove the Drive Unit oil pan. Refer to Go to Step 7 Go to Step 8
2. Disconnect the C1 and C2 Blocking Appendix B
solenoids from the internal wiring harness.
3. Using a digital volt/ohmmeter (DVOM),
measure the resistance of each solenoid.
Is the resistance within the specified value?
7 Replace the internal wiring harness (refer to Go to Step 10
Service Manual).
Is the replacement complete?
8 Replace the solenoid(s) with the resistance Go to Step 10
value not within the specified range (refer to
Service Manual).
Is the replacement complete?
9 NOTE: In most cases, the TCM is not at fault. Go to Step 10
Investigate thoroughly before replacing the
TCM.

Replace the TCM.

Is the replacement complete?
10 In order to verify the repair: Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under normal driving Go to Step 1
conditions.
Did the DTC return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 108 of 135

DTC 45­75 Solenoid High Side Driver 2 Short to Ground

Overview:
A High Side Driver 2 (HSD2) short to ground fault occurs when the TCM detects that pin 71 is shorted to ground
through low or no resistance. When this short to ground condition is sensed by the TCM, code 45­75 is set. This
code will clear when the TCM no longer detects a short to ground condition.

Actions Taken When DTC Sets:

When DTC 45­75 is active, the following conditions will occur:

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 109 of 135

DTC 45­75 Solenoid High Side Driver 2 Short to Ground (cont’d)

• Check System light illuminates

• Disable Clutch Adaptive
– TCM will not adapt clutch logic

Causes:
• Short to ground in wire 371 between TCM and Drive Unit
• Short to ground in both of the following wires between TCM and Drive Unit: 333 and 352
• Short to ground in Drive Unit internal wiring harness
• Faulty C1 and C2 Block solenoid
• Faulty TCM

Tool Requirements:
• Allison DOC® For PC (AED)
• J­39700 Universal Electronic Breakout Box
• J­47275 Breakout Harness 4th Gen TCM/VCM
• J­46712 Breakout Harness Drive Unit/ESS
• J­46708 Multimeter

Step Action Value(s) Yes No

1 1. Install Allison DOC® For PC (AED). 9–18V Go to Step 2 Resolve voltage
2. Start the engine. problem. Go to
3. Record the DTC failure record data. Step 10
4. Monitor TCM ignition voltage.
Is the voltage within the specified values?
2 1. Clear the DTC. Go to Step 3 System OK
2. Attempt to duplicate the conditions in the
failure record (mode, temperature, etc.)

NOTE: This DTC is intended to detect

a short­to­ground condition in the HSD2
electrical circuit.
Does code 45­75 return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 110 of 135

DTC 45­75 Solenoid High Side Driver 2 Short to Ground (cont’d)

Step Action Value(s) Yes No

3 1. Turn OFF the ignition. Go to Step 4 Go to Step 5
2. Disconnect the TCM 80­way connector.
3. Install the OEM­side 80­way connector
to the J­47275, TCM Breakout Harness
Adapter. Leave the TCM disconnected.
4. Disconnect the Drive Unit 31­way
connector.
5. At J­47275­1, TCM Overlay, test for shorts
to other wires between pin 71 and all
other pins in the 80­way connector, and
shorts­to­ground between pin 71 and
chassis ground.
Were any shorts to other wires or
shorts­to­ground found?
4 NOTE: The vehicle OEM has responsibility Go to Step 10
for all external wiring harness repair. Harness
repairs performed by Allison Transmission
distributors and dealers are not covered by
Allison Transmission warranty.

Coordinate with the vehicle OEM to repair or

replace the chassis harness.
Is the repair complete?
5 1. Leave the ignition OFF. Go to Step 6 Go to Step 9
2. Install J­46712, Breakout Harness to the
Drive Unit 31­way connector. Leave the
OEM harness disconnected.
3. At J­46712­1, Drive Unit Overlay, test for
shorts to other wires at pins Q and A. Also,
test for shorts­to­ground at pins Q and A.

NOTE: The resistance value between pins Q

and R, and pins A and B, should read normal
solenoid resistance.
Were any shorts to other wires or
shorts­to­ground found?
6 1. Remove the Drive Unit oil pan. Go to Step 7 Go to Step 8
2. Disconnect the C1 and C2 Blocking
solenoids.
3. At J­46712­1, Drive Unit Overlay, test for
shorts to other wires at pins Q and A. Also,
test for shorts­to­ground at pins Q and A.
Were any shorts to other wires or
shorts­to­ground found?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 111 of 135

DTC 45­75 Solenoid High Side Driver 2 Short to Ground (cont’d)

Step Action Value(s) Yes No

7 Replace the Drive Unit internal wiring harness Go to Step 10
(refer to Service Manual).
Is the replacement complete?
8 Replace the solenoid(s) with the resistance Go to Step 10
value not within the specified range, or any
solenoid(s) that indicated a short to ground in
Step 5 before they were disconnected, (refer
to Service Manual).

NOTE: If you are unsure which solenoid is

faulty, measure each solenoid terminal for a
short­to­ground and replace any solenoids that
indicate a short­to­ground.
Is the replacement complete?
9 NOTE: In most cases, the TCM is not at fault. Go to Step 10
Investigate thoroughly before replacing the
TCM.

Replace the TCM.

Is the replacement complete?
10 In order to verify the repair: Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under normal driving Go to Step 1
conditions.
Did the DTC return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 112 of 135

DTC 45­76 Solenoid High Side Driver 2 Short to Power

Overview:
A High Side Driver 2 (HSD2) short to power fault occurs when the TCM detects that pin 71 is shorted to power
through low or no resistance. When this short to power condition is sensed by the TCM, code 45­76 is set. This
code will clear when the TCM no longer detects a short to power condition.

Actions Taken When DTC Sets:

When DTC 45­76 is active, the following conditions will occur:

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 113 of 135

DTC 45­76 Solenoid High Side Driver 2 Short to Power (cont’d)

• Disable Clutch Adaptive

– TCM will not adapt clutch logic

Causes:
• Short to power in wire 371 between TCM and Drive Unit
• Short to power in any of the following wires: 333 or 352
• Short to power in Drive Unit internal wiring harness
• Faulty TCM

Tool Requirements:
• Allison DOC® For PC (AED)
• J­39700 Universal Electronic Breakout Box
• J­47275 Breakout Harness 4th Gen TCM/VCM
• J­46712 Breakout Harness Drive Unit/ESS
• J­46708 Multimeter

Step Action Value(s) Yes No

1 1. Install AllisonDOC® For PC (AED). 9–18V Go to Step 2 Resolve voltage
2. Start the engine. problem. Go to
3. Record the DTC failure record data. Step 11
4. Monitor TCM ignition voltage.
Is the voltage within the specified values?
2 1. Clear the DTC. Go to Step 3 System OK
2. Cycle the key OFF/ON.

NOTE: During the ignition cycle, the ignition

must remain in the OFF position until the shift
selector is no longer illuminated or Allison
DOC® for PC (AED), if connected, goes
OFFLINE.
3. Attempt to duplicate the conditions in the
failure record (mode, temperature, etc.)

NOTE: This DTC is intended to detect

a short­to­battery condition in the HSD2
electrical circuit.
Does code 45­76 return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 114 of 135

DTC 45­76 Solenoid High Side Driver 2 Short to Power (cont’d)

Step Action Value(s) Yes No

3 1. Turn OFF the ignition. Less than 0.5 Go to Step 7 Go to Step 4
2. Install J­47275, TCM Breakout Harness VDC
Adapter, between the OEM and TCM
80­way connector.
3. Install J­46712, Breakout Harness,
between the OEM and Drive Unit 31­way
connector.
4. Turn ON the ignition, leave engine OFF.
5. Using Allison DOC®, enter solenoid test
mode and command C1 Block solenoid
ON.
6. Determine the voltage drop in the high
side of the C1 circuit as follows:
• At J­47275­1, TCM Overlay,
measure voltage between pin 71
and an isolated ground.
• At J­46712­1, Drive Unit Overlay,
measure voltage between pin A and
ground. It will be necessary to use
J­39700, Universal Breakout Box,
at J­46712, TCM Breakout Harness
Adapter, and J­47275, Breakout
Harness.
• Subtract the two voltage
measurements to obtain the
voltage drop in the circuit.

Repeat for low side, pins B – 52.

NOTE: A voltage drop of more than 0.5V

across either circuit indicates an excessive
voltage loss in the OEM harness.
Did the high side voltage drop exceed 0.5
VDC?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 115 of 135

DTC 45­76 Solenoid High Side Driver 2 Short to Power (cont’d)

Step Action Value(s) Yes No

4 1. Leave the ignition ON. Less than 0.5 Go to Step 7 Go to Step 5
2. Using Allison DOC®, turn C1 Block VDC
Solenoid OFF and command C2 Block
Solenoid ON.
3. Determine the voltage drop in the high
side of the C2 circuit as follows:
• At J­47275­1, TCM Overlay,
measure voltage between pin 71
and an isolated ground.
• At J­46712­1, Drive Unit Overlay,
measure voltage between pin Q and
ground. It will be necessary to use
J­39700, Universal Breakout Box,
at J­46712, TCM Breakout Harness
Adapter, and J­47275, Breakout
Harness.
• Subtract the two voltage
measurements to obtain the
voltage drop in the circuit.

Repeat for low side, pins R – 33.

NOTE: A voltage drop of more than 0.5V

across either circuit indicates an excessive
voltage loss in the OEM harness.
Did the high side voltage drop exceed 0.5
VDC?
5 1. Turn OFF the ignition. Go to Step 7 Go to Step 6
2. Disconnect the J­47275, TCM Breakout
Harness Adapter, from the TCM. Leave
the OEM 80­way connector connected.
3. Disconnect the OEM 31­way connector
from J­46712, Breakout Harness.
4. Turn ON the ignition.
5. At J­47275­1, TCM Overlay, test for
shorts­to­power at pins 33, 52, and 71.

NOTE: The voltage at pins 33, 52, and 71

should be 0 Volts with the TCM disconnected.
Were any shorts­to­power found?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 116 of 135

DTC 45­76 Solenoid High Side Driver 2 Short to Power (cont’d)

Step Action Value(s) Yes No

6 1. Turn OFF the ignition. Go to Step 7 Go to Step 8
2. At J­467275­1, TCM Overlay, test for
shorts to other wires at pins 33, 52, and
71. Also, test for shorts­to­ground at pins
33, 52, and 71.
Were any shorts to other wires or
shorts­to­ground found?
7 NOTE: The vehicle OEM has responsibility Go to Step 11
for all external wiring harness repair. Harness
repairs performed by Allison Transmission
distributors and dealers are not covered by
Allison Transmission warranty.

Coordinate with the vehicle OEM to repair or

replace the chassis harness.
Is the repair complete?
8 1. Leave the ignition OFF. Go to Step 9 Go to Step 10
2. If not performed previously, disconnect
the OEM 31­way connector from J­46712,
Breakout Harness. Leave the Drive
Unit 31­way connector connected to the
breakout box.
3. At J­46712­1, Drive Unit Overlay, test for
shorts to other wires at pins Q and R. Also,
test for shorts­to­ground at pins Q and R.

NOTE: The resistance value between pins A

and B, and pins Q and R, should read normal
solenoid resistance.
Were any shorts to other wires or
shorts­to­ground found?
9 Replace the Drive Unit internal wiring harness
(refer to Service Manual).
Is the replacement complete?
10 NOTE: In most cases, the TCM is not at fault. Go to Step 11
Investigate thoroughly before replacing the
TCM.

Replace the TCM.

Is the replacement complete?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 117 of 135

DTC 45­76 Solenoid High Side Driver 2 Short to Power (cont’d)

Step Action Value(s) Yes No

11 In order to verify the repair: Begin the System OK
1. Clear the DTC. diagnosis again.
2. Cycle the key OFF/ON. Go to Step 1

NOTE: During the ignition cycle, the ignition

must remain in the OFF position until the shift
selector is no longer illuminated or Allison
DOC® for PC (AED), if connected, goes
OFFLINE.
3. Operate the vehicle under normal driving
conditions.
Did the DTC return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 118 of 135

DTC 66­40 CAN Link Lost with Fan Drive Controller

Overview:
TCM has detected that the Fan Drive Controller is not communicating on the CAN link.

Actions Taken When DTC Sets:

• None

Causes:
• Loss of power or ground to the fan drive controller
• Incorrect SID
• CAN Wiring Integrity

Tool Requirements:
• Allison DOC® For PC (AED)
• J­39700 Universal Electronic Breakout Box
• J­47275 Breakout Harness 4th Gen TCM/VCM
• J­46708 Multimeter

Step Action Value(s) Yes No

1 1. Install Allison DOC® For PC (AED). 9–18V Go to Step 3 Resolve voltage
2. Start the engine. problem. Go to
3. Record the DTC failure record data. Step 11
4. Monitor TCM ignition voltage.
Is the voltage within the specified values?
2 Is code 66­40 active? Go to Step 4 Go to Step 3
3 1. Clear the DTC. Go to Step 4 System OK
2. Attempt to duplicate the conditions in the
failure record (mode, temperature, etc.)
Does code 66­40 return?
4 Determine the correct SID for the vehicle. Go to Step 6 Go to Step 5
Does the vehicle contain the correct SID?
5 Connect TCM Reflashing Tool to the vehicle Go to Step 11 Attempt a single
and recalibrate the entire system with the device load for
correct SID. any components
Was the entire vehicle reflash successful? that failed to
load.

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 119 of 135

DTC 66­40 CAN Link Lost with Fan Drive Controller (cont’d)

Step Action Value(s) Yes No

6 1. Inspect the CAN wiring to the fan drive Go to Step 9 Go to Step 7
controller for the following conditions:
• Connector stubs not fully locked
together at modules.
• Terminals not fully locked in place in
connector back shell.
• Chafing of insulation
• Terminal damage
• Signs of corrosion
Were any wiring defects found?
7 1. Turn OFF the ignition. 60 Ohms Go to Step 10 Go to Step 8
2. Measure resistance between pins C and D
at the vehicle diagnostic connector.
Is the resistance within the specified range?
8 Return the vehicle to the OEM for repair. Go to Step 11

NOTE: NOTE: A resistance reading other than

60 Ohms indicates that a terminating resistor
is missing or a resistor with an improper value
is installed. For proper communication there
should be two 120 Ohm resistors wired in
parallel in the CAN 2 backbone.
Is the repair complete?
9 NOTE: The vehicle OEM has responsibility for Go to Step 11
all external wiring harness repairs. Harness
repairs performed by Allison Transmission
distributors and dealers are not covered by
Allison Transmission warranty.

Coordinate with the vehicle OEM to repair or

replace the vehicle wiring.
Is the repair complete?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 120 of 135

DTC 66­40 CAN Link Lost with Fan Drive Controller (cont’d)

Step Action Value(s) Yes No

10 Return the vehicle to OEM for inspection of Go to Step 11
the following:
1. Confirm that the fan drive controller is
properly set to broadcast J1939 messages.
2. Improper pin location at the fan drive
controller.
3. Defective fan drive controller.
4. Any other common wiring issues in the
CAN wiring (CAN wiring issues anywhere
in the circuit can cause communication
problems between controllers).
Is the repair complete?
11 In order to verify the repair: Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under normal driving Go to Step 1
conditions.
Did the DTC return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 121 of 135

DTC 67­18 Fan Drive Controller CAN Data Error/Fault or Unavailable

Overview:
This code is logged if the CAN status field for this controller is anything other than CAN­STATUS­OK for more than
2 seconds.

Actions Taken When DTC Sets:

• None

Causes:
• Wrong calibration
• Wrong software

Tool Requirements:
• Allison DOC® For PC (AED)
• TCM Reflashing Tool

Step Action Value(s) Yes No

1 1. Install AllisonDOC® For PC (AED). 9–18V Go to Step 2 Resolve voltage
2. Start the engine. problem. Go to
3. Record the DTC failure record data. Step 4
4. Monitor TCM ignition voltage.
Is the voltage within the specified values?
2 1. Clear the DTC. Go to Step 3 System OK
2. Attempt to duplicate the conditions in the
failure record (mode, temperature, etc.)
Does code 67­18 return?
3 Are there any other Drive Unit DTCs at this Perform Go to Step 4
time? troubleshooting
procedure for
active DTCs.
4 Contact Technical Assistance Center (TAC)
at 1­800­252­5283 for further assistance with
67­18.

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 122 of 135

DTC 67­19 PBSS CAN Data Error/Fault or Unavailable

Overview:
This code is logged if the PBSS CAN Data for this controller is anything other than CAN­STATUS­OK for more than
2 seconds.

Actions Taken When DTC Sets:

• None

Causes:
• Wrong calibration
• Wrong software

Tool Requirements:
• Allison DOC® For PC (AED)
• TCM Reflashing Tool

Step Action Value(s) Yes No

1 1. Install AllisonDOC® For PC (AED). 9–18V Go to Step 2 Resolve voltage
2. Start the engine. problem. Go to
3. Record the DTC failure record data. Step 4
4. Monitor TCM ignition voltage.
Is the voltage within the specified values?
2 1. Clear the DTC. Go to Step 3 System OK
2. Attempt to duplicate the conditions in the
failure record (mode, temperature, etc.)
Does code 67­19 return?
3 Are there any other Drive Unit DTCs at this Perform Go to Step 4
time? troubleshooting
procedure for
active DTCs.
4 Contact Technical Assistance Center (TAC)
at 1­800­252­5283 for further assistance with
67­19.

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 123 of 135

DTC 70­23 Controller Hardware Watchdog Timeout TCM

Overview:
This code is set when the required TCM hardware did not complete execution in the required amount of time.

Actions Taken When DTC Sets:

When DTC 70­23 is active, the following conditions will occur:
• Check System light illuminates

Causes:
• CAN wiring integrity
• Corrupt software or calibration

Tool Requirements:
• Allison DOC® For PC (AED)
• TCM Reflashing Tool

Step Action Value(s) Yes No

1 1. Install AllisonDOC® For PC (AED). 9–18V Go to Step 2 Resolve voltage
2. Start the engine. problem. Go to
3. Record the DTC failure record data. Step 7
4. Monitor TCM ignition voltage.
Is the voltage within the specified values?
2 Is code 70­23 active? Go to Step 4 Go to Step 3
3 1. Clear the DTC. Go to Step 4 System OK
2. Attempt to duplicate the conditions in the
failure record (mode, temperature, etc.)
Does code 70­23 return?
4 Reinstall entire vehicle software/calibrations Go to Step 5 Attempt a single
using TCM Reflashing Tool to rule out corrupt device load for
software. any components
Was the entire vehicle reflash successful? that failed to
load.
5 Operate the vehicle under normal driving Go to Step 6 Go to Step 7
conditions.
Does code 70­23 return?
6 Replace the TCM. Go to Step 7
Is the replacement complete?
7 In order to verify the repair: Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under normal driving Go to Step 1
conditions.
Did the DTC return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 124 of 135

DTC 70­24 Controller Hardware Watchdog Timeout VCM

Overview:
This code is set when the required VCM hardware did not complete execution in the required amount of time.

Actions Taken When DTC Sets:

When DTC 70­24 is active, the following conditions will occur:
• Check System light illuminates

Causes:
• CAN wiring integrity
• Corrupt software or calibration

Tool Requirements:
• Allison DOC® For PC (AED)
• VCM Reflashing Tool

Step Action Value(s) Yes No

1 1. Install AllisonDOC® For PC (AED). 9–18V Go to Step 2 Resolve voltage
2. Start the engine. problem. Go to
3. Record the DTC failure record data. Step 7
4. Monitor TCM ignition voltage.
Is the voltage within the specified values?
2 Is code 70­24 active? Go to Step 4 Go to Step 3
3 1. Clear the DTC. Go to Step 4 System OK
2. Attempt to duplicate the conditions in the
failure record (mode, temperature, etc.)
Does code 70­24 return?
4 Reinstall entire vehicle software/calibrations Go to Step 5 Attempt a single
using VCM Reflashing Tool to rule out corrupt device load for
software. any components
Was the entire vehicle reflash successful? that failed to
load.
5 Operate the vehicle under normal driving Go to Step 6 Go to Step 7
conditions.
Does code 70­24 return?
6 Replace the VCM. Go to Step 7
Is the replacement complete?
7 In order to verify the repair: Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under normal driving Go to Step 1
conditions.
Did the DTC return?

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 125 of 135

Appendix B. Calculated Solenoid Resistance vs. Temperature Table

Figure 7. Solenoid Resistance vs. Temperature Graph

Table 5. Solenoid Resistance vs. Temperature

Main Boost Solenoid, C1 and
Sump Temperature C1 and C2 Block Solenoids
C2 Trim Solenoids
(°C) (°F) (Ω) (Ω)
0 32 4.5 20.0
20 68 5.5 22.0
40 104 6.5 24.5
80 176 7.5 27.0
120 248 8.5 29.5

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 126 of 135

Appendix C. AED Wiring Reference Tables

Table 6. TCM
PRE 4TH 4TH GEN
PRE 4TH GEN PRE 4TH GEN PRE 4TH GEN GEN PIN WIRE 4TH GEN
DESCRIPTION CONNECTOR GM WIRE NO. WIRE NO. NO. NO. PIN NO.
+12V BATTERY RETURN Gray TCM 138­PT13­1 301 1 309 9
IGNITION Gray TCM 101B­PT13­2 302 2 363 63
+12V BATTERY Gray TCM 139­PT13­3 303 3 310 10
+12V BATTERY NA NA NA NA 370 70
IGNITION Gray TCM 101C­PT13­4 304 4 NA NA
TCM ID (+12V BATTERY
RETURN) Gray TCM 252­PT13­11 311 11 362 62
ESS PRE­TUNNEL CHARGE Gray TCM 255­PT13­6 306 6 323 23
STATION MODE Gray TCM 240­PT13­7 307 7 302 2
FRONT OPERATION MODE 1 Gray TCM 143­PT13­8 308 8 343 43
FRONT OPERATION MODE 2 Gray TCM 144­PT13­9 309 9 322 22
+12V BATTERY RETURN Gray TCM 140­PT13­5 305 5 362 62
FAST IDLE Gray TCM 145­PT13­12 312 12 342 42
AUX FUNCTION RANGE
INHIBIT Gray TCM 220­PT13­13 313 13 301 1
ENERGY STORAGE RELAY
CLOSED Gray TCM 146­PT13­14 314 14 379 79
OIL LEVEL SENSOR SIGNAL Gray TCM 147­PT13­15 315 15 316 16
OIL LEVEL SENSOR
EXCITATION (SUPPLY) Gray TCM 148­PT13­17 317 17 312 12
OIL LEVEL SENSOR RETURN
(ANALOG RETURN) Gray TCM 170­PT14­20 420 20 358 58
AUX BRAKE INDICATOR Gray TCM 150­PT13­20 320 20 304 4
OUTPUT SPEED INDICATOR Gray TCM 151­PT13­22 322 22 345 45
ENERGY STORAGE WAKEUP Gray TCM 152­PT13­23 323 23 305 5
ENGINE WAKEUP Gray TCM 153­PT13­24 324 24 324 24
SPEEDOMETER SIGNAL Gray TCM 154­PT13­26 326 26 325 25
CAN HI Gray TCM 155­PT13­29 329 29 328 28
CAN SHIELD Gray TCM 156­PT13­31 331 31 349 49
CAN LO Gray TCM 157­PT13­32 332 32 308 8
C1 PRESSURE SWITCH Red TCM 158­PT14­1 401 1 357 57
FAST IDLE 2 Red TCM 160­PT14­5 405 5 361 61

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 127 of 135

Table 6. TCM (cont’d)

PRE 4TH 4TH GEN

PRE 4TH GEN PRE 4TH GEN PRE 4TH GEN GEN PIN WIRE 4TH GEN
DESCRIPTION CONNECTOR GM WIRE NO. WIRE NO. NO. NO. PIN NO.
REMOTE SHUTDOWN
REQUEST Red TCM 250­PT14­6 406 6 321 21
ACCELERATOR INTERLOCK Red TCM 251­PT14­7 407 7 317 17
C2 PRESSURE SWITCH Red TCM 161­PT14­8 408 8 377 77
SUMP OIL TEMP Red TCM 163­PT14­10 410 10 354 54
DRIVE UNIT OUTPUT SPEED
2 HI Red TCM 165­PT14­13 413 13 380 80
DRIVE UNIT OUTPUT SPEED
2 LO Red TCM 166­PT14­14 414 14 320 20
DRIVE UNIT OUTPUT SPEED
1 HI Red TCM 167­PT14­15 415 15 360 60
DRIVE UNIT OUTPUT SPEED
1 LO Red TCM 168­PT14­16 416 16 340 40
ANALOG GROUND (RETURN) Red TCM 170­PT14­20 420 20 358 58
DRIVE UNIT ID Red TCM 171­PT14­21 421 21 NA NA
C1 (TRIM) SOLENOID
COMMAND HI Red TCM 172­PT14­22 422 22 311 11
C1 (TRIM) SOLENOID
ENABLE LO Red TCM 173­PT14­23 423 23 355 55
C2 (TRIM) SOLENOID
COMMAND HI Red TCM 174­PT14­24 424 24 311 11
C2 (TRIM) SOLENOID
ENABLE LO Red TCM 175­PT14­25 425 25 374 74
C1 BLOCK SOLENOID
COMMAND Red TCM 176­PT14­26 426 26 352 52
C1 BLOCK SOLENOID OEM Supplied
ENABLE HI (Solenoid HSD2) 12V Wire NA NA NA 371 71
C2 BLOCK SOLENOID
COMMAND (Solenoid HSD2) Red TCM 177­PT14­27 427 27 333 33
C2 BLOCK SOLENOID OEM Supplied
ENABLE HI 12V Wire NA NA NA 371 71
INVERTER WAKEUP A B Red TCM 178­PT14­28 428 28 364 64
ANALOG/PRESSURE
SWITCH RETURN NA NA NA NA 303 3
HUSH PRE­CHARGE MODE
ACTIVE Gray TCM 256­PT13­21 321 21 313 13

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 128 of 135

NOTE: The following wires were on the Pre 4th Gen VCM connectors, but are now located on the 4th
Gen TCM 80­way connector.

Table 7. VCM / TCM

PRE 4TH 4TH GEN
PRE 4TH GEN PRE 4TH GEN PRE 4TH GEN GEN PIN WIRE 4TH GEN
DESCRIPTION CONNECTOR GM WIRE NO. WIRE NO. NO. NO. PIN NO.
MAIN PRESSURE BOOST
COMMAND HI Red VCM 132­PV12­24 224 24 311 11
MAIN PRESSURE BOOST
ENABLE LO Red VCM 133­PV12­25 225 25 378 78
SHIFT SELECTOR WAKEUP Red VCM 135­PV12­28 228 28 350 50
SHIFT SELECTOR SERIAL
DATA LINK Gray VCM 117­PV11­26 126 26 334 34

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 129 of 135

Table 8. VCM
PRE 4TH 4TH GEN
PRE 4TH GEN PRE 4TH GEN PRE 4TH GEN GEN PIN WIRE 4TH GEN
DESCRIPTION CONNECTOR GM WIRE NO. WIRE NO. NO. NO. PIN NO.
+12V BATTERY RETURN Gray VCM 100­PV11­1 101 1 109 9
IGNITION Gray VCM 101­PV11­2 102 2 163 63
+12V BATTERY Gray VCM 102­PV11­3 103 3 110 10
+12V BATTERY NA NA NA NA 170 70
IGNITION Gray VCM 101A­PV11­4 104 4 NA NA
+12V BATTERY RETURN Gray VCM 100A­PV11­5 105 5 169 69
ENGINE START REQUEST Gray VCM 103­PV11­6 106 6 123 23
ACCELERATOR PEDAL IVS 1 Gray VCM 104­PV11­7 107 7 102 2
ACCELERATOR PEDAL IVS 2 Gray VCM 105­PV11­8 108 8 143 43
AUTOMATIC NEUTRAL Gray VCM 254­PV11­9 109 9 122 22
SHIFT SELECTOR INPUTS
MODE Gray VCM 106­PV11­12 112 12 NA NA
SYSTEM OVERRIDE
REQUEST Gray VCM 107­PV11­14 114 14 142 42
BRAKE (SENSOR SIGNAL) Gray VCM 108­PV11­15 115 15 116 16
BRAKE EXCITATION
(SENSOR SUPPLY) Gray VCM 109­PV11­17 117 17 112 12
ANALOG GROUND ACC
PEDAL RETURN Gray VCM 110­PV11­18 118 18 158 58
ANALOG GROUND BRAKE
EXCITATION RETURN Red VCM 131­PV12­20 220 20 158 58
WAIT TO START INDICATOR Gray VCM 111­PV11­19 119 19 104 4
BATTERY COOLING
REQUEST Gray VCM 112­PV11­20 120 20 145 45
STOP SYSTEM INDICATOR Gray VCM 113­PV11­21 121 21 129 29
RANGE INDICATOR Gray VCM 114­PV11­22 122 22 124 24
SYSTEM OVERTEMP
INDICATOR Gray VCM 115­PV11­23 123 23 164 64
REVERSE WARNING Gray VCM 116­PV11­24 124 24 165 65
CAN HI Gray VCM 118­PV11­29 129 29 128 28
CAN SHIELD Gray VCM 119­PV11­31 131 31 149 49
CAN LO Gray VCM 120­PV11­32 132 32 108 8
HUSH MODE REQUEST Red VCM 121­PV12­1 201 1 101 1
AUXILLARY BRAKE ENABLE
REQUEST Red VCM 122­PV12­2 202 2 161 61
SHIFT SELECTOR INPUTS
SS1 Red VCM 123­PV12­4 204 4 NA NA

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 130 of 135

Table 8. VCM (cont’d)

PRE 4TH 4TH GEN

PRE 4TH GEN PRE 4TH GEN PRE 4TH GEN GEN PIN WIRE 4TH GEN
DESCRIPTION CONNECTOR GM WIRE NO. WIRE NO. NO. NO. PIN NO.
SHIFT SELECTOR INPUTS
SS2 Red VCM 124­PV12­5 205 5 NA NA
SHIFT SELECTOR INPUTS
SS4 Red VCM 125­PV12­6 206 6 NA NA
SHIFT SELECTOR INPUTS
SS8 Red VCM 126­PV12­7 207 7 NA NA
SHIFT SELECTOR INPUTS
PARITY Red VCM 127­PV12­8 208 8 NA NA
ACCELERATOR PEDAL
INPUT Red VCM 128­PV12­9 209 9 144 44
ACCLERATOR PEDAL
EXCITATION Red VCM 130­PV12­19 219 19 112 12
ANALOG GROUND / RETURN Red VCM 131­PV12­20 220 20 158 58
CHECK SYSTEM INDICATOR Red VCM 134­PV12­26 226 26 105 5
HUSH MODE ACTIVE Red VCM 253­PV12­27 227 27 150 50
SIGNAL RETURN NA NA NA NA 103 3

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 131 of 135

Appendix D. 4th Gen Wiring

Figure 8. TCM 4th Generation Wiring

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 132 of 135

Figure 9. VCM 4th Generation Wiring

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 133 of 135

Figure 10. DPIM 4th Generation Wiring

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 134 of 135

Figure 11. ESS 4th Generation Wiring

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.

 #2009, Rev. A
June, 2010
Product Code(s): 70, 71
Page 135 of 135

Figure 12. CAN 4th Generation Wiring

Figure 13. PBSS 4th Generation Wiring

Copyright 2010 Allison Transmission, Inc. All Rights Reserved.