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Transmission Control
Unit (TCU)
Diagnostic Manual
COMPONENT TECHNICAL
MANUAL
Transmission Control Unit (TCU)
Diagnostic Manual
CTM157 15JUL05 (ENGLISH)
This manual is written for an experienced technician. Information is organized in groups for the various
Essential tools required in performing certain service components requiring service instruction. At the
work are identified in this manual and are beginning of each group are summary listings of all
recommended for use. applicable essential tools, service equipment and tools,
other materials needed to do the job, service parts kits,
Live with safety: Read the safety messages in the specifications, wear tolerances, and torque values.
introduction of this manual and the cautions presented
throughout the text of the manual. Technical Manuals are concise guides for specific
machines. They are on-the-job guides containing only
the vital information needed for diagnosis, analysis,
This is the safety-alert symbol. When you see this
testing, and repair.
symbol on the machine or in this manual, be alert to
the potential for personal injury.
Fundamental service information is available from
other sources covering basic theory of operation,
Technical manuals are divided in two parts: repair and
fundamentals of troubleshooting, general maintenance,
operation and tests. Repair sections tell how to repair
and basic type of failures and their causes.
the components. Operation and tests sections help you
identify the majority of routine failures quickly.
DX,TMIFC 1929SEP981/1
P R O O F
P R O O F
005
INDX
P R O O F
005
Transmission Control Unit
Contents
Page Page
005
Page Page
P R O O F
Safety
005
Recognize Safety Information 05
1
UN07DEC88
Follow recommended precautions and safe operating
practices.
T81389
DX,ALERT 1929SEP981/1
UN23AUG88
hospital, and fire department near your telephone.
TS291
DX,FIRE2 1903MAR931/1
UN23AUG88
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
TS206
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating machine.
DX,WEAR 1910SEP901/1
005
05 Work In Ventilated Area
2
UN23AUG88
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area
TS220
DX,AIR 1917FEB991/1
UN18OCT88
Have the right parts on hand.
Read all instructions thoroughly; do not attempt
shortcuts.
T6642EJ
DX,CLEAN 1904JUN901/1
UN23AUG88
TS223
DX,LIGHT 1904JUN901/1
DPSG,YZ07927,186 1904MAR991/1
005
Use Proper Lifting Equipment 05
3
UN23AUG88
TS226
DX,LIFT 1904JUN901/1
UN08NOV89
For loosening and tightening hardware, use the correct
size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping
TS779
wrenches.
DX,REPAIR 1917FEB991/1
DX,LOWER 1924FEB001/1
005
05 Handle Fluids SafelyAvoid Fires
4
UN23AUG88
Make sure machine is clean of trash, grease, and debris.
TS227
spontaneously.
DX,FLAME 1929SEP981/1
UN23AUG88
Do not charge a frozen battery; it may explode. Warm
P R O O F
TS204
DX,SPARKS 1903MAR931/1
005
Prevent Acid Burns 05
5
UN23AUG88
If acid is swallowed:
TS203
exceed 2 L (2 quarts).
3. Get medical attention immediately.
P R O O F
DX,POISON 1921APR931/1
DX,TORCH 1910DEC041/1
005
05 Avoid High-Pressure Fluids
6
UN23AUG88
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
X9811
and body from high pressure fluids.
DX,FLUID 1903MAR931/1
1907OCT88
TS231
DX,LIVE 1925SEP921/1
P R O O F
General Information
005
Theory Of Operation 10
1
UN08AUG98
YZ1571
Transmission Control Unit>
The purpose of the Transmission Control Unit (TCU) is until the problem has been resolved and the gear
to control the functions of the transmission. Upshifting, selector cycled back through the neutral or park
downshifting, control of the proportional solenoids and position.
capability to communicate with a panel mounted
gear/diagnostic indicator are the main functions. The If no diagnostics code conditions are detected, based
transmissions performance is determined by the upon a combination of inputs from the gear selector
various inputs to the TCU. Based upon these inputs, and other applicable inputs, the TCU will select the
the TCU commands the transmission so that maximum proper transmission gear and command the
P R O O F
performance can be achieved under the present transmission to shift to this gear. The gear/diagnostic
operating conditions. All functions of the TCU are indicator will now show the actual transmission gear.
under software control.
The TCU uses electrohydraulic proportional valves to
Operation begins when the vehicles ignition is control the operation of the transmission. The
switched to the ON position, supplying electrical solenoids controlling the transmission clutches
power to the TCU and related system components (solenoids A through D & 1 through 4) are driven by a
from the vehicles power source. The TCU now begins signal that produces proportional pressure/flow
monitoring all inputs and outputs. If a known conflict in changes. During modulation, the solenoids are started
inputs or a fault condition is detected, the TCU will out with a low duty cycle and ramped up to full on. The
command the transmission to stay in neutral initial duty cycle is dependent upon several factors and
regardless of the gear selector position. A flashing is not a preset value. The process of modulating these
diagnostic code will be displayed on the clutches greatly enhances shift quality.
gear/diagnostic indicator, and will remain displayed
AG,YZ07927,4 1910OCT981/1
005
10 Understanding The TCU Label
2
UN03MAR99
D TCU hardware part number
E Original programming date (week/year)
YZ1812
TCU Label Information
DPSG,YZ07927,185 1903MAR991/1
AG,YZ07927,31 1914OCT981/1
005
Glossary 10
3
Active The high voltage state of a digital signal. Legal Conditions A set or sets of input signal
Also called high or binary 1. states which will result in correct system operation;
Actual Gear The actual physical gear of the i.e. no diagnostic codes will be generated by the
transmission, regardless of shift lever position or TCU.
controller operation. Neutral Recoverable The process where a detected
Analog A signal which has a continuous range of fault is maintained and displayed by the TCU until
possible voltages. the shift lever is cycled to neutral (park on some
Bus A serial communications link which systems) and the TCU detects the proper
interconnects intelligent electronic modules. combination of inputs for a legal neutral (park)
Come-Home A hardware function which allows condition, at which time the displayed fault will be
limited vehicle motion in the event of failure of cleared. The fault code will still be stored in
certain components. memory.
Commanded Gear The gear selected by the Next Gear The next gear the controller plans to
combination of the shift lever position and the state enter. The next gear will become the current gear
of the Forward, Reverse, Neutral, and Not Neutral if no faults are detected and all conditions for
TCU inputs. The destination gear. entering the next gear are met.
Current Gear The gear the controller is currently Nonvolatile Memory Memory that retains its data
attempting to send the transmission into by the even though power to the system has been
application of current to the valves. removed.
Digital A signal which may take one of two voltage Passive The low voltage state of a digital signal.
levelsusually 0 volts and +5 volts. On/Off type Also called low or binary 0.
signals are also considered to be digital. Previous Direction The direction of vehicle motion
Downshift Inhibit The prohibiting of downshifting by before a shuttle shift is initiated
the TCU to prevent harsh and abrupt shifts or Previous Gear The previous current gear.
possible overspeed conditions of the engine. The Sequence Shift The type of shift which consists of
downshift will be inhibited until the current speed shifting from a gear to an adjacent gear.
ratio will permit the shift to take place. Shuttle Shift A shift to a gear in the opposite
Fault An abnormal condition which results in a direction of vehicle travel made by moving the shift
P R O O F
perceived performance change or in a loss of lever between the Forward and Reverse positions.
function which may result in performance loss or
system damage.
Intershift Pause Time A preprogrammed value in
the TCU which sets the minimum time delay
between shifts.
AG,YZ07927,43 1916OCT981/1
005
10 Multimeter
4
ADisplay
BVoltage AC (Alternating current) setting
CVoltage DC (Direct current) setting
DResistance setting
1903SEP93
EDiode test/continuity setting
FCurrent AC (Alternating current) setting
GCurrent DC (Direct current) setting
HVoltage, Resistance, Diode/continuity input (Red
T8074AA
lead)
IGround input (Black lead)
JCurrent/amps input (Red lead)
Digital Multimeter
P R O O F
AG,YZ07927,34 1909OCT981/1
005
Malfunctions 10
5
1927FEB92
T7713AD
Common Circuit Components
P R O O F
Before the controlling switch (C). Reason: High resistance caused by a dirty switch
Between the controlling switch and before the connector caused a voltage drop which prevented the
component, light (D). proper amount of current from flowing to the light.
AG,YZ07927,27 1908OCT981/1
005
10 High Resistance Circuit Malfunction Example
6
1926FEB92
T7713AG
High Resistance Circuit
P R O O F
A high resistance circuit can result in slow, dim or no If less than battery voltage is measured, check again
component operation. closer to switch.
With switch (C) ON, check for battery voltage between Repeat check-out procedure after repair.
switch and ground (I) at an easily accessible location,
like harness connector (F).
AG,YZ07927,29 1908OCT981/1
005
10
7
P R O O F
005
10 Open Circuit Malfunction Example
8
1927FEB92
T7713AF
Open Circuit
P R O O F
An open circuit will result in no components operating. With switch (C) ON check for battery voltage at switch
Fuse may or may not be blown. terminal (D).
To locate an open circuit: If battery voltage had been measured, the next check
for voltage would be at ground connection (I).
Check fuse. If blown, replace and operate circuit. If
fuse blows a second time, continue check.
005
Normal measured voltage at a ground connection When the problem is located, repair as needed, then 10
9
should be 0.0 to 0.5 volts. repeat the last check.
AG,YZ07927,30 1908OCT982/2
P R O O F
005
10 Grounded Circuit Malfunction Example
10
1927FEB92
T7713AE
ABattery DSwitch GHarness Connector JLight
P R O O F
If no component operates, the fuse is blown and connector (F), turn switch (D) ON, and check for
replacement fuses blow immediately or the circuit continuity to the ground at harness connector (F). This
breaker is open and reopens when reset, a grounded will check the harness from the harness connector to
circuit exists. the fuse.
005
If continuity exists, disconnect the circuit at the light Repeat check-out procedure after repair. 10
11
terminal (I) and measure continuity to ground on the
light terminal. In the example continuity will not exist,
indicating a grounded circuit between the light and
harness connector (G).
AG,YZ07927,31 1908OCT982/2
P R O O F
005
10 Shorted Circuit Malfunction Example
12
1927FEB92
T7713AH
Shorted Circuit
P R O O F
A shorted circuit causes components in separate Turn switch (F) ON. Both lights (J and L) will be ON;
circuits to operate when a switch in either circuit is only light (L) should be ON.
turned ON.
Disconnect the wire from switch of the component that
Example: should not be ON. In the example, disconnect wire
from terminal (E) at switch (D). Light (J) remains ON.
Both lights (J and L) will be ON when either switch
(D or F) is ON.> Disconnect the circuit at convenient places like
harness connectors (G), (I) and light terminal (K) until
Possible Causes: light (J) goes OFF.
Two harnesses rubbing together until insulation is The short circuit will be between the last two places
worn through allowing bare wires to touch). the circuit was disconnected. In the example, it is
Components can also become shorted. However, between harness connectors (G and I). Light (J) will go
shorted components will usually blow the fuse. OFF when harness connector (I) is disconnected.
Inspect harness between connectors (G and I).
To locate a shorted circuit:
005
Repair or replace wires and harnesses as needed. Repeat check-out procedure after repair. 10
13
Install tie bands and clamps on harnesses as required
to prevent future failures.
AG,YZ07927,33 1909OCT982/2
P R O O F
005
10 Seven Step Electrical Test Procedure Example
14
1905MAR92
T7719AA
Seven Step Electrical Test Procedure
P R O O F
ABattery ground DFuse or circuit breaker GBattery side of component IGround side of component
BBattery EComponent side of fuse or terminal terminal
CBattery side of fuse or circuit breaker HLight (Component) JComponent ground
circuit breaker FSwitch
005
Step 1Switch ON 10
15
Check battery side of circuit breaker (C) for battery voltage Battery voltage normal. Go to step 2.
Low voltage, repair high resistance.
Open circuit from battery
Step 2Switch OFF
Check component side of circuit breaker for battery voltage Battery voltage normal. Go to step 4.
Low voltage, repair high resistance.
No voltage. Go to step 3.
Step 3Switch OFF
Check component side of circuit breaker for continuity to ground Continuity to ground. Repair grounded circuit at or before switch.
No continuity to ground, replace circuit breaker.
Step 4Switch ON
Check component side of circuit breaker for battery voltage Battery voltage normal. Go to step 6.
Low voltage, repair high resistance.
No voltage. Go to step 5.
Step 5
Disconnect wire at battery side of component (G). Switch ON. Check Battery voltage, repair component.
wire at (G) for battery voltage
No voltage, repair grounded or open circuit at or after switch.
Step 6Switch ON
Check lead to component at (G) for battery voltage Battery voltage normal. Go to step 7.
Low voltage, repair high resistance in circuit between fuse and
component.
No voltage, repair high resistance or open circuit between fuse and
component.
Step 7Switch ON
Check ground wire of component at (I) for voltage No voltage, good continuity to ground.
P R O O F
Repair component.
Voltage, poor continuity to ground. Repair high resistance or open
ground circuit.
AG,YZ07927,36 1909OCT982/2
005
10
16
P R O O F
P R O O F
Test and Troubleshooting
005
Troubleshooting Introduction 100
1
AG,YZ07927,2 1918NOV981/1
005
100 Visually Inspect Electrical System
2
Make the following visual electrical inspection prior to 6. After machine has been shut down for five minutes
starting the vehicle. inspect for overheated parts.
1. Look for bare wires that could ground a component 7. If your visual inspection does not indicate the
or short across to another component. possible malfunction, turn the key to the ON
position. Visually check out the accessory circuits,
2. Look for missing or worn conduit. indicator lights, gauge lights. Look for sparks or
smoke which might indicate a possible short.
3. Look for loose or broken connectors and wires.
8. Start machine. Check all gauges for good operation
4. Inspect batteries for: and check to see if system is charging or
discharging.
Corroded terminals
Loose terminals or battery posts Many electrical failures cannot be detected even if the
Dirty condition machine is started. Therefore, a systematic and
Damp condition complete inspection of the electrical system is
necessary.
5. Check alternator belt tension.
DPSG,YZ07927,187 1915MAR991/1
P R O O F
005
General Troubleshooting Tips 100
3
1. Troubleshoot with the vehicle engine off. 7. If using the vehicle frame as a ground reference
during electrical measurements, make certain that it
2. During the troubleshooting process, be sure to is in fact ground. If in doubt, use the negative
check the integrity of all connector pins. Replace or battery terminal.
repair any broken or damaged pins as needed.
8. Whenever checking a device (switch, etc.) remotely
3. Check for damaged connectors. through a wire harness, dont forget to rule out the
possibility that the problem is in the wiring rather
4. Verify that wires are connected to the correct than the device being tested.
harness or device pins.
Assumptions:
5. When troubleshooting at a connector with many
pins, take special care to correctly identify and 1. Correct battery voltage is available to the TVP
accurately probe the pins of interest. Probing the module (except for Code 60-low supply voltage).
correct pins is crucial to solving the problem. Look
for wire labels on wiring harness. 2. Only single-point failures are considered.
6. When using the multimeter, take care not to 3. An application-specific wiring diagram is available
damage female terminals by forcing in a probe, for reference.
especially one with a diameter larger than the
terminals are designed for. This can lead to open 4. If a short to GND caused a fuse to blow, the TCU
circuits or bad connections after the troubleshooting would not be operational. Troubleshooting would
process is completed. have to proceed without the added benefit of
diagnostic codes.
IMPORTANT: Always use the correct terminals
when making repairs or
replacements.
P R O O F
DPSG,YZ07927,188 1915MAR991/1
005
100 Troubleshooting The Gear Selector
4
NOTE: (This procedure applies only to FUNK 12V 3. Check integrity and cleanliness of the terminal pins
gear selector p/n YZ102155 and 24V gear on both the harness and the gear selector. Check
selector p/n YZ102827) gear selector pins to insure that the connector pins
have not been pushed up into the connector.
Several of the diagnostic codes involve signals that
come from the gear selector. With this simple list of 4. Connect the black multimeter lead to the black
tests, it can be checked out in just a few minutes. The common jack on the multimeter.
only tool required is a multimeter.
5. Connect the red multimeter lead to the red
1. Turn the ignition to the "OFF" position. volts/ohms "V-ohms" jack on the multimeter.
2. Remove the round J4 connector from the bottom of 6. Proceed with the tests in Table A:
the gear selector. (Testing will go even faster if the Troubleshooting the Gear Selector, taking careful
gear selector is removed from its mounting point, note of the pin letter designations on the connector.
since the connector pins are more easily accessible
when the gear selector is completely detached from
the vehicle.)
005
100
5
UN23SEP98
YZ1805
J4 Gear Selector Pinout
G J1-J1 FORWARD
H J1-A2 Ground
J S1-A Neutral start
005
100 Table A: Troubleshooting the Gear Selector
6
To Check Multimeter Mode Multimeter Gear Selector Expected Reading Faulty Gear
Connections Position for Good Gear Selector Reading
Selector
*NEUTRAL relay coil Diode check Black lead on pin A Neutral 0.4 to 0.7 V Open circuit ("OL")
diode Red lead on pin H or short circuit (0 V)
*NOT NEUTRAL Diode check Same as previous Not neutral 0.4 to 0.7 V Open circuit ("OL") or
relay coil diode step. short circuit (0 V)
*NOT NEUTRAL Resistance Same as previous Not neutral 12V: 640 to 800 Infinite resistance
relay coil step. ohms (open circuit)
24V: 2600 to 3180
ohms
*NEUTRAL relay coil Resistance Same as previous Neutral 12V: 640 to 800 Infinite resistance
step. ohms (open circuit)
24V: 2600 to 3180
ohms
DOWNSHIFT switch Resistance or Black lead on pin A Downshift Less than 2 ohms, More than 2 ohms,
audible continuity Red lead on pin D or "beep." or no "beep."
Resistance or Black lead on pin A Not downshift More than 2 ohms, Less than 2 ohms, or
DOWNSHIFT switch
audible continuity Red lead on pin D or no "beep." "beep."
UPSHIFT switch Resistance or Black lead on pin A Upshift Less than 2 ohms, More than 2 ohms,
audible continuity Red lead on pin E or "beep." or no "beep."
Resistance or Black lead on pin A Not upshift More than 2 ohms, Less than 2 ohms, or
UPSHIFT switch
audible continuity Red lead on pin E or no "beep." "beep."
REVERSE switch Resistance or Black lead on pin A Reverse Less than 2 ohms, More than 2 ohms,
audible continuity Red lead on pin F or "beep." or no "beep."
REVERSE switch Resistance or Black lead on pin A Not reverse More than 2 ohms, Less than 2 ohms, or
audible continuity Red lead on pin F or no "beep." "beep."
FORWARD switch Resistance or Black lead on pin A Forward Less than 2 ohms, More than 2 ohms,
audible continuity Red lead on pin G or "beep." or no "beep."
Resistance or Black lead on pin A Not forward More than 2 ohms, Less than 2 ohms, or
P R O O F
FORWARD switch
audible continuity Red lead on pin G or no "beep." "beep."
*NOT NEUTRAL Diode check Black lead on pin B Any 0.4 to 0.7 V Open circuit ("OL") or
diode Red lead on pin H short circuit (0 V)
*NEUTRAL diode Diode check Black lead on pin C Any 0.4 to 0.7 V Open circuit ("OL") or
Red lead on pin H short circuit (0 V)
*All the tests in the above table were done with the without connecting system battery voltage to the gear
ignition "OFF." The gear selectors NEUTRAL and selector.
NOT NEUTRAL signal outputs cannot be checked
DPSG,YZ07927,169 1901DEC983/3
005
Troubleshooting The Gear Selector with PC Diagnostics 100
7
The Funk gear selectors can be checked using the The table below summarizes the states that should be
FGDIAG diagnostic software running on a laptop PC. observed for each gear selector position. A blank entry
in the table represents an OFF signal state.
1. Connect the diagnostic cable between the PCs
serial port and 3-pin harness diagnostic connector If one or more of the signal states is not correct for a
S6. particular gear selector position, the diagnostics
2. Turn the ignition to the ON position, but do not software should provide an indication, and the gear
start the engine. This is to ensure that system selector may be faulty. In this case, replace it with a
battery voltage is supplied to the gear selector. known good selector if one is available.
3. Start the diagnostic software.
4. Select menu item 2, Display input & output status. IMPORTANT: If gear selector handle is moved too
5. Select 1 to view the present state of each of the slowly between neutral and forward
TCUs digital inputs. The TCU pins are labeled, and positions or between neutral and
next to each pin is an ON or OFF indication. reverse, a false diagnostic code may
ON means the TCU is seeing system battery occur. This is not an indication that
voltage on that pin. OFF means the TCU is seeing the gear selector is faulty. Handle
zero volts. movement must be crisp.
NOT J2-A2 ON - ON ON ON - - ON ON
NEUTRAL
DPSG,YZ07927,180 1911FEB991/1
005
100 YZ102710 RS-232 Diagnostic Cable and J1939 Adapter
8
UN08JUN04
YZ5181
P R O O F
AConnect to Serial Port on BStandard DB-9 Connector, C3-Pin Weather Pack Tower, DW/P Tower 1201 5792,
Laptop PC Female Terminals Female Terminals Terminals 1208 9188, Seals
1201 5323
YZ07927,0000307 1908JUN041/1
005
Troubleshooting The Inching Pedal System 100
9
NOTE: (This procedure written for FUNK pedal, p/n 5. Check integrity of pins on TCU, inching pedal, and
YZ103310) harness mating connectors. Repair or replace any
pins that are bent, missing, or damaged.
If laptop diagnostic capability is available, inching
pedal function and the operation of the BOC and TOC Three requirements must be met for proper inching
(if present) switches can be quickly verified. pedal operation:
If laptop diagnostics are not available, this procedure 1. All signal lines between the TCU and the pedal
may be used. must be intact and wired correctly, with no short or
open circuits.
With this list of tests, the inching pedal system can be
checked out in just a few minutes. The only tools 2. The inching pedal must be working properly.
required are a multimeter and a 1/4" nut driver.
3. The TCU must supply the correct voltage to the
1. Turn the ignition to the "OFF" position. inching pedal.
2. Remove the inching pedal mounting bolts. To check that these requirements are met, perform
each test listed in the tables below. Each table
3. At the pedal, disconnect the wiring harness from addresses one of the three requirements listed above.
the inching pedal. If any test fails, replace or repair wire or part (TCU or
pedal) as necessary.
4. At the TCU, disconnect connector J1.
P R O O F
005
100
10
UN17FEB99
YZ1813
Inching Pedal Connector
Table A: Check Integrity of Signal Lines Between TCU and Inching Pedal
To Check Multimeter Mode Multimeter Connections Expected Reading for Good
Pedal
Continuity of inching pedal "HI" Resistance or audio continuity One lead on harness pin J1-F2, Less than 10 ohms, or "beep."
reference voltage line other lead on pedals mating
harness pin C.
Continuity of inching pedal signal Resistance or audio continuity One lead on harness pin J1-F3, Less than 10 ohms, or "beep."
line other lead on pedals mating
harness pin A.
Continuity of inching pedal "LO" Resistance or audio continuity One lead on harness pin J1-G1, Less than 10 ohms, or "beep."
reference voltage line other lead on pedals mating
harness pin B.
Continuity of "NOT BOC" signal Resistance or audio continuity One lead on harness pin J1-K2, Less than 10 ohms, or "beep."
line other lead on pedals mating
harness pin E.
Continuity of system battery Resistance or audio continuity One lead on harness pin J2-F2, Less than 10 ohms, or "beep."
voltage supply line other lead on pedals mating
harness pin F.
For shorts between any two Resistance or audio continuity One lead on pedals mating Infinite resistance, or no "beep"
signal lines, or between a signal harness pin A, other lead on pin for all pin combinations.
line and ground B, then C, then E, then F, then
ground. Repeat for all other
combinations of pins and ground.
005
Table B: Verify Operation of Inching Pedal 100
11
To Check Multimeter Mode Multimeter Connections Pedal Position Expected Reading for
Good Pedal
Total potentiometer One lead on pedal pin B,
Resistance Fully up 2000 to 3000 ohms
resistance other lead on pedal pin C.
Total potentiometer One lead on pedal pin B,
Resistance Fully depressed 2000 to 3000 ohms
resistance other lead on pedal pin C.
Output variation with One lead on pedal pin A,
Resistance Fully up 150 to 450 ohms
pedal travel other lead on pedal pin B.
Output variation with One lead on pedal pin A,
Resistance Fully depressed 2000 to 3000 ohms
pedal travel other lead on pedal pin B.
Double-check output One lead on pedal pin A,
Resistance Fully up 2000 to 3000 ohms
variation with pedal travel other lead on pedal pin C.
Double-check output One lead on pedal pin A, 150 to 450
Resistance Fully depressed
variation with pedal travel other lead on pedal pin C. ohms
"BOTTOM OF CLUTCH" Resistance or audio One lead on pedal pin E,
Fully depressed Open circuit, "no beep."
switch continuity other lead on pedal pin F.
"BOTTOM OF CLUTCH" Resistance or audio One lead on pedal pin E, Less than 100 ohms, or
Not fully depressed
switch continuity other lead on pedal pin F. "beep."
DPSG,YZ07927,170 1915DEC983/3
005
100 Calibration
12
Reasons to Calibrate
When to Calibrate
AG,YZ07927,5 1910OCT981/1
005
Clutch Calibration Procedure: Four Forward Speeds and Four Reverse 100
13
For Funk analog system DF150 or DF250 Series 4. Power up the TCU by turning on the vehicle
Transmissions. ignition. The display should show "CAL".
5. Start and hold the engine speed at 1600 RPM. The
IMPORTANT: Attempting to calibrate with sump engine governor must hold the engine speed 50
temperature below minimum RPM.
calibration temperature (120F for 6. Move the gear selector to the forward position.
converter drives and 90F for most 7. During the first few seconds of the calibration
direct drives) will trigger the process, the display will show "---" while testing the
"warm-up" mode. This mode will cylinder speed and response.
show "---" on the display as the 8. At this time the clutch calibration process starts.
transmission warms to the minimum a. Directional and Speed Clutch Holds. The display
calibration temperature at which time will show C1H, C2H, C3H, C4H, CAH, and
the calibration process will CBH while acquiring the respective "hold" level
automatically begin. Temperatures of each clutch.
below 50F will result in "sump b. Directional and Speed Clutch Fills. The display
temperature too cold" diagnostic will show C1F, C2F, C3F, C4F, CAF, and CBF
code 100. while acquiring the respective "fill" level of each
clutch.
1. Bring the transmission oil temperature up to 140 to
160F (60 to 71C) for optimum calibration. 9. The display will show END when the routine is
2. With the vehicle ignition off, apply the park brake. finished. At that time move the gear selector back
3. Plug a jumper plug (which connects pin A to pin B) to the neutral position.
in the calibration connector (S16) on the vehicle 10. Shut the vehicles ignition OFF, which will power
harness. down the TCU.
11. Remove the jumper plug from the calibration
IMPORTANT: Any diagnostics code that appear connector (S16).
during calibration will cause the
procedure to terminate, and you will The calibration is complete.
P R O O F
AG,YZ07927,6 1910OCT981/1
005
100 Clutch Calibration Procedure: Eight Forward Speeds And Four Reverse
14
For Funk analog system DF150 or DF250 Series 4. Power up the TCU by turning on the vehicle
Transmissions. ignition. The display should show "CAL".
5. Start and hold the engine speed at 1600 RPM. The
IMPORTANT: Attempting to calibrate with sump engine governor must hold the engine speed 50
temperature below minimum RPM.
calibration temperature (120F for 6. Move the gear selector to the forward position.
converter drives and 90F for most 7. During the first few seconds of the calibration
direct drives) will trigger the process, the display will show "---" while testing the
"warm-up" mode. This mode will cylinder speed and response.
show "---" on the display as the 8. At this time the clutch calibration process starts.
transmission warms to the minimum a. Directional and Speed Clutch Holds. The display
calibration temperature at which time will show C1H, C2H, C3H, CAH, CBH, CCH
the calibration process will and CDH while acquiring the respective "hold"
automatically begin. Temperatures level of each clutch.
below 50F will result in "sump b. Directional and Speed Clutch Fills. The display
temperature too cold" diagnostic will show C1F, C2F, C3F, CAF, CBF, CCF and
code 100. CDF while acquiring the respective "fill" level of
each clutch.
1. Bring the transmission oil temperature up to 140 to
160F (60 to 71C) for optimum calibration. 9. The display will show END when the routine is
2. With the vehicle ignition off, apply the park brake. finished. At that time move the gear selector back
3. Plug a jumper plug (which connects pin A to pin B) to the Neutral position.
in the calibration connector (S16) on the vehicle 10. Shut the vehicles ignition OFF, which will power
harness. down the TCU.
11. Remove the jumper plug from the calibration
IMPORTANT: Any diagnostics code that appear connector (S16).
during calibration will cause the
procedure to terminate, and you will The calibration is complete.
P R O O F
AG,YZ07927,7 1912OCT981/1
P R O O F
TCU and Accessories
005
System Components 105
1
AG,YZ07927,8 1912OCT981/1
P R O O F
005
105 Transmission Control Unit (TCU)
2
FUNCTION
UN08AUG98
The TCU is the "brain" of the system. It is responsible for
the logic, computation, and decision-making processes of
the transmission based on calculations. TCU operation is
determined by software programmed into the TCUs
YZ1576
memory. This software is tailored to meet the
requirements of the vehicle manufacturer, and is based on
a vehicle performance analysis. It is application specific; Transmission Control Unit
therefore TCUs from different types of vehicles are not
interchangeable. TCUs can only be interchanged on
vehicles which are identical in all ways (same
engine/drivetrain combination, wiring, gear selector,
vehicle voltage, etc.)
MOUNTING
AG,YZ07927,9 1912OCT981/1
005
TCU Mounting, Grounding, and Enviromental 105
3
Considerations
Location
Orientation
YZ07927,0000306 1902JUN041/4
UN08JUN04
YZ5179
005
105 Under no circumstances should the TCU be mounted
4
with the connectors pointing up and down (vertical).
Examples of non-recommended mounting orientations
are shown in the photograph:
UN08JUN04
NOTE: Vertical mounting moisture can collect around or
wick toward connectors. Vertical mounting
YZ5180
moisture can follow harness to connector.
Moisture
Welding
005
Grounding 105
5
YZ07927,0000306 1902JUN044/4
P R O O F
005
105 J1 Connector
6
UN09SEP98
YZ1589
J1 and Mating Connector
005
CONNECTOR PINOUT 105
7
J1 CONECTOR PIN DESCRIPTION
A1 Main battery 1 (TCU Power, +12/24V)
A2 Ground 1
A3 Output speed magnetic pickup sensor input (frequency input)
B1 Engine speed magnetic pickup sensor input (frequency input)
B2 Cylinder speed magnetic pickup sensor input (frequency input)
B3 Spare magnetic pickup sensor input (frequency input)
C1 Fuel Flow (input)
C2 MPU sensor ground
C3 Temperature sensor (analog voltage input)
D1 Temperature sensor ground
D2 Rear-steer HI (voltage reference output)
D3 Rear-steer position (analog voltage input)
E1 Rear-steer LO (voltage reference output)
E2 Load sense HI (voltage reference output)
E3 Load sense (analog voltage input)
F1 Load sense LO (voltage reference output)
F2 Inching pedal HI (voltage reference output)
F3 Inching pedal position (analog voltage input)
G1 Inching pedal LO (voltage reference output)
G2 Spare ground
G3 Spare ground
H1 Magnetic pickup sensor shield
H2 UPSHIFT (shift code E), (digital input)
H3 DOWNSHIFT (shift code D), (digital input)
P R O O F
NOTE: Connector pinouts reference the wiring vehicle manufacturers wiring harness diagram
harness diagram in this group. Reference the for your application.
AG,YZ07927,21 1913OCT982/2
005
105 J2 Connector
8
UN10AUG98
YZ1590
J2 and Mating Connector
P R O O F
005
CONNECTOR PINOUT 105
9
J2 CONNECTOR PIN DESCRIPTION
A1 NEUTRAL (digital input)
A2 NOT NEUTRAL (shift code B), (digital input)
A3 Brake cutoff (shift code C), (digital input)
B1 Program (shift code A), (digital input)
B2 Start (digital input)
B3 Park or park brake pressure (digital input)
C1 Auto / manual mode select (digital input)
C2 Calibrate (digital input)
C3 Disconnect (digital input)
D1 CAN HI (communication input/output)
D2 CAN LO (communication input/output)
D3 RS232 TxD (serial communication output)
E1 RS232 RxD (serial communication input)
E2 CCD Bus+ (gear/diagnostic indicator communication input/output)
E3 CCD Bus- (gear/diagnostic indicator communication input/output)
F1 Bus ground for communication lines
F2 +12/24 supply voltage output (supply voltage output)
F3 +12/24 supply voltage output (supply voltage output)
NOTE: Connector pinouts reference the wiring vehicle manufacturers wiring harness diagram
harness diagram in this group. Reference the for your application.
P R O O F
AG,YZ07927,22 1914OCT982/2
005
105 J3 Connector
10
UN11AUG98
YZ1591
J3 and Mating Connector
005
CONNECTOR PINOUT 105
11
J3 CONNECTOR PIN DESCRIPTION
A1 Main battery 2 (TCU power +12/24V)
A2 Ground 2
A3 Solenoid 1 (PWM output)
B1 Solenoid 1 return (current sense input)
B2 Solenoid 2 (PWM output)
B3 Solenoid 2 return (current sense input)
C1 Solenoid 3 (PWM output)
C2 Solenoid 3 return (current sense input)
C3 Solenoid 4 (PWM output)
D1 Solenoid 4 return (curent sense input)
D2 Solenoid A (PWM output)
D3 Solenoid A return (current sense input)
E1 Solenoid B (PWM output)
E2 Solenoid B return (current sense input)
E3 Solenoid C (PWM output)
F1 Solenoid C return (current sense input)
F2 Solenoid D (PWM output)
F3 Solenoid D return (current sense input)
G1 Driver 9 (PWM output)
G2 Driver 9 return (current sense input)
G3 Torque converter lock-up solenoid (PWM output)
H1 Torque converter lock-up solenoid return (current sense input)
H2 Disconnect solenoid (PWM output)
H3 Disconnect solenoid return (current sense input)
P R O O F
NOTE: Connector pinouts reference the wiring vehicle manufacturers wiring harness diagram
harness diagram in this group. Reference the for your application.
AG,YZ07927,21CONV1 1913OCT982/2
005
105 Gear/diagnostic Indicator
12
CONNECTOR PINOUT
UN30JUN98
YZ1574
Gear/Diagnostic Indicator
AG,YZ07927,16 1912OCT981/1
P R O O F
005
Electronic Gear Selector 105
13
UN30JUN98
release ring under the handle knob must be pulled up to
release the neutral lock.
YZ1572
"bumped" to the right to request an upshift or to the left to
request a downshift.
Electronic Gear Selector
005
105
14
UN12FEB99
YZ1501A
Gear Selector Shift Pattern
AG,YZ07927,14 1912OCT982/2
P R O O F
005
J4 Connector 105
15
UN23SEP98
YZ1805
J4 Gear Selector Pinout
F J1-J2 REVERSE
G J1-J1 FORWARD
H J1-A2 Ground
J S1-A Neutral start
AG,YZ07927,23 1914OCT981/1
005
105 Inching Pedal (Application Dependent)
16
UN30JUN98
CONNECTOR PINOUT
YZ1575
Inching Pedal
005
There is no connection to inching pedal pin D (pin T11-D). 105
17
AG,YZ07927,18 1913OCT982/3
P R O O F
UN16MAR99
YZ1594
Inching Pedal
AG,YZ07927,18 1913OCT983/3
005
105 Engine Speed Magnetic Pickup Sensor
18
UN01JUL98
Input RPM is calculated by pulses per minute divided by
the number of teeth on the input gear.
YZ1577
Engine Speed Magnetic Pickup Sensor
AG,YZ07927,11 1912OCT981/2
YZ1809 UN11FEB99
CONNECTOR PINOUT
Sensor Connector
P R O O F
AG,YZ07927,11 1912OCT982/2
005
Cylinder Speed Magnetic Pickup Sensor 105
19
UN09FEB99
Cylinder RPM is calculated by pulses per minute divided
by the number of teeth on the cylinder gear.
YZ1734A
Cylinder Speed Magnetic Pickup Sensor
AG,YZ07927,12 1912OCT981/2
YZ1809 UN11FEB99
CONNECTOR PINOUT
Sensor Connector
P R O O F
AG,YZ07927,12 1912OCT982/2
005
105 Output Speed Magnetic Pickup Sensor
20
UN10FEB99
stage pinion which drives the output gear.
YZ1733A
Output Speed Magnetic Pickup Sensor
AG,YZ07927,13 1912OCT981/2
YZ1809 UN11FEB99
CONNECTOR PINOUT
Sensor Connector
P R O O F
AG,YZ07927,13 1912OCT982/2
005
Park Brake Pressure Switch 105
21
UN23FEB99
YZ1810
Park Brake Pressure Switch
DPSG,YZ07927,181 1911FEB991/2
YZ1809 UN11FEB99
CONNECTOR PINOUT
Sensor Connector
P R O O F
DPSG,YZ07927,181 1911FEB992/2
005
105 Temperature Sensor
22
UN06NOV98
YZ1808
Temperature Sensor
AG,YZ07927,15 1912OCT981/2
YZ1809 UN11FEB99
CONNECTOR PINOUT
Sensor Connector
P R O O F
AG,YZ07927,15 1912OCT982/2
005
Function Of Proportional Valves 105
23
UN16FEB99
Proportional valves differ from on/off valves in that the
spool is not just fully on or off, but may also be controlled
to an intermediate position using a solenoid capable of
generating a variable force. The proportional valve is pilot
YZ1811
operated. The pilot section is the part of the valve that
forces the spool open against the spring. It is a chamber
Proportional Valve
within which the spool moves like a hydraulic cylinder.
There are two openings in the chamber; one is an inlet
from system pressure, the other is an outlet. The outlet
opening may be shut off by a small poppet that is
normally held away from the opening by fluid exiting the
chamber. The poppet is forced shut against the outlet by
the solenoid, increasing pilot pressure and forcing the
valve spool against the spring and bringing the valve on.
As the spool moves against the spring, the clutch is
increasingly open to system pressure and less open to
sump. The pressure forces the clutch piston against the
friction plates, engaging the clutch.
AG,YZ07927,28 1914OCT981/1
005
105 Proportional Valve Pinouts
24
SIGNAL DESCRIPTION TRANSMISSION CONNECTOR PIN TCU PIN
SOLENOID 1 J6-2 J3-A3
SOLENOID 1 RETURN J6-1 J3-B1
SOLENOID 2 J6-3 J3-B2
SOLENOID 2 RETURN J6-15 J3-B3
SOLENOID 3 J6-4 J3-C1
SOLENOID 3 RETURN J6-19 J3-C2
SOLENOID 4 J6-5 J3-C3
SOLENOID 4 RETURN J6-6 J3-D1
SOLENOID A J6-10 J3-D2
SOLENOID A RETURN J6-17 J3-D3
SOLENOID B J6-12 J3-E1
SOLENOID B RETURN J6-11 J3-E2
SOLENOID C J6-23 J3-E3
SOLENOID C RETURN J6-22 J3-F1
SOLENOID D J6-8 J3-F2
SOLENOID D RETURN J6-7 J3-F3
AG,YZ07927,29 1914OCT981/1
P R O O F
005
Solenoid/Gear Combinations 105
25
UN04MAR99
YZ734B
Solenoids and Valve Port Locations
P R O O F
005
105 DF Series Transmission Four Speeds Forward and Four Reverse
26
GEAR ENGAGED ACTIVE SOLENOIDS
F 4th 2 and B
F 3rd 1 and B
F 2nd 2 and A
F 1st 1 and A
Neutral
R 1st 3 and A
R 2nd 4 and A
R 3rd 3 and B
R 4th 4 and B
DPSG,YZ07927,174 1928JAN992/2
P R O O F
005
105
27
P R O O F
005
105 Transient Voltage Protection Module
28
UN30JUN98
YZ1573
Transient Voltage Protection (TVP) Module
005
105
29
UN08JUN04
YZ5182
IMPORTANT: A and B are tied together inside the D1, D2 = 1N4005 diode rectifier
TVP. C and D are tied together inside D3 = Sussex zener diode (John Deere P/N
the TVP. RE10019)
K1 = Fairchild ND012/01CS relay (John Deere P/N
The schematic for the 12V TVP Module, John Deere R91911B)
P/N RE30711.
AG,YZ07927,20 1913OCT982/3
P R O O F
UN09JUN04
YZ5183
The schematic for the 24V TVP Module, Funk P/N D3 = PRZ95T060 zener diode
YZ102080. K1 = Fairchild 57ND24-N relay
AG,YZ07927,20 1913OCT983/3
005
105 Transmission Wiring Harness 1 of 4
30
AG,YZ07927,25 1914OCT981/2
P R O O F
UN19SEP98
YZ1596
Part 1 of 4
AG,YZ07927,25 1914OCT982/2
005
Transmission Wiring Harness 2 of 4 (continued) 105
31
P R O O F
UN04MAR99
YZ1597
Part 2 of 4
AG,YZ07927,25CONV1 1914OCT981/1
005
105 Transmission Wiring Harness 3 of 4 (continued)
32
P R O O F
UN04MAR99
YZ1598
Part 3 of 4
AG,YZ07927,26 1914OCT981/1
005
Transmission Wiring Harness 4 of 4 (continued) 105
33
UN30MAR99
P R O O F
YZ1599
Part 4 of 4
AG,YZ07927,27 1914OCT981/1
005
105 J6 Connector
34
UN24SEP98
YZ1806
J6 Connector Pinout
005
NOTE: The J6 connector is located on the 105
35
transmission.
CONNECTOR PINOUT
J6 CONNECTOR PIN TCU PIN DESCRIPTION
1 J3-B1 Solenoid 1 return
2 J3-A3 Solenoid 1 output
3 J3-B2 Solenoid 2 output
4 J3-C1 Solenoid 3 output
5 J3-C3 Solenoid 4 output
6 J3-D1 Solenoid 4 return
7 J3-F3 Solenoid D return
8 J3-F2 Solenoid D output
9 J1-B2 Cylinder speed MPU input
10 J3-D2 Solenoid A output
11 J3-E2 Solenoid B return
12 J3-E1 Solenoid B output
13 J3-H2 Disconnect solenoid output
14 J3-G3 Torque converter lockup solenoid output
15 J3-B3 Solenoid 2 return
16 J1-G3 Cylinder speed MPU sensor ground
17 J3-D3 Solenoid A return
18 J1-A3 Output speed MPU input
19 J3-C2 Solenoid 3 return
20 J1-A1 Main battery 1 (TCU power, +12/24V)
21 J2-B3 Park brake pressure switch input
P R O O F
AG,YZ07927,24 1914OCT982/2
005
105
36
P R O O F
P R O O F
Diagnostic Codes
005
System Diagnostics Codes 110
1
The TCU provides troubleshooting assistance in the causing the diagnostics code
form of diagnostic codes. prevents the TCU from detecting a
legal neutral condition. After a
Diagnostic codes may appear due to a number of neutral recovery, the shift lever may
causes, including: be placed back into a legal forward
or reverse position. If the condition
Pinched or broken wiring causing the diagnostics code still
Shorted or open solenoids exists, the diagnostics code will
Bad connections again be detected and displayed.
Shorted wiring (to either ground or vehicle voltage)
Invalid signal combinations from the gear selector. The TCU retains the last eight non-repeating
Magnetic pickup sensor failures diagnostics codes in nonvolatile memory in the order in
which they have occurred. These codes are available
IMPORTANT: All diagnostics codes are neutral for future retrieval, except in the earliest-model TCUs.
recoverable, unless the condition
AG,YZ07927,30 1914OCT981/1
005
110 Diagnostic Codes in Summary Form
2
Codes Description
20 Solenoid 1, low or no current
21 Solenoid 2, low or no current
22 Solenoid 3, low or no current
23 Solenoid 4, low or no current
24 Solenoid A, low or no current
25 Solenoid B, low or no current
26 Solenoid C, low or no current
27 Solenoid D, low or no current
28 Driver 9, low or no current
29 TCLU Solenoid, low or no current
30 Solenoid 1, current too high
31 Solenoid 2, current too high
32 Solenoid 3, current too high
33 Solenoid 4, current too high
34 Solenoid A, current too high
35 Solenoid B, current too high
36 Solenoid C, current too high
37 Solenoid D, current too high
38 Driver 9, current too high
39 TCLU solenoid, current too high
40 Undefined shift request
41 No NEUTRAL signal since power-up
42 BOC signal passive
43 NOT PARK, PARK PRESSURE simultaneously passive
P R O O F
005
Diagnostic Codes in Summary Form 110
3
Codes Description
86 TOC active, BOC passive
87 PARK and FORWARD simultaneously active
88 PARK and REVERSE simultaneously active
89 NOT PARK, PARK simultaneously passive
90 NOT PARK, PARK simultaneously active
91 Seat switch signal and NEUTRAL simultaneously passive
92 Engine speed approaching engine warranty maximum
93 Engine speed too high for neutral-to-gear engagement
98 WHEELS-UP and WHEELS-DOWN inputs simultaneously active
99 Wheels mode change attempted when not in neutral
100 Sump temperature too low for calibration
101 Engine speed too high for calibration
102 Engine speed too low for calibration
103 Output speed detected during calibration
104 No cylinder speed detected during calibration
105 Forward cylinder speed ratio incorrect
106 Reverse cylinder speed ratio incorrect
107 Cylinder speed will not drop below the start count speed
108 Holding clutch pressure exceeds 90 psi
109 Clutch 1 fast fill time exceeds 300 ms
110 Clutch 2 fast fill time exceeds 300 ms
111 Clutch 3 fast fill time exceeds 300 ms
112 Clutch 4 fast fill time exceeds 300 ms
113 Clutch A fast fill time exceeds 300 ms
P R O O F
005
110 Diagnostic Codes in Summary Form
4
Codes Description
172 Group two enable signal active; should be passive
173 Group three enable signal active; should be passive
175 Solenoid driver 11, low or no current
176 Solenoid driver 12, low or no current
177 Solenoid driver 13, low or no current
178 Solenoid driver 11, current too high
179 Solenoid driver 12, current too high
180 Solenoid driver 13, current too high
198 CCD communications link failure between master and slave TCUs
199 Non-functional base TCU
DPSG,YZ07927,189 1930MAR994/4
P R O O F
005
Code 20 110
5
Symptom Problem Solution
005
110 Symptom Problem Solution
6
3. Resistance should be
P R O O F
AG,YZ07927,35 1915OCT982/2
005
Code 21 110
7
Symptom Problem Solution
005
110 Symptom Problem Solution
8
3. Resistance should be
P R O O F
AG,YZ07927,36 1915OCT982/2
005
Code 22 110
9
Symptom Problem Solution
005
110 Symptom Problem Solution
10
3. Resistance should be
P R O O F
AG,YZ07927,40 1916OCT982/2
005
Code 23 110
11
Symptom Problem Solution
005
110 Symptom Problem Solution
12
3. Resistance should be
P R O O F
AG,YZ07927,44 1916OCT982/2
005
Code 24 110
13
Symptom Problem Solution
005
110 Symptom Problem Solution
14
3. Resistance should be
P R O O F
AG,YZ07927,46 1916OCT982/2
005
Code 25 110
15
Symptom Problem Solution
005
110 Symptom Problem Solution
16
3. Resistance should be
P R O O F
AG,YZ07927,47 1916OCT982/2
005
Code 26 110
17
Symptom Problem Solution
005
110 Symptom Problem Solution
18
3. Resistance should be
P R O O F
AG,YZ07927,49 1916OCT982/2
005
Code 27 110
19
Symptom Problem Solution
005
110 Symptom Problem Solution
20
3. Resistance should be
P R O O F
AG,YZ07927,51 1916OCT982/2
005
Code 28 110
21
Symptom Problem Solution
005
110 Symptom Problem Solution
22
3. Resistance should be
P R O O F
AG,YZ07927,52 1916OCT982/2
005
Code 29 110
23
Symptom Problem Solution
005
110 Symptom Problem Solution
24
3. Resistance should be
P R O O F
AG,YZ07927,54 1916OCT982/2
005
110
25
P R O O F
005
110 Code 30
26
Symptom Problem Solution
Solenoid 1 cannot drop to Short circuit in solenoid, or solenoid 1. Disconnect solenoid from harness.
requested current. has low resistance.
2. Measure solenoid resistance.
-
3. Resistance should be
There is a problem in the pin approximately 10 ohms for a 12V
J3-A3 (output) to pin J3-B1 system (may range from 7 to 14
(return) circuit path. ohms depending on solenoid
temperature), and approximately 40
ohms for a 24V system (may range
from 30 to 65 ohms depending on
solenoid temperature).
AG,YZ07927,55 1916OCT981/1
005
Code 30 (Continued) 110
27
Symptom Problem Solution
Solenoid 1 cannot drop to Short circuit in wiring to solenoid. 1. Disconnect connector J3 from the
requested current. (Output line shorted to return line in TCU.
harness.)
- 2. Disconnect solenoid from harness.
pin J3-B1.
YZ07927,00000B9 1930APR031/1
005
110 Code 31
28
Symptom Problem Solution
Solenoid 2 cannot drop to Short circuit in solenoid, or solenoid 1. Disconnect solenoid from harness.
requested current. has low resistance.
2. Measure solenoid resistance.
-
3. Resistance should be
There is a problem in the pin approximately 10 ohms for a 12V
J3-B2 (output) to pin J3-B3 system (may range from 7 to 14
(return) circuit path. ohms depending on solenoid
temperature), and approximately 40
ohms for a 24V system (may range
from 30 to 65 ohms depending on
solenoid temperature).
AG,YZ07927,56 1916OCT981/1
005
Code 31 (Continued) 110
29
Symptom Problem Solution
Solenoid 2 cannot drop to Short circuit in wiring to solenoid. 1. Disconnect connector J3 from the
requested current. (Output line shorted to return line in TCU.
harness)
- 2. Disconnect solenoid from harness.
pin J3-B3.
YZ07927,00000BA 1930APR031/1
005
110 Code 32
30
Symptom Problem Solution
Solenoid 3 cannot drop to Short circuit in solenoid, or solenoid 1. Disconnect solenoid from harness.
requested current. has low resistance.
2. Measure solenoid resistance.
-
3. Resistance should be
There is a problem in the pin approximately 10 ohms for a 12V
J3-C1 (output) to pin J3-C2 system (may range from 7 to 14
(return) circuit path. ohms depending on solenoid
temperature), and approximately 40
ohms for a 24V system (may range
from 30 to 65 ohms depending on
solenoid temperature).
AG,YZ07927,57 1916OCT981/1
005
Code 32 (Continued) 110
31
Symptom Problem Solution
Solenoid 3 cannot drop to Short circuit in wiring to solenoid. 1. Disconnect connector J3 from the
requested current. (Output line shorted to return line in TCU.
harness.)
- 2. Disconnect solenoid from harness.
pin J3-C2.
YZ07927,00000BB 1930APR031/1
005
110 Code 33
32
Symptom Problem Solution
Solenoid 4 cannot drop to Short circuit in solenoid, or solenoid 1. Disconnect solenoid from harness.
requested current. has low resistance.
2. Measure solenoid resistance.
-
3. Resistance should be
There is a problem in the pin approximately 10 ohms for a 12V
J3-C3 (output) to pin J3-D1 system (may range from 7 to 14
(return) circuit path. ohms depending on solenoid
temperature), and approximately 40
ohms for a 24V system (may range
from 30 to 65 ohms depending on
solenoid temperature).
AG,YZ07927,58 1916OCT981/1
005
Code 33 (Continued) 110
33
Symptom Problem Solution
Solenoid 4 cannot drop to Short circuit in wiring to solenoid. 1. Disconnect connector J3 from the
requested current. (Output line shorted to return line in TCU.
harness.)
- 2. Disconnect solenoid from harness.
pin J3-D1.
YZ07927,00000BC 1930APR031/1
005
110 Code 34
34
Symptom Problem Solution
Solenoid A cannot drop to Short circuit in solenoid, or solenoid 1. Disconnect solenoid from harness.
requested current. has low resistance.
2. Measure solenoid resistance.
-
3. Resistance should be
There is a problem in the pin approximately 10 ohms for a 12V
J3-D2 (output) to pin J3-D3 system (may range from 7 to 14
(return) circuit path. ohms depending on solenoid
temperature), and approximately 40
ohms for a 24V system (may range
from 30 to 65 ohms depending on
solenoid temperature).
AG,YZ07927,59 1919OCT981/1
005
Code 34 (Continued) 110
35
Symptom Problem Solution
Solenoid A cannot drop to Short circuit in wiring to solenoid. 1. Disconnect connector J3 from the
requested current. (Output line shorted to return line in TCU.
harness.)
- 2. Disconnect solenoid from harness.
pin J3-D3.
YZ07927,00000BD 1930APR031/1
005
110 Code 35
36
Symptom Problem Solution
Solenoid B cannot drop to Short circuit in solenoid, or solenoid 1. Disconnect solenoid from harness.
requested current. has low resistance.
2. Measure solenoid resistance.
-
3. Resistance should be
There is a problem in the pin approximately 10 ohms for a 12V
J3-E1 (output) to pin J3-E2 system (may range from 7 to 14
(return) circuit path. ohms depending on solenoid
temperature), and approximately 40
ohms for a 24V system (may range
from 30 to 65 ohms depending on
solenoid temperature).
AG,YZ07927,60 1919OCT981/1
005
Code 35 (Continued) 110
37
Symptom Problem Solution
Solenoid B cannot drop to Short circuit in wiring to solenoid. 1. Disconnect connector J3 from the
requested current. (Output line shorted to return line in TCU.
harness.)
- 2. Disconnect solenoid from harness.
pin J3-E2.
YZ07927,00000BE 1930APR031/1
005
110 Code 36
38
Symptom Problem Solution
Solenoid C cannot drop to Short circuit in solenoid, or solenoid 1. Disconnect solenoid from harness.
requested current. has low resistance.
2. Measure solenoid resistance.
-
3. Resistance should be
There is a problem in the pin approximately 10 ohms for a 12V
J3-E3 (output) to pin J3-F1 system (may range from 7 to 14
(return) circuit path. ohms depending on solenoid
temperature), and approximately 40
ohms for a 24V system (may range
from 30 to 65 ohms depending on
solenoid temperature).
AG,YZ07927,61 1919OCT981/1
005
Code 36 (Continued) 110
39
Symptom Problem Solution
Solenoid C cannot drop to Short circuit in wiring to solenoid. 1. Disconnect connector J3 from the
requested current. (Output line shorted to return line in TCU.
harness.)
- 2. Disconnect solenoid from harness.
pin J3-F1.
YZ07927,00000BF 1930APR031/1
005
110 Code 37
40
Symptom Problem Solution
Solenoid D cannot drop to Short circuit in solenoid, or solenoid 1. Disconnect solenoid from harness.
requested current. has low resistance.
2. Measure solenoid resistance.
-
3. Resistance should be
There is a problem in the pin approximately 10 ohms for a 12V
J3-F2 (output) to pin J3-F3 system (may range from 7 to 14
(return) circuit path. ohms depending on solenoid
temperature), and approximately 40
ohms for a 24V system (may range
from 30 to 65 ohms depending on
solenoid temperature).
AG,YZ07927,62 1920OCT981/1
005
Code 37 (Continued) 110
41
Symptom Problem Solution
Solenoid D cannot drop to Short circuit in wiring to solenoid. 1. Disconnect connector J3 from the
requested current. (Output line shorted to return line in TCU.
harness.)
- 2. Disconnect solenoid from harness.
pin J3-F3.
YZ07927,00000C0 1930APR031/1
005
110 Code 38
42
Symptom Problem Solution
Driver 9 cannot drop to Short circuit in solenoid, or solenoid 1. Disconnect solenoid from harness.
requested current. has low resistance.
2. Measure solenoid resistance.
-
3. Resistance should be
There is a problem in the pin approximately 10 ohms for a 12V
J3-G1 (output) to pin J3-G2 system (may range from 7 to 14
(return) circuit path. ohms depending on solenoid
temperature), and approximately 40
ohms for a 24V system (may range
from 30 to 65 ohms depending on
solenoid temperature).
AG,YZ07927,63 1920OCT981/1
005
Code 38 (Continued) 110
43
Symptom Problem Solution
Driver 9 cannot drop to Short circuit in wiring to solenoid. 1. Disconnect connector J3 from the
requested current. (Output line shorted to return line in TCU.
harness.)
- 2. Disconnect solenoid from harness.
YZ07927,00000C1 1930APR031/1
005
110 Code 39
44
Symptom Problem Solution
TCLU (Torque Converter Short circuit in solenoid, or solenoid 1. Disconnect solenoid from harness.
Lock-Up) solenoid (Driver 10) has low resistance.
cannot drop to requested 2. Measure solenoid resistance.
current.
3. Resistance should be
- approximately 10 ohms for a 12V
system (may range from 7 to 14
There is a problem in the pin ohms depending on solenoid
J3-G3 (output) to pin J3-H1 temperature), and approximately 40
(return) circuit path. ohms for a 24V system (may range
from 30 to 65 ohms depending on
solenoid temperature).
AG,YZ07927,64 1920OCT981/1
005
Code 39 (Continued) 110
45
Symptom Problem Solution
TCLU (Torque Converter Short circuit in wiring to solenoid. 1. Disconnect connector J3 from the
Lock-Up) solenoid (Driver 10) (Output line shorted to return line in TCU.
cannot drop to requested harness.)
current. 2. Disconnect solenoid from harness.
YZ07927,00000C2 1930APR031/1
005
110 Code 40
46
Symptom Problem Solution
Request for an undefined shift is Internal TCU diagnostics code. 1. Turn ignition to "OFF" position.
being made.
2. Restart vehicle with gear selector
- in neutral.
AG,YZ07927,65 1920OCT981/1
P R O O F
005
Code 41 110
47
Symptom Problem Solution
No NEUTRAL signal since initial Gear selector is out of neutral Move gear selector to neutral
system power-up. position. position.
005
110 Symptom Problem Solution
48
4. If measurement indicates no
continuity, inspect and repair or
replace NEUTRAL signal line.
5. If measurement indicates
continuity, NEUTRAL signal line is
OK.
4. If measurement indicates no
P R O O F
5. If measurement indicates
continuity, system battery voltage
line is OK.
005
Symptom Problem Solution 110
49
information refer to
TROUBLESHOOTING
THE GEAR
SELECTOR in
Group 100 (Test and
Troubleshooting).
AG,YZ07927,66 1920OCT983/3
005
110 Code 42
50
Symptom Problem Solution
BOTTOM Of CLUTCH signal is No jumper wire between BOC input 1. Visually examine TCU connector
passive. and system battery voltage. J1 and verify the presence of a wire
connected to the J1-K2 input.
-
2. If no wire is present, install one
The TCU expects the BOTTOM between J1-K2 and system battery
OF CLUTCH (BOC) input line at voltage. (TCU pins J2-F2 or J2-F3
J1-K2 to be active on are system battery voltage.)
applications which do not utilize
an inching function.
Jumper wire between BOC input and 1. Disconnect connector J1 from the
system battery voltage is open. TCU.
005
Symptom Problem Solution 110
51
Jumper wire connected to wrong 1. Trace the J1-K2 line from the
pins. TCU to its opposite end.
AG,YZ07927,67 1920OCT982/2
P R O O F
005
110 Code 43 (For applications using disc brakes)
52
Symptom Problem Solution
NOT PARK and PARK signals Faulty park switch. 1. Turn ignition to "OFF" position.
simultaneously passive at TCU.
2. Disconnect connector T9 from the
- park switch or park switch harness.
The TCU expects the J1-K1 NOT 3. Testing directly at switch pins,
PARK input and the J2-B3 PARK check for continuity between switch
input to have opposite states. pins A and B while actuating switch.
YZ07927,00003E3 1908MAR051/1
005
Code 43 (For applications using disc brakes) 110
53
Continued
Symptom Problem Solution
NOT PARK and PARK signals Open in wiring between park switch 1. Disconnect connector T9 from the
simultaneously passive at TCU. connector S9 and park switch. park switch or park switch harness.
4. If no continuity is indicated,
inspect this line for an open circuit,
and repair or replace as needed.
005
110 Symptom Problem Solution
54
4. If no continuity is indicated,
inspect this line for an open circuit,
and repair or replace as needed.
AG,YZ07927,68 1908MAR052/2
005
Code 43 (For applications using wet brakes) 110
55
Symptom Problem Solution
Possible causes for a wet brake Faulty park brake pressure switch. The park brake pressure switch is
system: normally closed; it is closed
(providing an active signal to the
TCU) when the park brake is
applied. With the park brake
disengaged, the wet brake relay is
energized, which in turn energizes
the wet brake solenoid, which then
opens the park brake pressure
switch, allowing the vehicle to move.
switch is OK.
005
110 Symptom Problem Solution
56
4. If no continuity is indicated,
inspect this line for an open circuit,
and repair or replace as needed.
4. If no continuity is indicated,
P R O O F
005
Symptom Problem Solution 110
57
4. If no continuity is indicated,
inspect this line for an open circuit,
and repair or replace as needed.
DPSG,YZ07927,172 1905JAN993/3
P R O O F
005
110 Code 44
58
Symptom Problem Solution
NOT PARK and NEUTRAL Faulty park switch. With ignition in "OFF" position,
signals simultaneously passive disconnect connector T9 from the
at TCU. park switch.
LEGAL CONDITIONS:
005
Symptom Problem Solution 110
59
005
110 Symptom Problem Solution
60
Open in NOT PARK signal line. For 1. Disconnect connector T9 from the
a disc brake system only: park switch.
4. If no continuity is indicated,
inspect this line for an open circuit,
and repair or replace as needed.
4. If no continuity is indicated,
inspect this line for an open circuit,
P R O O F
005
Symptom Problem Solution 110
61
4. If no continuity is indicated,
inspect this line for an open circuit,
and repair or replace as needed.
5. If continuity is indicated,
NEUTRAL signal line is OK.
005
110 Symptom Problem Solution
62
005
Symptom Problem Solution 110
63
TROUBLESHOOTING
THE GEAR
SELECTOR in
Group 100 (Test and
Troubleshooting).
AG,YZ07927,72 1923OCT986/6
005
110 Code 45
64
Symptom Problem Solution
PARK signal is active and Faulty park switch. For a disc brake With ignition in "OFF" position,
NEUTRAL signal is passive at system only: disconnect connector T9 from the
TCU. park switch.
LEGAL CONDITIONS:
005
Symptom Problem Solution 110
65
4. If no continuity is indicated,
inspect wire for open circuit, and
replace or repair as needed.
005
110 Symptom Problem Solution
66
3. If no continuity is indicated,
inspect wire for open circuit, and
replace or repair as needed.
Open wet brake solenoid. For a wet 1. Disconnect the wet brake solenoid
brake system only: from its harness.
005
Symptom Problem Solution 110
67
4. If no continuity is indicated,
inspect this line for an open circuit,
and repair or replace as needed.
5. If continuity is indicated,
NEUTRAL signal line is OK.
005
110 Symptom Problem Solution
68
005
Symptom Problem Solution 110
69
AG,YZ07927,73 1923OCT986/6
005
110 Code 48
70
Symptom Problem Solution
NOT PARK and PARK signals Faulty park switch. For a disc brake With ignition in "OFF" position,
simultaneously active at TCU. system only: disconnect connector T9 from the
park switch.
-
1. Check for continuity between
The TCU expects the J1-K1 NOT switch pins A and B while actuating
PARK input and the J2-B3 PARK switch.
input to have opposite states.
2. Repeat continuity check, this time
- between switch pins A and C.
Faulty park brake pressure switch. The park brake pressure switch is
For a wet brake system only: normally closed; it is closed
(providing an active signal to the
TCU) when the park brake is
applied. With the park brake
disengaged, the wet brake relay is
energized, which in turn energizes
the wet brake solenoid, which then
opens the park brake pressure
switch, allowing the vehicle to move.
005
Symptom Problem Solution 110
71
NOT PARK and PARK signal lines 1. Turn ignition to "OFF" position.
shorted together between connector
S9 and park switch. For a disc 2. Disconnect connector S9 from T9.
brake system only:
3. Check for continuity between pins
S9-B and S9-C.
005
110 Symptom Problem Solution
72
NOT PARK and PARK signal lines 1. Turn ignition to "OFF" position.
shorted together between connector
T9 and TCU. For a disc brake 2. Disconnect connector S9 from T9.
system only:
3. Disconnect connector J1 from the
TCU.
005
Symptom Problem Solution 110
73
005
110 Symptom Problem Solution
74
Faulty wet brake relay. For a wet Specific installations will vary;
brake system only: consult wiring diagram for the
application.
P R O O F
Replace relay.
Open wet brake solenoid. For a wet 1. Disconnect the wet brake solenoid
brake system only: from its harness.
005
Symptom Problem Solution 110
75
AG,YZ07927,76 1923OCT986/6
005
110 Code 49
76
Symptom Problem Solution
Signals coming from gear Faulty park brake pressure switch. The park brake pressure switch is
selector indicate park but PARK normally closed; it is closed
PRESSURE is passive at TCU. (providing an active signal to the
TCU) when the park brake is
- applied. With the park brake
disengaged, the wet brake relay is
The TCU sees a conflict; the gear energized, which in turn energizes
selector indicates park, but the the wet brake solenoid, which then
PARK PRESSURE signal input at opens the park brake pressure
J2-B3 indicates the vehicle is out switch, allowing the vehicle to move.
of park.
1. Disconnect harness from park
- brake pressure switch.
LEGAL CONDITIONS:
CAUTION: Make sure
vehicle will not roll.
1. PARK PRESSURE signal
active while gear selector is in
2. With engine off and ignition in
park position.
"ON" position, check for continuity
between the two switch pins while
2. PARK PRESSURE signal
the park brake is engaged, then
passive while gear selector is in
disengaged.
gear.
3. If continuity does not change with
-
park brake engagement and
disengagement, replace switch.
P R O O F
005
Symptom Problem Solution 110
77
4. If no continuity is indicated,
inspect this line for an open circuit,
and repair or replace as needed.
4. If no continuity is indicated,
inspect this line for an open circuit,
and repair or replace as needed.
AG,YZ07927,77 1924OCT982/2
005
110 Code 50
78
LEGAL CONDITIONS:
005
Symptom Problem Solution 110
79
UPSHIFT and DOWNSHIFT Faulty gear selector. 1. Disconnect connector J4 from the
signals are simultaneously active gear selector.
at TCU.
2. Check for continuity between pins
- J4-D (DOWNSHIFT) and J4-E
(UPSHIFT) when selector is in the
Code 50 applicable only to upshift position.
systems with a FUNK gear
selector handle. 3. Hold selector in the downshift
position and repeat continuity check.
-
4. If continuity is indicated in either
The TCU sees a conflict; it measurement, replace gear selector.
cannot instruct the transmission
to upshift and downshift at the IMPORTANT: For more
same time. During a requested information refer to
shift, it expects the UPSHIFT TROUBLESHOOTING
input at J1-H2 and the THE GEAR
DOWNSHIFT input at J1-H3 to SELECTOR in
have opposite states. Group 100 (Test and
Troubleshooting).
-
005
110 Symptom Problem Solution
80
AG,YZ07927,78 1924OCT983/3
005
Code 51 110
81
LEGAL CONDITIONS:
005
110 Symptom Problem Solution
82
FORWARD and REVERSE Faulty gear selector. 1. Disconnect connector J4 from the
signals are simultaneously active gear selector.
at TCU.
2. Check for continuity between pins
- J4-F (REVERSE) and J4-G
(FORWARD) when selector is in the
The TCU sees a conflict; it reverse position.
cannot instruct the transmission
to move forward and reverse at 3. Hold selector in the forward
the same time. While the vehicle position and repeat continuity check.
is in gear, it expects the
FORWARD input at J1-J1 and the 4. If continuity is indicated in either
REVERSE input at J1-J2 to have measurement, replace gear selector.
opposite states.
IMPORTANT: For more
- information refer to
TROUBLESHOOTING
THE ELECTRONIC
GEAR SELECTOR
in Group 100 (Test
and
Troubleshooting).
(FORWARD)
005
Symptom Problem Solution 110
83
AG,YZ07927,79 1924OCT983/3
005
110 Code 52
84
Symptom Problem Solution
FORWARD, NEUTRAL, and Open in FORWARD signal line. 1. Disconnect connector J4 from the
REVERSE signals are all gear selector.
simultaneously passive at TCU.
2. Disconnect connector J1 from the
- TCU.
LEGAL CONDITIONS:
-
P R O O F
005
Symptom Problem Solution 110
85
4. If no continuity is indicated,
inspect this line for an open circuit
and replace or repair as needed.
5. If continuity is indicated,
REVERSE line is OK.
4. If no continuity is indicated,
inspect this line for an open circuit
and replace or repair as needed.
P R O O F
5. If continuity is indicated,
NEUTRAL line is OK.
005
110 Symptom Problem Solution
86
005
Symptom Problem Solution 110
87
005
110 Symptom Problem Solution
88
AG,YZ07927,81 1924OCT985/5
005
Code 54 110
89
Symptom Problem Solution
Invalid requested gear Requested gear is an invalid value. 1. Turn ignition to "OFF" position.
calculation.
2. Restart vehicle with gear selector
- in neutral.
AG,YZ07927,82 1924OCT981/1
P R O O F
005
110 Code 56
90
Symptom Problem Solution
NEUTRAL and FORWARD inputs Short to system battery voltage in 1. Turn ignition to "OFF" position.
simultaneously active at TCU. NEUTRAL signal line.
2. Disconnect connector J4 from
- gear selector.
- 5. If no continuity is indicated,
NEUTRAL signal line is OK.
LEGAL CONDITIONS:
005
Symptom Problem Solution 110
91
5. If no continuity is indicated,
FORWARD signal line is OK.
005
110 Symptom Problem Solution
92
AG,YZ07927,83 1924OCT983/3
005
Code 57 110
93
Symptom Problem Solution
NEUTRAL and REVERSE inputs Short to system battery voltage in 1. Turn ignition to "OFF" position.
simultaneously active at TCU. NEUTRAL signal line.
2. Disconnect connector J4 from
- gear selector.
- 5. If no continuity is indicated,
NEUTRAL signal line is OK.
LEGAL CONDITIONS:
005
110 Symptom Problem Solution
94
5. If no continuity is indicated,
REVERSE signal line is OK.
005
Symptom Problem Solution 110
95
AG,YZ07927,84 1924OCT983/3
005
110 Code 58
96
Symptom Problem Solution
START signal went active at Ignition turned to "START" position Do not crank starter once vehicle
TCU. after vehicle is running. has started.
LEGAL CONDITIONS:
AG,YZ07927,85 1924OCT981/1
005
Code 59 110
97
Symptom Problem Solution
Invalid 5-bit selector code. Faulty wiring between gear selector Refer to gear selector documentation
and TCU. and application wiring diagram.
- Check for miswiring, shorted or open
lines between the gear selector and
The TCU does not recognize the the TCU.
code being sent by the gear
selector.
AG,YZ07927,86 1924OCT981/1
P R O O F
005
110 Code 60
98
Symptom Problem Solution
Valve driver supply voltage too Insufficient vehicle battery voltage. System battery supply voltage must
low. be above 8 volts on a 12V system,
or above 17 volts on a 24V system.
-
1. Check voltage at vehicle battery
There is insufficient voltage to terminals.
properly operate the solenoids.
2. If measurement is below 8 volts
on a 12V system or below 17 volts
on a 24V system, recharge or
replace battery.
AG,YZ07927,87 1924OCT981/1
005
Code 80 110
99
Wrong sensor in the engine speed Verify the sensor has not been
sensor port. accidentally exchanged with the
cylinder speed or transmission
output speed MPU sensor.
P R O O F
Faulty engine speed MPU sensor. 1) Remove and inspect MPU. Look
for physical damage.
2) Replace MPU.
YZ07927,0000436 1928APR051/1
005
110 Code 84
,100
LEGAL CONDITIONS:
Incorrect or undefined vehicle Open in DRILL MODE signal line. 1. Turn the ignition to the "OFF"
mode. position.
005
Symptom Problem Solution 110
,101
voltage).
005
110 Symptom Problem Solution
,102
AG,YZ07927,92 1924OCT983/3
P R O O F
005
Code 85 110
,103
LEGAL CONDITIONS:
PARK signal is active and Faulty park switch. For a disc brake With ignition in "OFF" position,
NEUTRAL signal is passive at system only: disconnect connector T9 from the
TCU. park switch.
J2-A1 indicates that the vehicle 2. Repeat continuity check, this time
is in gear, yet the active PARK between switch pins A and C.
signal on pin J2-B3 indicates the
vehicle is parked. 3. If for either test 3 or 4, continuity
fails to alternate as the switch is
- actuated, replace the switch.
005
110 Symptom Problem Solution
,104
4. If no continuity is indicated,
inspect wire for open circuit, and
replace or repair as needed.
3. If no continuity is indicated,
inspect wire for open circuit, and
P R O O F
005
Symptom Problem Solution 110
,105
Open wet brake solenoid. For a wet 1. Disconnect the wet brake solenoid
brake system only: from its harness.
4. If no continuity is indicated,
inspect this line for an open circuit,
and repair or replace as needed.
5. If continuity is indicated,
NEUTRAL signal line is OK.
005
110 Symptom Problem Solution
,106
005
Symptom Problem Solution 110
,107
005
110 Symptom Problem Solution
,108
TROUBLESHOOTING
THE GEAR
SELECTOR in
Group 100 (Test and
Troubleshooting).
AG,YZ07927,93 1924OCT986/6
005
Code 86 110
,109
Symptom Problem Solution
Inching pedal TOP OF CLUTCH Faulty TOC switch 1. Disconnect connector T21 from
signal is active but BOTTOM OF TOC switch.
CLUTCH signal is passive at
TCU. 2. Check for continuity between pins
S21-A and S21-B as switch is
- actuated.
LEGAL CONDITIONS:
005
110 Symptom Problem Solution
,110
BOC signal line open between T11 1. Disconnect connector J1 from the
connector and TCU. TCU.
BOC signal line open between S11 1. Disconnect connector from the
connector and BOC switch. inching pedal.
005
Symptom Problem Solution 110
,111
005
110 Symptom Problem Solution
,112
DPSG,YZ07927,94 1906NOV984/4
005
Code 87 110
,113
Symptom Problem Solution
PARK and FORWARD signals are Faulty park switch. For a disc brake With ignition in "OFF" position,
simultaneously active at TCU. system only: disconnect connector T9 from the
park switch.
-
1. Check for continuity between
The TCU sees a conflict; the switch pins A and B while actuating
active PARK signal on pin J2-B3 switch.
indicates that the vehicle is
parked, yet the active FORWARD 2. Repeat continuity check, this time
signal on pin J1-J1 says the between switch pins A and C.
vehicle is in gear.
3. If for either test 3 or 4, continuity
- fails to alternate as the switch is
actuated, replace the switch.
LEGAL CONDITIONS:
005
110 Symptom Problem Solution
,114
005
Symptom Problem Solution 110
,115
1. Disconnect connector J6 at
transmission.
005
110 Symptom Problem Solution
,116
DPSG,YZ07927,96 1909NOV984/4
P R O O F
005
Code 88 110
,117
Symptom Problem Solution
PARK and REVERSE signals are Faulty park switch. For a disc brake With ignition in "OFF" position,
simultaneously active at TCU. system only: disconnect connector T9 from the
park switch.
-
1. Check for continuity between
The TCU sees a conflict; the switch pins A and B while actuating
active PARK signal on pin J2-B3 switch.
indicates that the vehicle is
parked, yet the active REVERSE 2. Repeat continuity check, this time
signal on pin J1-J2 indicates the between switch pins A and C.
vehicle is in gear.
3. If for either test 3 or 4, continuity
- fails to alternate as the switch is
actuated, replace the switch.
LEGAL CONDITIONS:
005
110 Symptom Problem Solution
,118
005
Symptom Problem Solution 110
,119
005
110 Symptom Problem Solution
,120
DPSG,YZ07927,97 1909NOV984/4
NOT PARK and PARK signals Faulty park switch. 1. Turn ignition to "OFF" position.
simultaneously passive at TCU.
2. Disconnect connector T9 from the
- park switch or park switch harness.
P R O O F
The TCU expects the J1-K1 NOT 3. Testing directly at switch pins,
PARK input and the J2-B3 PARK check for continuity between switch
input to have opposite states. pins A and B while actuating switch.
005
Symptom Problem Solution 110
,121
005
110 Symptom Problem Solution
,122
4. If no continuity is indicated,
inspect this line for an open circuit,
and repair or replace as needed.
4. If no continuity is indicated,
inspect this line for an open circuit,
and repair or replace as needed.
P R O O F
005
Symptom Problem Solution 110
,123
DPSG,YZ07927,98 1909NOV984/4
005
110 Code 89 (For applications using wet brakes)
,124
Symptom Problem Solution
Possible causes for a wet brake Faulty park brake pressure switch. The park brake pressure switch is
system. normally closed; it is closed
(providing an active signal to the
TCU) when the park brake is
applied. With the park brake
disengaged, the wet brake relay is
energized, which in turn energizes
the wet brake solenoid, which then
opens the park brake pressure
switch, allowing the vehicle to move.
switch is OK.
005
Symptom Problem Solution 110
,125
4. If no continuity is indicated,
inspect this line for an open circuit,
and repair or replace as needed.
4. If no continuity is indicated,
P R O O F
005
110 Symptom Problem Solution
,126
4. If no continuity is indicated,
inspect this line for an open circuit,
and repair or replace as needed.
DPSG,YZ07927,184 1903MAR993/3
P R O O F
005
Code 90 110
,127
Symptom Problem Solution
NOT PARK and PARK signals Faulty park switch. For a disc brake With ignition in "OFF" position,
simultaneously active at TCU. system only: disconnect connector T9 from the
park switch.
-
1. Check for continuity between
The TCU expects the J1-K1 NOT switch pins A and B while actuating
PARK input and the J2-B3 PARK switch.
input to have opposite states.
2. Repeat continuity check, this time
- between switch pins A and C.
Faulty park brake pressure switch. The park brake pressure switch is
For a wet brake system only: normally closed; it is closed
(providing an active signal to the
TCU) when the park brake is
applied. With the park brake
disengaged, the wet brake relay is
energized, which in turn energizes
the wet brake solenoid, which then
opens the park brake pressure
switch, allowing the vehicle to move.
005
110 Symptom Problem Solution
,128
NOT PARK and PARK signal lines 1. Turn ignition to "OFF" position.
shorted together between connector
S9 and park switch. For a disc 2. Disconnect connectors S9 and T9.
brake system only:
3. Check for continuity between pins
S9-B and S9-C.
005
Symptom Problem Solution 110
,129
NOT PARK and PARK signal lines 1. Turn ignition to "OFF" position.
shorted together between connector
T9 and TCU. For a disc brake 2. Disconnect connectors S9 and T9.
system only:
3. Disconnect connector J1 from the
TCU.
005
110 Symptom Problem Solution
,130
005
Symptom Problem Solution 110
,131
Faulty wet brake relay. For a wet Specific installations will vary;
brake system only: consult wiring diagram for the
application.
P R O O F
Replace relay.
Open wet brake solenoid. For a wet 1. Disconnect the wet brake solenoid
brake system only: from its harness.
005
110 Symptom Problem Solution
,132
DPSG,YZ07927,99 1913NOV986/6
005
Code 91 110
,133
LEGAL CONDITIONS:
005
110 Symptom Problem Solution
,134
Seat switch signal and NEUTRAL Faulty seat switch. 1. Disconnect seat switch from
signal are simultaneously wiring harness.
passive at TCU.
2. Check continuity between switch
- pins as the switch is actuated.
4. If no continuity is indicated,
inspect this line for an open circuit
and replace or repair as necessary.
005
Symptom Problem Solution 110
,135
4. If no continuity is indicated,
inspect this line for an open circuit
and replace or repair as necessary.
4. If no continuity is indicated,
inspect this line for an open circuit,
and repair or replace as needed.
5. If continuity is indicated,
NEUTRAL signal line is OK.
P R O O F
005
110 Symptom Problem Solution
,136
005
Symptom Problem Solution 110
,137
TROUBLESHOOTING
THE GEAR
SELECTOR in
Group 100 (Test and
Troubleshooting).
DPSG,YZ07927,100 1913NOV985/5
005
110 Code 92
,138
Symptom Problem Solution
Engine speed is at or near Engine speed too high. Reduce engine speed.
manufacturers warranty void
level.
DPSG,YZ07927,101 1913NOV981/1
Code 93
Symptom Problem Solution
Engine speed too high for Engine speed too high. Reduce engine speed below the
neutral-to-gear engagement. neutral-to-gear engagement
threshold specified for the vehicle.
P R O O F
DPSG,YZ07927,102 1913NOV981/1
005
Code 98 110
,139
Symptom Problem Solution
WHEELS-UP and Short to system battery voltage in 1. Turn ignition to OFF position.
WHEELS-DOWN inputs are WHEELS-UP signal line.
simultaneously active at TCU. 2. Disconnect connector J1 from
TCU.
-
3. Disconnect connector J3 from
The TCU expects the TCU.
WHEELS-UP input signal on pin
J1-H1 and the WHEELS-DOWN 4. Check for continuity between
input signal on pin J1-H2 to have harness pins J3-A1 (system battery
opposite states. voltage) and J1-H1.
005
110 Symptom Problem Solution
,140
DPSG,YZ07927,107 1920NOV982/2
Code 99
Symptom Problem Solution
Attempt to change wheels mode An attempt was made to change Change wheels mode only when
while vehicle is not in neutral. wheels mode while vehicle was out vehicle is neutral.
of neutral.
-
P R O O F
DPSG,YZ07927,108 1920NOV981/1
005
Code 100 110
,141
Symptom Problem Solution
Sump temperature too low for Cold transmission. Warm transmission to above 50
calibration. degrees F. (10 degrees C)
005
110 Symptom Problem Solution
,142
DPSG,YZ07927,109 1920NOV982/2
005
Code 101 110
,143
Symptom Problem Solution
Engine speed too high for Engine speed too high. Reduce engine speed below 1700
calibration. RPM, preferably 1600 RPM.
DPSG,YZ07927,110 1920NOV981/1
Code 102
Symptom Problem Solution
Engine speed too low for Engine speed too low. Increase engine speed above 1500
calibration. RPM, preferably 1600 RPM.
-
P R O O F
DPSG,YZ07927,111 1920NOV981/1
005
110 Code 103
,144
Symptom Problem Solution
Output speed sensed during Vehicle is moving during calibration. Set vehicle park brake, and verify
calibration. that it is properly adjusted.
DPSG,YZ07927,112 1920NOV981/1
005
Code 104 110
,145
Symptom Problem Solution
No cylinder speed during Cylinder speed MPU sensor Verify that cylinder speed MPU is
calibration. disconnected. connected to the wiring harness.
Open in cylinder speed MPU sensor 1. Turn ignition to the "OFF" position.
signal line between TCU and
connector J6. 2. Disconnect connector J1 from the
TCU.
5. If no continuity is indicated,
inspect this line for an open circuit
and replace or repair as necessary.
P R O O F
Open in cylinder speed MPU sensor 1. Turn ignition to the "OFF" position.
ground line between TCU and
connector J6. 2. Disconnect connector J1 from the
TCU.
5. If no continuity is indicated,
inspect this line for an open circuit
and replace or repair as necessary.
005
110 Symptom Problem Solution
,146
Open in cylinder speed MPU sensor 1. Turn ignition to the "OFF" position.
signal line between connector J6
and the cylinder speed MPU sensor. 2. Disconnect the engine cylinder
MPU sensor from the harness.
5. If no continuity is indicated,
inspect this line for an open circuit
and replace or repair as necessary.
Open in cylinder speed MPU sensor 1. Turn ignition to the "OFF" position.
ground line between connector J6
and the cylinder speed MPU sensor. 2. Disconnect the engine cylinder
MPU sensor from the harness.
5. If no continuity is indicated,
inspect this line for an open circuit
and replace or repair as necessary
Cylinder speed MPU sensor not Verify that sensor and cover is
seated properly. tightened securely and has not
loosened from the transmission
housing.
Wrong sensor in the cylinder speed Verify that sensor has not been
sensor port. accidentally exchanged with the
engine speed or transmission output
speed MPU sensor.
005
Symptom Problem Solution 110
,147
2. Resistance should be
approximately 515 ohms (may range
from 200 to 600 ohms).
DPSG,YZ07927,113 1920NOV983/3
Code 105
Symptom Problem Solution
Incorrect FWD cylinder ratio. Oil temperature too low. Increase oil temperature and retry. If
Converter-driven units only. problem persists at sump
temperatures above 120 degrees F,
(49 degrees C) then another solution
is needed.
DPSG,YZ07927,114 1920NOV981/1
005
110 Code 106
,148
Symptom Problem Solution
Incorrect REV cylinder ratio. Oil temperature too low. Increase oil temperature and retry. If
Converter-driven units only. problem persists at sump
temperatures above 120 degrees F,
(49 degrees C) then another solution
is needed.
DPSG,YZ07927,115 1920NOV981/1
P R O O F
005
Code 107 110
,149
Symptom Problem Solution
Cylinder speed will not drop New clutches need to be exercised. Retry calibration three times, noting
below start count speed. the message being displayed just
previous to getting the diagnostic
code message.
3. Retry calibration.
3. Retry calibration.
DPSG,YZ07927,116 1920NOV981/1
005
110 Code 108
,150
Symptom Problem Solution
Holding clutch hold pressure Holding clutch valve not performing If the message displayed previous to
exceeding 90 psi. properly. the diagnostics code is "C3F" or
"C4F," then replace valve 1 and retry
calibration.
DPSG,YZ07927,118 1920NOV981/1
Code 109
Symptom Problem Solution
Fast fill time for clutch 1 exceeds Valve 1 is not performing properly. Replace valve 1.
300ms.
DPSG,YZ07927,119 1920NOV981/1
Code 110
Symptom Problem Solution
Fast fill time for clutch 2 exceeds Valve 2 is not performing properly. Replace valve 2.
300ms.
DPSG,YZ07927,120 1920NOV981/1
005
Code 111 110
,151
Symptom Problem Solution
Fast fill time for clutch 3 exceeds Valve 3 not performing properly. Replace valve 3.
300ms.
DPSG,YZ07927,121 1920NOV981/1
Code 112
Symptom Problem Solution
Fast fill time for clutch 4 exceeds Valve 4 (R2) is not performing Replace valve 4.
300ms. properly.
DPSG,YZ07927,122 1920NOV981/1
Code 113
P R O O F
Fast fill time for clutch A Valve A is not performing properly. Replace valve A.
exceeds 300ms.
DPSG,YZ07927,123 1920NOV981/1
Code 114
Symptom Problem Solution
Fast fill time for clutch B Valve B is not performing properly. Replace valve B.
exceeds 300ms.
DPSG,YZ07927,124 1920NOV981/1
005
110 Code 115
,152
Symptom Problem Solution
Fast fill time for clutch C Valve C is not performing properly. Replace valve C.
exceeds 300ms.
DPSG,YZ07927,125 1920NOV981/1
Code 116
Symptom Problem Solution
Fast fill time for clutch D Valve D is not performing properly. Replace valve D.
exceeds 300ms.
DPSG,YZ07927,126 1920NOV981/1
Code 117
P R O O F
Calibrating clutch hold pressure Valve being calibrated is not Replace valve that was being
exceeds 90 psi. performing properly. calibrated at the time the diagnostics
code was indicated.
DPSG,YZ07927,127 1920NOV981/1
005
Code 127 (For applications using disc 110
,153
brakes)
Symptom Problem Solution
Calibrating without park brake Park brake is not set. Set the park brake.
set.
005
110 Symptom Problem Solution
,154
005
Symptom Problem Solution 110
,155
4. If no continuity is indicated,
inspect this line for an open circuit,
and repair or replace as needed.
DPSG,YZ07927,132 1920NOV983/3
005
110 Code 127 (For applications using wet brakes)
,156
Symptom Problem Solution
Calibrating without park brake Faulty park brake pressure switch. 1. Disconnect harness from park
set. brake pressure switch.
005
Symptom Problem Solution 110
,157
005
110 Symptom Problem Solution
,158
4. If no continuity is indicated,
inspect this line for an open circuit,
and repair or replace as needed.
4. If no continuity is indicated,
P R O O F
DPSG,YZ07927,175 1905FEB993/3
005
Code 127 (For applications using a pressure 110
,159
switch)
Symptom Problem Solution
Calibrating without park brake Faulty pressure switch. 1. Disconnect harness from pressure
set. switch.
4. If no continuity is indicated,
inspect this line for an open circuit,
and repair or replace as needed.
005
110 Symptom Problem Solution
,160
4. If no continuity is indicated,
inspect this line for an open circuit,
and repair or replace as needed.
DPSG,YZ07927,182 1919FEB992/2
Code 145
P R O O F
Analog inching voltage is too Faulty inching pedal. IMPORTANT: For more
low. information refer to
TROUBLESHOOTING
- THE GEAR
SELECTOR in
The analog inching signal Group 100 (Test and
voltage at pin J1-F3 is below the Troubleshooting).
minimum level required by the
TCU.
DPSG,YZ07927,135 1920NOV981/1
005
Code 146 110
,161
Symptom Problem Solution
Temperature sensor circuit is Temperature sensor disconnected. Verify that temperature sensor is
shorted or open. connected to wiring harness.
005
110 Symptom Problem Solution
,162
005
Symptom Problem Solution 110
,163
DPSG,YZ07927,136 1920NOV983/3
Code 148
Symptom Problem Solution
Analog inching voltage is too Faulty inching pedal. IMPORTANT: For more
high. information refer to
TROUBLESHOOTING
- THE GEAR
SELECTOR in
The analog inching signal Group 100 (Test and
voltage at pin J1-F3 is above the Troubleshooting).
maximum level allowed by the
TCU.
DPSG,YZ07927,137 1920NOV981/1
005
110 Code 150
,164
Symptom Problem Solution
005
Symptom Problem Solution 110
,165
DPSG,YZ07927,183 1903MAR992/2
005
110 Code 154
,166
Symptom Problem Solution
Engine speed circuit is open. Engine speed MPU sensor Verify that the engine speed MPU
disconnected. sensor is connected to the wiring
- harness.
Open in engine speed MPU sensor 1. Turn ignition to the "OFF" position.
signal line between TCU and
connector J6. 2. Disconnect connector J1 from the
TCU.
5. If no continuity is indicated,
inspect this line for an open circuit
and replace or repair as necessary.
Open in engine speed MPU sensor 1. Turn ignition to the "OFF" position.
ground line between TCU and
connector J6. 2. Disconnect connector J1 from the
P R O O F
TCU.
5. If no continuity is indicated,
inspect this line for an open circuit
and replace or repair as necessary.
005
Symptom Problem Solution 110
,167
Open in engine speed MPU sensor 1. Turn ignition to the "OFF" position.
signal line between connector J6
and the engine speed MPU sensor. 2. Disconnect the engine speed
MPU sensor from the harness.
5. If no continuity is indicated,
inspect this line for an open circuit
and replace or repair as necessary.
Open in engine speed MPU sensor 1. Turn ignition to the "OFF" position.
ground line between connector J6
and the engine speed MPU sensor. 2. Disconnect the engine speed
MPU sensor from the harness.
5. If no continuity is indicated,
inspect this line for an open circuit
and replace or repair as necessary.
2. Resistance should be
approximately 515 ohms (may range
from 200 to 600 ohms).
DPSG,YZ07927,140 1930NOV982/2
005
110 Code 155
,168
Symptom Problem Solution
Transmission output speed Transmission output speed MPU Verify that the transmission output
circuit is open. sensor disconnected. speed MPU sensor is connected to
the wiring harness.
-
5. If no continuity is indicated,
inspect this line for an open circuit
and replace or repair as necessary.
5. If no continuity is indicated,
inspect this line for an open circuit
and replace or repair as necessary.
005
Symptom Problem Solution 110
,169
5. If no continuity is indicated,
inspect this line for an open circuit
and replace or repair as necessary.
pin B.
5. If no continuity is indicated,
inspect this line for an open circuit
and replace or repair as necessary.
005
110 Symptom Problem Solution
,170
2. Resistance should be
approximately 515 ohms (may range
from 200 to 600 ohms).
DPSG,YZ07927,141 1930NOV983/3
Code 160
Symptom Problem Solution
Cannot get shift constants from Internal TCU diagnostics code. 1. Turn ignition to "OFF" position.
EEPROM.
2. Restart vehicle with gear selector
- in neutral.
P R O O F
DPSG,YZ07927,142 1930NOV981/1
005
Code 161 110
,171
Symptom Problem Solution
Internal group one enable Improper signal state combination. 1. With ignition OFF disconnect
signal is low; should be high. connector J1 from TCU.
DPSG,YZ07927,143 1930NOV981/1
005
110 Legal Conditions For Code 161
,172
DPSG,YZ07927,176 1905FEB991/1
P R O O F
005
Code 162 110
,173
Symptom Problem Solution
Internal group two enable Improper signal state combination. 1. With ignition OFF disconnect
signal is low; should be high. connector J1 from TCU.
DPSG,YZ07927,143CONV1 1930NOV981/1
005
110 Legal Conditions For Code 162
,174
DPSG,YZ07927,176CONV1 1905FEB991/1
P R O O F
005
Code 163 110
,175
Symptom Problem Solution
Internal group three enable Improper signal state combination. 1. With ignition OFF disconnect
signal is low; should be high. connector J1 from TCU.
DPSG,YZ07927,143CONV2 1930NOV981/1
005
110 Legal Conditions For Code 163
,176
DPSG,YZ07927,176CONV2 1905FEB991/1
P R O O F
005
Code 171 110
,177
Symptom Problem Solution
Internal group one enable Improper signal state combination. 1. With ignition OFF disconnect
signal is high; should be low. connector J1 from TCU.
DPSG,YZ07927,143CONV3 1930NOV981/1
005
110 Legal Conditions For Code 171
,178
DPSG,YZ07927,176CONV3 1905FEB991/1
P R O O F
005
Code 172 110
,179
Symptom Problem Solution
Internal group two enable Improper signal state combination. 1. With ignition OFF disconnect
signal is high; should be low. connector J1 from TCU.
DPSG,YZ07927,143CONV4 1930NOV981/1
005
110 Legal Conditions For Code 172
,180
DPSG,YZ07927,176CONV4 1905FEB991/1
P R O O F
005
Code 173 110
,181
Symptom Problem Solution
Internal group three enable Improper signal state combination. 1. With ignition OFF disconnect
signal is high; should be low. connector J1 from TCU.
DPSG,YZ07927,143CONV5 1930NOV981/1
005
110 Legal Conditions For Code 173
,182
DPSG,YZ07927,176CONV5 1905FEB991/1
P R O O F
005
Code 175 (12 Volt System) 110
,183
This code pertains to the TCU output that controls the transmission front axle output disconnect.
If transmission does not have the front axle output disconnect option refer to vehicle manual for vehicle option device that this TCU
output controls
Solenoid / relay driver 11 cannot Relay disconnected. Verify harness is connected to relay.
get up to requested current.
005
110 Symptom Problem Solution
,184
DPSG,YZ07927,157 1915JUL052/2
005
Code 175 (24 Volt System) 110
,185
This code pertains to the TCU output that controls the transmission front axle output disconnect.
If transmission does not have the front axle output disconnect option refer to vehicle manual for vehicle option device that this TCU
output controls.
005
110 Symptom Problem Solution
,186
005
Symptom Problem Solution 110
,187
YZ03225,00001C5 1915JUL053/3
P R O O F
005
110 Code 176
,188
This code pertains to TCU output that is used to operate available vehicle option device per customers request. Refer to vehicle manual
for available vehicle options that use this TCU output.
Vehicle option device driver 12 Vehicle option device disconnected. Verify harness is connected to
cannot get up to requested vehicle option device.
current.
005
Symptom Problem Solution 110
,189
DPSG,YZ07927,158 1915JUL052/2
005
110 Code 177
,190
The code pertains to the TCU output that is used to operate available vehicle option device per customer request.
Refer to vehicle manual for available options that uses this TCU output.
Vehicle option device driver 13 Vehicle option device disconnected. Verify harness is connected to
cannot get up to requested vehicle option device.
current.
005
Symptom Problem Solution 110
,191
DPSG,YZ07927,160 1915JUL052/2
005
110 Code 178 (12 Volt System)
,192
This code pertains to the TCU output that controls the transmission front axle output disconnect.
If transmission does not have the front axle output disconnect option refer to vehicle manual for vehicle option device that this TCU
output controls.
Solenoid/relay driver 11 cannot Short circuit in relay, or relay has 1. Disconnect relay from harness.
drop to requested current. low resistance.
2. Measure relay resistance.
Due to a problem in the pin
J3-H2 (output) to pin J3-H3 3. Check relay resistance. Refer to
(return) circuit path. vehicle manual for relay resistance
specifications.
NOTE: Due to the current
requirements of the 12 volt 4. If a direct short or low resistance
output disconnect solenoid, is indicated, replace relay. See
all 12 volt systems requires Continuity Measurement Note below.
the output disconnect
solenoid to be driven by NOTE: Continuity Measurement:
vehicle electrical power Some multi-meters have an
through an external relay audio continuity indication
controlled by this TCU feature. Getting the "beep"
output. Refer to the during a continuity check
vehicle manual. does not mean a direct short
circuit exists! Rely on the
actual resistance value
during the measurement
rather than going by the
beep. (For example: the
P R O O F
YZ03225,00001CC 1915JUL051/1
005
Code 178 (12 Volt System) - Continued 110
,193
Symptom Problem Solution
YZ03225,00001CB 1915JUL051/1
005
110 Code 178 (24 Volt System)
,194
This code pertains to the TCU output that controls the transmission front axle output disconnect.
If transmission does not have the front axle output disconnect option refer to vehicle manual for vehicle option device that this TCU
output controls.
Solenoid driver 11 cannot drop Short circuit in solenoid, or solenoid 1. Disconnect relay from harness.
to requested current. has low resistance.
2. Measure solenoid resistance.
Due to a problem in the pin
J3-H2 (output) to pin J3-H3 3. Check solenoid resistance, which
(return) circuit path. for a 24 Volt solenoid should be
approximately 24 ohms (may range
from 16 to 40 ohms with solenoid at
room temperature. Resistance will
increase as temperature increases.)
YZ03225,00001C4 1915JUL051/1
005
Code 178 (24 Volt System) - Continued 110
,195
Symptom Problem Solution
YZ03225,00001C8 1915JUL051/1
005
110 Code 179
,196
This code pertains to TCU output that is used to operate available vehicle option per customer request. Refer to the vehicle manual for
available vehicle options that use this TCU output.
Vehicle option devise driver 12 Short circuit in vehicle option devise, 1. Disconnect solenoid from harness.
cannot drop to requested or vehicle option devise has low
current. resistance. 2. Measure vehicle option devise
resistance.
Due to a problem in the pin J3-J1
(output) to pin J3-J2 (return) 3. Check resistance of vehicle option
circuit path. devise. Refer to Vehicle Manual for
Specifications.
005
Symptom Problem Solution 110
,197
005
110 Symptom Problem Solution
,198
DPSG,YZ07927,162 1915JUL053/3
Code 180
P R O O F
This code pertains to TCU output that is used to operate available vehicle option per customer request. Refer to the vehicle manual for
available vehicle options that use this TCU output.
Vehicle option devise driver 13 Short circuit in vehicle option devise, 1. Disconnect vehicle option devise
cannot drop to requested or vehicle option devise has low from harness.
current. resistance.
2. Measure vehicle option devise
Due to a problem in the pin J3-J3 resistance.
(output) to pin J3-K1 (return)
circuit path. 3. Check resistance of vehicle option
devise. Refer to Vehicle Manual for
specifications.
005
Symptom Problem Solution 110
,199
005
110 Symptom Problem Solution
,200
DPSG,YZ07927,163 1915JUL053/3
P R O O F
005
Code 198 110
,201
Symptom Problem Solution
CCD communications link failure Open in CCD BUS- signal line 1. Turn ignition to "OFF" position.
between master and slave TCUs. between master and slave TCUs.
2. Disconnect connector J2 from
- both TCUs.
4. If no continuity is indicated,
inspect this line for an open circuit
and replace or repair wire as
necessary.
4. If no continuity is indicated,
inspect this line for an open circuit
and replace or repair wire as
P R O O F
necessary
005
110 Symptom Problem Solution
,202
DPSG,YZ07927,164 1901DEC982/2
Code 199
Symptom Problem Solution
Non-functional base TCU. The TCU is missing Contact field service for information
application-specific programming. regarding return of TCU for
- programming.
DPSG,YZ07927,165 1901DEC981/1
005
Flashing ECU Message 110
,203
Symptom Problem Solution
Gear/Diagnostic indicator display No application software in TCU. 1. If a known good spare TCU is
is flashing or displaying "ECU". available, substitute it. If ECU
message is eliminated, original TCU
- likely has no program or is otherwise
faulty.
The display itself has power, but
the TCU is not communicating 2. If laptop PC diagnostics is
with the display. available, verify that communications
with TCU can be established. If not,
TCU likely has no program or is
otherwise faulty.
5. If no continuity is indicated,
inspect this line for an open circuit
and replace or repair wires as
necessary.
P R O O F
005
110 Symptom Problem Solution
,204
5. If no continuity is indicated,
inspect this line for an open circuit
and replace or repair wires as
necessary.
DPSG,YZ07927,166 1901DEC982/2
P R O O F
Page Page
Code 27 . . . . . . . . . . . . . . . . . . . . . . . .005-110-19
Code 28 . . . . . . . . . . . . . . . . . . . . . . . .005-110-21
Code 29 . . . . . . . . . . . . . . . . . . . . . . . .005-110-23
Code 30 . . . . . . . . . . . . . . . . . . . . . . . .005-110-26 E
Code 31 . . . . . . . . . . . . . . . . . . . . . . . .005-110-28
Code 32 . . . . . . . . . . . . . . . . . . . . . . . .005-110-30 Engine Speed MPU
Code 33 . . . . . . . . . . . . . . . . . . . . . . . .005-110-32 Connector pinout. . . . . . . . . . . . . . . . . .005-105-18
Code 34 . . . . . . . . . . . . . . . . . . . . . . . .005-110-34 TCU pin . . . . . . . . . . . . . . . . . . . . . . . .005-105-18
Code 35 . . . . . . . . . . . . . . . . . . . . . . . .005-110-36
Code 36 . . . . . . . . . . . . . . . . . . . . . . . .005-110-38
Code 37 . . . . . . . . . . . . . . . . . . . . . . . .005-110-40 F
Code 38 . . . . . . . . . . . . . . . . . . . . . . . .005-110-42
Code 39 . . . . . . . . . . . . . . . . . . . . . . . .005-110-44 Fault
Code 40 . . . . . . . . . . . . . . . . . . . . . . . .005-110-46 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-3
Code 41 . . . . . . . . . . . . . . . . . . . . . . . .005-110-47
Code 42 . . . . . . . . . . . . . . . . . . . . . . . .005-110-50
Code 43 disc brake system. . . . . . . . . 005-110-52,
005-110-53 G
Code 43 wet brake system . . . . . . . . . .005-110-55
Code 44 . . . . . . . . . . . . . . . . . . . . . . . .005-110-58 Gear Selector
Code 45 . . . . . . . . . . . . . . . . . . . . . . . .005-110-64 Connector pinout. . . . . . . . . . . . . . . . . . .005-100-4
Code 48 . . . . . . . . . . . . . . . . . . . . . . . .005-110-70 Gear selector
Code 49 . . . . . . . . . . . . . . . . . . . . . . . .005-110-76 PC diagnostics . . . . . . . . . . . . . . . . . . . .005-100-7
Code 50 . . . . . . . . . . . . . . . . . . . . . . . .005-110-78 Gear Selector
Code 51 . . . . . . . . . . . . . . . . . . . . . . . .005-110-81 Shift pattern . . . . . . . . . . . . . . . . . . . . .005-105-13
Page Page
Output Speed
J MPU . . . . . . . . . . . . . . . . . . . . . . . . . . .005-105-20
Output speed MPU
J1 Connector pinout. . . . . . . . . . . . . . . . . .005-105-20
Connector pin . . . . . . . . . . . . . . . . . . . . .005-105-6 TCU pin . . . . . . . . . . . . . . . . . . . . . . . .005-105-20
Page Page
Solenoid . . . . . . . . . . . . . . . . . . . . . .005-105-24
Gear indicator . . . . . . . . . . . . . . . . . . . .005-105-12
Temperature sensor . . . . . . . . . . . . . . .005-105-22
Inching pedal . . . . . . . . . . . . . . . . . . . .005-105-16
Temperature Sensor
Output speed MPU sensor . . . . . . . . . .005-105-20
Connector pinout. . . . . . . . . . . . . . . . . .005-105-22
Park brake switch . . . . . . . . . . . . . . . . .005-105-21
TCU pin . . . . . . . . . . . . . . . . . . . . . . . .005-105-22
Proportional valve . . . . . . . . . . . . . . . . .005-105-24
Test and Troubleshooting
TCU . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-105-2
Calibrate 4 speeds forward . . . . . . . . . .005-100-13
Temperature sensor . . . . . . . . . . . . . . .005-105-22
Calibrate 8 speeds forward . . . . . . . . . .005-100-14
Transient voltage protection module . . .005-105-28
Calibration. . . . . . . . . . . . . . . . . . . . . . .005-100-12
Transmission wiring harness . . . . . . . . .005-105-30
Electrical system . . . . . . . . . . . . . . . . . . .005-100-2
Electronic gear selector. . . . . . . . . . . . . .005-100-4
Gear selector with PC diagnostics . . . . .005-100-7
T General troubleshooting tips . . . . . . . . . .005-100-3
Inching pedal system . . . . . . . . . . . . . . .005-100-9
TCU and Accessories Troubleshooting introduction . . . . . . . . . .005-100-1
Cylinder speed MPU . . . . . . . . . . . . . . .005-105-19 Visually inspect electrical system . . . . . .005-100-2
Electronic gear selector. . . . . . . . . . . . .005-105-13 Transient Voltage Protection Module
Engine speed magnetic pickup sensor (input Connector pinout. . . . . . . . . . . . . . . . . .005-105-28
speed) . . . . . . . . . . . . . . . . . . . . . . . .005-105-18 Transmission Control Unit
Function of proportional valves . . . . . . .005-105-23 Abbreviations . . . . . . . . . . . . . . . . . . . . . .005-10-2
Gear combinations . . . . . . . . . . . . . . . .005-105-25 Acronyms . . . . . . . . . . . . . . . . . . . . . . . . .005-10-2
Gear selector . . . . . . . . . . . . . . . . . . . .005-105-13 Calibrate 4 speed . . . . . . . . . . . . . . . . .005-100-13
Gear/diagnostic indicator. . . . . . . . . . . .005-105-12 Calibration. . . . . . . . . . . . . . . . . . . . . . .005-100-12
Inching pedal . . . . . . . . . . . . . . . . . . . .005-105-16 Calibration 8 speed . . . . . . . . . . . . . . . .005-100-14
J1 and mating connector. . . . . . . . . . . . .005-105-6 High-pressure washers . . . . . . . . . . . . . . .005-05-2
Page
Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-2
Theory of operation. . . . . . . . . . . . . . . . . .005-10-1
Transmission Wiring Harness
1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . .005-105-30 Indx
2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . .005-105-31 5
3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . .005-105-32
4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . .005-105-33
Troubleshooting
Calibration. . . . . . . . . . . . . . . . . . . . . . .005-100-12
Calibration 4 forward 4 reverse . . . . . . .005-100-13
Calibration 8 forward 4 reverse . . . . . . .005-100-14
Gear selector . . . . . . . . . . . . . . . . . . . . .005-100-4
Gear selector w/ PC diagnostics . . . . . . .005-100-7
Inching pedal . . . . . . . . . . . . . . . . . . . . .005-100-9
Introduction . . . . . . . . . . . . . . . . . . . . . . .005-100-1
Warranty
TCU and welding . . . . . . . . . . . . . . . . . .005-105-2
Wiring Harness
1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . .005-105-30
2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . .005-105-31
3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . .005-105-32
4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . .005-105-33
P R O O F
Indx
6
P R O O F