Allison 3000 and 4000 Series Transmission Parts Catalog and Repair Manual

Troubleshooting Manual (3000 and 4000 Series)	861 Pages
Repair Manual (3000 Series )	180 Pages
Parts Catalog Manual (3000 Series)	1,754 Pages
Repair Manual (4000 Series)	185 Pages
Parts Catalog Manual (4000 Series)	1,126 Pages

Brand	Allison
Models Covered	3000 and 4000 Series
Machine Type	Transmission
Documentation	Troubleshooting Manual, Repair Manual, Parts Catalog
Publication Numbers	TS3989EN & SM4013EN & SM2457EN & PC2150EN & PC2456EN
Language	English
Format	PDF

Overview

The Allison 3000 and 4000 Series Transmission Troubleshooting, Service Repair Manuals and Parts Catalogs provide technical documentation for diagnosing, servicing and identifying replacement components for Allison automatic transmissions. This five-manual collection includes dedicated troubleshooting information for the 3000 and 4000 Product Families, separate service repair manuals for each transmission series, and individual parts catalogs. The troubleshooting documentation covers Allison 4th Generation electronic controls, transmission control modules (TCM), shift selectors, speed sensors, wiring harnesses, hydraulic circuits, diagnostic trouble codes and transmission performance problems.

Technical coverage includes electronic transmission diagnostics, diagnostic trouble code (DTC) interpretation, transmission fluid level checks, speed sensor faults, shift solenoid testing, pressure control solenoid circuits, torque converter clutch faults, clutch and retarder pressure measurements, CAN communication problems and electrical connector repairs. Additional references include transmission hydraulic schematics, solenoid and clutch charts, electronic control input/output functions, Allison DOC diagnostic software, wiring repairs and service information for the 3000 and 4000 Series transmission families.

Safety: Transmission diagnosis and repair must follow the applicable safety precautions, warnings and service procedures. Certain operations require specialised tools and testing equipment. Follow the relevant publication and equipment manufacturer’s instructions before performing electrical tests, hydraulic pressure measurements, component repairs or transmission servicing.

Important Information: The troubleshooting manual specifically addresses Allison 4th Generation electronic control systems. Transmission configurations, electronic controls, optional equipment and diagnostic procedures can vary between models. Confirm the transmission identification, installed control system and applicable publication before selecting a service procedure or replacement part. Additional updates may be issued through Allison Service Information Letters (SIL).

Allison 3000 and 4000 Series Manual

01. General Description and Electronic Controls
- Allison 3000 and 4000 Product Family Transmissions
- Transmission Control Module (TCM)
- Electronic Shift Selector
- Pushbutton Shift Selector
- Lever Shift Selector
- Throttle Position Sensor
- Transmission Speed Sensors
- Transmission Control Module and Control System
- Control System Prognostics Operation and Display
- Filter Life Valve Body
- External Transmission Wiring Harness
- Internal Transmission Wiring Harness
- Vehicle Interface Module (VIM)
- Automatic Component Detection (Autodetect)
- Retarder Detection
- Oil Level Sensor (OLS)
- Throttle Source Identification
- Engine Coolant Temperature Input
- Transmission Identification (TransID)
- Special Electronic and Electrical Service Tools
02. Definitions, Abbreviations and Prognostics
- CHECK TRANS Warning Light
- Transmission Oil Life Monitor
- Transmission Filter Life Monitor
- Filter Life Valve and Pressure Switch PS2
- Transmission Health Monitor
- Allison Transmission Diagnostic Tool
- Technical Definitions and Abbreviations
03. Basic Transmission Troubleshooting
- Technical Knowledge Required for Troubleshooting
- Using the Troubleshooting Manual
- Electronic Transmission Control System Overview
- Information Required Before Troubleshooting
- Transmission Operation During Cold Weather Starts
- High Transmission Fluid Temperature Conditions
- Beginning the Troubleshooting Process
- Transmission Control Module Diagnostic Procedure
- Resetting TCM Parameters Following Engine Updates
- Resetting TCM Autoselect
- Transmission Hydraulic Operation During Electrical Interruption
04. Electrical Wiring and Harness Test Procedures
- Electrical Wire Testing Procedures
- Testing for Open Electrical Circuits
- Testing for Short Circuits Between Wires
- Testing for Short Circuits to Ground
- Digital Volt/Ohmmeter Testing
- Electrical Jumper Wire Test Procedures
- Transmission Feedthrough Connector Testing
- Internal Transmission Wiring Harness Testing
- Internal Harness Open-Circuit Diagnosis
- Internal Harness Short-Circuit Diagnosis
05. Transmission Fluid Level and Condition Checks
- Transmission Oil Level Sensor Introduction
- Electronic Fluid Level Reading Using Shift Selector
- Electronic Fluid Level Check Procedure
- Electronic Fluid Level Reading Using Allison DOC
- Cold Transmission Fluid Level Check
- Hot Transmission Fluid Level Check
- Maintaining Transmission Fluid Cleanliness
- Foreign Material and Fluid Contamination
- Transmission Fluid Recommendations
06. Diagnostic Trouble Codes and Fault Diagnosis
- Diagnostic Trouble Code (DTC) Memory
- DTC List Positions and Code Identification
- Active and Historical Diagnostic Codes
- CHECK TRANS Indicator Responses
- Diagnostic Failure Records
- Reading Diagnostic Trouble Codes
- Clearing Active Diagnostic Indicators
- Clearing Stored Diagnostic Trouble Codes
- Exiting Diagnostic Display Mode
- Transmission Responses to Diagnostic Faults
- Shift Selector Displays for Active Codes
- Diagnostic Trouble Code Reference List
- Diagnostic Trouble Code Troubleshooting Procedures
- Shift Solenoid Locations and Electrical Schematics
- Retarder Request Sensor Faults – C1312 and C1313
- Throttle and Pedal Position Sensor Faults – P0122 and P0123
- Transmission Fluid Over-Temperature – P0218
- Low System Voltage – P0562
- TCM Programming and Vehicle Options Faults – P0602 and P0610
- Torque Control Data Mismatch – P0614
- TCM Internal Temperature Fault – P0634
- Automatic Configuration Input Faults – P063E and P063F
- Actuator Supply Voltage Faults – P0657, P0658 and P0659
- Transmission Control Electrical Fault – P0702
- Brake Switch Circuit Fault – P0703
- Transmission Range Sensor Fault – P0708
- Transmission Fluid Level Sensor Faults – P070C and P070D
- Transmission Fluid Temperature Sensor Faults – P0711, P0712 and P0713
- Turbine Speed Sensor Faults – P0716 and P0717
- Brake Switch and Auxiliary Input Faults – P0719, P071A and P071D
- Transmission Output Speed Sensor Faults – P0721 and P0722
- Engine Speed Sensor Faults – P0726 and P0727
- Incorrect Transmission Gear Ratios – P0729 and P0731–P0736
- Torque Converter Clutch Fault – P0741
- Shift Solenoid Valve Performance – P0752
- Pressure Control Solenoid Performance Faults – P0776, P0777, P0796 and P0797
- Transmission Pressure Switch Circuit Faults – P0842, P0843, P0847 and P0848
- TCM Power Input Faults – P0880–P0883
- Transmission Fluid Filter Deterioration – P088A and P088B
- Transmission Component Slipping – P0894
- Transmission Fluid Deterioration – P0897
- Main Modulation Pressure Control Solenoid Circuit Faults – P0960, P0962 and P0963
- Pressure Control Solenoid 2 and 3 Circuit Faults – P0964–P0971
- Shift Solenoid 1 and 2 Electrical Faults – P0973–P0977
- Retarder Pressure Sensor Faults – P0989 and P0990
- Incorrect Low Gear Ratio – P1739
- Throttle Position Sensor PWM Faults – P1891 and P1892
- Engine Coolant Temperature Sensor Faults – P2184 and P2185
- Torque Management Feedback Faults – P2637 and P2641
- Actuator Supply Voltage 2 and 3 Faults – P2669–P2686
- Pressure Control Solenoid 1, 4, 5 and 6 Faults – P2714–P2739 and P2808–P2815
- Retarder Oil Temperature Faults – P2740, P2742 and P2743
- Torque Converter Clutch Pressure Control Solenoid Faults – P2761, P2763 and P2764
- Clutch Adaptive Learning Limit – P2789
- Kickdown and Gear Shift Direction Faults – P278A and P2793
- CAN Bus and Communication Faults – U0001 and U0010
- Engine and Shift Selector Communication Faults – U0100, U0103, U0115 and U0291
- Electronic Control Software Compatibility Faults – U0304, U0333, U0404, U0592
- J1939 Communication and Invalid Data Faults – U0400 and U0442
07. Transmission Input and Output Functions
- Transmission Electronic Input Functions
- Transmission Electronic Output Functions
08. General Troubleshooting of Transmission Performance
- Transmission Performance Complaint Troubleshooting
- General Transmission Performance Diagnostic Procedures
Appendix A. Electrical Circuit Problem Identification
- Electrical Circuit Inspection
- Intermittent Electrical Fault Diagnosis
- Recurring Electrical Fault Conditions
Appendix B. Clutch and Retarder Pressure Measurements
- Transmission and Vehicle Preparation
- Recording Hydraulic Pressure Test Data
- Comparing Recorded Pressures with Specifications
- 3000 and 4000 Series Retarder Pressure Determination
Appendix C. Solenoid and Clutch Reference Charts
Appendix D. Wire and Connector Charts
Appendix E. Electrical Connectors, Terminals and Repairs
- Connector and Terminal Part Number Identification
- Electrical Connector Repair Tools
- AFL Automotive 80F Bolt-Assist TCM Connectors
- AFL Automotive 80F Cam-Assist TCM Connectors
- AFL Automotive 20F Bolt-Assist TCM Connectors
- Delphi-Packard Micro-Pack 100W Connectors
- Delphi-Packard GT150 Speed Sensor and Retarder Solenoid Connectors
- Delphi-Packard Metri-Pack 150 Connectors
- Delphi-Packard Metri-Pack 280 Connectors
- Delphi-Packard Weather-Pack Connectors
- AMP Retarder Control Connectors
- Deutsch J1939 Diagnostic Connectors
- ITT Cannon Bulkhead Connectors
- Deutsch DT Series Connectors
- Connector Terminal Removal and Crimping
- Broken Wire Repair Using In-Line Butt Splices
- Solenoid Connector Repairs
Appendix F. Throttle Position Sensor Adjustment
- Throttle Position Sensor Operating Principles
- Throttle Position Sensor Adjustment
Appendix G. Vehicle Welding and Interface Module
- Welding on Vehicles Equipped with Electronic Transmission Controls
- Vehicle Interface Module References
Appendix H. Transmission Hydraulic Schematics
- 3000 and 4000 Series Hydraulic Circuit – Neutral
- 3000 and 4000 Series Hydraulic Circuit – Reverse
- 3000 Series Seven-Speed Low-Range Hydraulic Circuit
- 4000 Series Seven-Speed Low-Range Hydraulic Circuit
- First-Range Hydraulic Circuit
- Second-Range Hydraulic Circuit
- Third-Range Hydraulic Circuit
- Fourth-Range Hydraulic Circuit
- Fifth-Range Hydraulic Circuit
- Sixth-Range Hydraulic Circuit
- 3000 Series Retarder OFF Hydraulic Circuit
- 3000 and 4000 Series Retarder ON Hydraulic Circuits
- Hydraulic Schematics with Prognostics
- Neutral, Reverse and Forward-Range Prognostics Circuits
Appendix J. TCM Connector Diagrams
Appendix K. Solenoid Resistance Charts
Appendix L. External Electronic Interference
- Electromagnetic and Radio Frequency Interference
- Radio Transmitter Installation Guidelines
- Radio Antenna Installation and Cable Routing
- Electrical Power and Ground Wire Routing
- Externally Generated Speed Sensor Signals
Appendix M. Hydraulic System Diagnostic Tree
Appendix N. Allison DOC for PC Diagnostic Tool
Appendix P. Electronic Input and Output Functions
Appendix Q. Thermistor Troubleshooting
Appendix R. SAE J1939 Communication Link

Allison 3000 and 4000 Series Transmission Model Coverage

The Allison 3000 and 4000 Series documentation covers a broad range of automatic transmission model designations used across vocational and other vehicle applications. The model references below help identify the appropriate transmission family when consulting troubleshooting procedures, service repair information and replacement parts catalogs.

Allison 3000 Series – Vocational Transmissions

3000 HS, 3000 RDS, 3000 EVS, 3000 MH, 3000 PTS, 3000 TRV, 3200 SP, 3200 TRV, 3500 SP, 3500 RDS, 3500 EVS and 3700 SP.

Allison 3000 Series – B and T Models

B 300, B 300P, B 300R, B 400, B 400P, B 400R, T 200, T 250, T 255, T 260, T 265, T 270, T 280, T 300, T 310, T 325 and T 350.

Allison 4000 Series – Vocational Transmissions

4000 EVS, 4000 HS, 4000 MH, 4000 RDS, 4000 TRV, 4500 HS, 4500 RDS, 4500 EVS, 4500 SP, 4500 TRV, 4700 EVS, 4700 RDS, 4700 OFS and 4800 EVS.

Allison 4000 Series – B and T Models

B 500, B 500P, B 500R, B 500PR, T 425 and T 450.

Selecting the Correct Technical Reference

Transmission identification is essential when locating model-specific service information and replacement components. The TS3989EN troubleshooting manual addresses Allison 4th Generation electronic control systems, including diagnostic trouble codes, transmission control module functions and electrical fault diagnosis. For mechanical repairs and parts identification, consult the corresponding 3000 or 4000 Series repair manual and parts catalog, verifying the exact transmission model and configuration.