NHTSA ID Number: 10054725
Manufacturer Communication Number: IK-1300138
TSB/Document Date: 2014-02-20
Summary
INTERNATIONAL
: INFORMATION PROVIDED REGARDING THE OPERATIONAL AND DIAGNOSTIC OF TRANSFER CASE WITH 4 FEEDBACK SWITCHES AND 2 ELECTRIC ACTUATORS. MODEL TERRASTAR. *PE
IK1300138 TerraStar Transfer Case Diagnostic and Operational Information
Page 1 of 4
SB-10054725-9154
Countries:
CANADA, UNITED STATES, PUERTO RICO Document ID: IK1300138
Availability:
ISIS, FleetISIS
Revision:
4
Major System:
Created:
8/10/2013
Current Language: English
Last Modified: 12/9/2013
Other Languages: NONE
Author:
Viewed:
Matthew Boyer
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Title : TerraStar Transfer Case Diagnostic and Operational Information
Applies To : TerraStar 4x4 Models
Description
TerraStar 4x4 model vehicles are built with a FABCO TC-28 transfer case with 4 feedback switches and 2 electric actuators. The body
controller monitors the feedback switches to regulate when it grounds each one of the 4 relays that control the amperage and polarity to
each of the 2 electric actuators. The transfer case has 3 modes, 4x2 high, 4x4 high, and 4x4 low.
Interlocks To Change Ranges
To shift the transfer case from 4X2 high mode to 4x4 high mode, the following interlocks must be met:
•
•
•
•
•
Key is in the run position
Engine speed is above programmable parameter 3047, Engine_Operating_Threshold. Default setting is 300 RPM
Vehicle speed is below programmable parameter 2812, Axle_Engage_Threshold. Default setting is 24 MPH
Axle differential speed is below programmable parameter 3052, FR2RR_Vel_Diff_ABS_Threshold. Default setting is 0.93 MPH
Front axle switch is in the upper position and has a good status
To shift the transfer case from 4x4 high mode to 4x4 low mode, the following interlocks must be met:
•
•
•
•
•
•
•
Transfer case is in 4x4 high mode
Vehicle speed is below programmable parameter 3045, Range_Engage_Threshold. Default setting is 3 MPH
Transmission is in the neutral range
Service brake is depressed
Key is in the run position
Engine speed is above programmable parameter 3047, Engine_Operating_Threshold. Default setting is 300 RPM
Range switch is in the lower position and has a good status
When shifting from 4x4 high to 4x4 low mode, the front axle indicator lamp in the front axle switch will flash. This is normal operation.
DLB Template
Click HERE for the DLB template for diagnosing this.
Signal Descriptions
Signal
B/C Pin
Transfer case Mode
Description
Xfer_Case_4x4_Cmd
1601-E13
N/A
This is the ground command to the 4x4 relay
Xfer_Case_4x2_Cmd
1601-E9
N/A
This is the ground command to the 4x2 relay
Xfer_Case_High_Cmd
1601-F4
N/A
This is the ground command to the high range relay
Xfer_Case_Low_Cmd
1601F5
N/A
This is the ground command to the low range relay
Transfer_Case_Front_Axle_Disengaged
1602-F11
Front axle is not engaged when checked
in DLB
This is the signal from switch SW1, indicating the
transfer case position.
Transfer_Case_Front_Axle_Engaged
1602_F13
Front axle is engaged when checked in
DLB
This is the signal from switch SW2, indicating the
transfer case position.
Transfer_Case_Driveline_Engaged_Low
1602F8
Transfer case is in low range when
checked in DLB
This is the signal from switch SW3, indicating the
transfer case position.
Transfer_Case_Driveline_Engaged_High
1602F9
Transfer case is in high range when
checked in DLB
This is the signal from switch SW4, indicating the
transfer case position.
Operational Values
Transfer Case Range
SW1
SW2
SW3
SW4
4x2 High
Closed
Open
Open
Closed
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 1/2/2014
IK1300138 TerraStar Transfer Case Diagnostic and Operational Information
4x4 High
Open
Closed
Open
Closed
4x4 Low
Open
Closed
Closed
Open
Page 2 of 4
Fault Codes
Signal
xfer_Case_4x4_cmd
xfer_Case_4x2_cmd
Transfer_Case_Front_Axle_Engaged
Transfer_Case_Front_Axle_Disengaged
B/C Pin
SPN
FMI
Description
Action
1601_E13
Transfer Case Front Driveline Actuator
1601_E9
1602_F13
4043
6
Transfer Case Front Driveline Solenoid
Short To Ground
This indicates there is a short to ground in either of of the transfer case
front axle mode circuits
1602_F11
Transfer Case Front Driveline Actuator
Transfer_Case_Front_Axle_Disengaged
1602_F11
4043
3
1602_F13
4043
4
Fault Via Transfer Case Front Axle
Disengaged
Open from SW1 to the body controller, body controller expects transfer
case to be in 4x2 high range
Transfer Case Front Driveline Actuator
Transfer_Case_Front_Axle_Engaged
Fault Via Transfer Case Front Axle
Engaged
Open from SW2 to the body controller, body controller expects transfer
case to be in 4x4 high range
Transfer Case Low Range Actuator
Transfer_Case_Driveline_Engaged_Low
1602_F8
4045
3
Fault Via Transfer Case Driveline
Engaged Low limit switch
Open from SW3 to the body controller, body controller expects transfer
case to be in 4x4 high range
Transfer Case High Range Actuator
Transfer_Case_Driveline_Engaged_High
xfer_Case_Low_cmd
xfer_Case_High_cmd
Transfer_Case_Driveline_Engaged_Low
Transfer_Case_Driveline_Engaged_High
Transfer_Case_Front_Axle_Engaged
Transfer_Case_Front_Axle_Disengaged
Transfer_Case_Driveline_Engaged_Low
Transfer_Case_Driveline_Engaged_High
1602_F9
4044
3
Fault Via Transfer Case Driveline
Engaged High limit switch
Open from SW4 to the body controller, body controller expects transfer
case to be in 4x4 low range
1601_F5
Transfer Case High Range Actuator
1601_F4
1602_F8
4044
6
Transfer Case High Range Solenoid
Short To Ground
This indicates there is a short to ground in either of of the transfer case
range circuits
1602_F9
1602_F13
Transfer case status
1602_F11
1602_F8
3645
5
All Limit switches for Electronic transfer
Case are open
All Limit switches for Electronic transfer Case are open
1602_F9
Transfer Case Front Driveline Actuator
Transfer_Case_Front_Axle_Engaged
Transfer_Case_Front_Axle_Disengaged
1602_F13
1602_F11
4043
7
System not responding Fault with Front
axle engagement motor
The body controller is sending a command either the axle engagement
or disengagement relay, but there is no status change from either
SW1 or SW2
Transfer Case High Range Actuator
Transfer_Case_Driveline_Engaged_Low
Transfer_Case_Driveline_Engaged_High
ABS Module
1602_F8
1602_F9
4044
7
3645
9
System not responding Fault with
Driveline Range(High/Low) engagement
motor
The body controller is sending a command either the low or high range
relay, but there is no status change from either SW3 or SW4
This is a fault code from the ABS module indicating the ABS does not
know which range the transfer case is in
Switch Locations
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IK1300138 TerraStar Transfer Case Diagnostic and Operational Information
Page 3 of 4
Troubleshooting
When the transfer case is in any range, the switch that corresponds with that location will be closed, completing the feedback circuit to the
body controller. The high and low range switches should never both be closed at the same time. The front axle engaged and front axle
disengaged switches should never both be closed at the same time either.
The first step to diagnosing the system is to understand which range the transfer case currently is in. There are two ways to figure this out.
The first way is to place the vehicle in neutral with the engine off and wheels chocked, and comparing the input and output rotations of each
shafts are they are being turned by hand in comparison to each other. The second is to drive the vehicle and see it the speedometer is
accurate, and if the vehicle is capable of reaching highway speeds. The transfer case low range is a 2.2:1 underdrive. This means that when
the transfer case is in low range, for every 2.2 turns of the output shaft from the transmission to the transfer case, the driveshafts that
connect to the axles turn one time. Once the transfer case range is understood, this should be compared to the reading of the feedback
switches in DLB with the key on. The table above gives signal descriptions for each range. If the feedback signals do not match the current
position of the transfer case, the body controller will not send a signal for the transfer case to shift.
Circuit Diagram
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IK1300138 TerraStar Transfer Case Diagnostic and Operational Information
Page 4 of 4
Transfer Case Mounted Wiring Harness Diagram
Click HERE for the transfer case mounted wiring diagram
Transfer Case Information
The parts and service manual for the FABCO TC-28 transfer case can be obtained by clicking HERE.
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Copyright © 2014 Navistar, Inc.
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TSB/Document ID: IK-1300138
Replacement Service Bulletin Number:
MFR Communication Date: 2013-12-09
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: POWER TRAIN:AUTOMATIC TRANSMISSION
MFR Component System:
MFR Component Subsystem:
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