NHTSA ID Number: 10218842
Manufacturer Communication Number: SIL 11-TR-22
TSB/Document Date: 2022-08-29
Summary
Introduction of 9832 Rapid Warmup and Output Brake Features.
by 100 rpm or more in N (Neutral)?
Copyright © 2022 Allison Transmission, Inc. All Rights Reserved.
SIL 11-TR-22
July 25, 2022
Page 19 of 40
DTC C0082 Transmission Output Brake Range Verification
(SPN 11752 / FMI 31) (cont'd)
Step
Action
11
Yes
No
Disassemble, inspect, and correct any issues
causing hydraulic circuit issues within the main
valve body, such as stuck valves, debris, broken
springs, etc.
Were there any main valve body issues to
correct that were causing hydraulic circuit
issues?
Repair issues
found in main
valve body. Go
to Step 15.
Replace all
solenoids that
are energized for
Output Brake
and Rapid
Warmup. Refer
to Appendix A
to determine
appropriate
solenoids. Go
to Step 12.
12
1.
2.
Go to Step 13.
System OK.
Clear inactive
DTCs and return
equipment to
service.
13
1.
2.
Turn ignition OFF.
Install a test TCM and tighten the bolt in
the TCM 80-way connector to 2.0-3.2 N·m
(18-28 lb in).
3. Start engine and operate equipment in the
same conditions noted from the failure
records from Step 1.
4. Using Allison DOC, check for active codes.
5. If codes are not active with test TCM
installed, then turn ignition OFF and
reinstall original TCM.
6. Restart engine, operate equipment in the
same conditions noted from the failure
records from Step 1 and check again for
active DTCs.
Is DTC C0082 still active with the original TCM
and inactive with a test TCM?
Install a new
TCM. Go to
Step 15 after
repairs are made.
If DTC is active
with both test
TCM and original
TCM, then
reinstall the
original TCM.
Go to Step 14.
14
1.
Go to Step 15.
Review
Diagnostic
Aids for this
DTC. Begin the
diagnosis again.
Go to Step 1.
Install main valve body.
Acquire a new Allison DOC snapshot
while operating the equipment under same
conditions, if possible, noted in failure
records for the DTC.
Did DTC C0082 return?
Refer to the service manual and remove
the transmission.
2. Disassemble and inspect all modules and
assemblies.
3. Check for wear, damage, or defects in all
modules.
4. Repair or replace parts that do not meet
service specification. Refer to the service
manual.
Was a transmission issue identified that was
causing this DTC?
Value(s)
Copyright © 2022 Allison Transmission, Inc. All Rights Reserved.
SIL 11-TR-22
July 25, 2022
Page 20 of 40
DTC C0082 Transmission Output Brake Range Verification
(SPN 11752 / FMI 31) (cont'd)
Step
15
Action
1.
Install or reconnect all OEM and
transmission connectors, if needed.
NOTE: TCM 80-way connector bolt must be
tightened to 2.0-3.2 N·m (18-28 lb in).
2.
Acquire new Allison DOC snapshot while
operating the equipment under same
conditions, if possible, noted in failure
records from Step 1.
Did DTC C0082 return?
Value(s)
Yes
No
Review
Diagnostic
Aids for this
DTC. Begin the
diagnosis again.
Go to Step 1
System OK.
Clear inactive
DTCs and return
equipment to
service.
Copyright © 2022 Allison Transmission, Inc. All Rights Reserved.
SIL 11-TR-22
July 25, 2022
Page 21 of 40
DTC P0504 Transmission Output Brake Switch Correlation
(SPN 11752 / FMI 7)
SWITCH CT2
62
TCM
3
17
OPTIONAL
VEHICLE
INTERFACE
WIRING
CONNECTOR
162
TRANSMISSION BRAKE INPUT 2
103
SIGNAL RETURN
117
TRANSMISSION BRAKE INPUT 1
SWITCH CT1
ALL ITEMS SHOWN EXCEPT TCM ARE SUPPLIED
AND INSTALLED BY THE EQUIPMENT BUILDER.
ACTUAL SYSTEM SCHEMATIC MAY VARY BY OEM.
6187887
Circuit Description
The Output Brake function is enabled when two separate switches are closed to complete the circuits between
wires 117 and 162 to Signal Return wire 103. The Output Brake feature requires both circuits to be closed
simultaneously to activate the function and both circuits to open simultaneously to deactivate the function. This test
determines if the two switch states match.
Conditions for Setting the DTC
The TCM continuously checks the signal state of wires 117 and 162. If the signal state of one of the wires does not
match the other for more than 9 seconds, the DTC will set.
Action Taken When the DTC Sets
• The TCM illuminates the CHECK TRANS light
• The TCM inhibits lockup
• The transmission remains in the last valid state for Output Brake
• DTC is stored in TCM history
Conditions for Clearing the DTC
The DTC will automatically become inactive and deactivate the Check Trans light if the signal states of both
wires match for at least 6 seconds.
Use Allison DOC to clear the DTC from the TCM history. The TCM automatically clears the DTC from the TCM
history if the vehicle completes 40 warm-up cycles without the DTC recurring.
Diagnostic Aids
• DTC P0504 can be caused by:
– W117 or W162 intermittently shorted to another wire or to ground in chassis harness or OEM switch.
– W117 or W162 intermittently open circuit in chassis harness or OEM switch.
– Broken or defective connector assemblies allowing pushed back pins to short together.
Copyright © 2022 Allison Transmission, Inc. All Rights Reserved.
SIL 11-TR-22
July 25, 2022
Page 22 of 40
DTC P0504 Transmission Output Brake Switch Correlation
(SPN 11752 / FMI 7) (cont'd)
– Unlocked or loose connectors, missing seal plugs allowing moisture in connectors.
– Defective or loose connections in OEM switch or switch wiring.
– Defective or damaged TCM.
• DTC P0504 can occur when the OEM switches that activate functions CT1 and CT2 are physically in
different states (open vs. closed) or the switches are installed incorrectly. If DTC P0504 persists, ensure
correct installation of the OEM switches using technical service information provided by the equipment
manufacturer and verify the physical switch states.
Tool Requirements
• Allison DOC
• J-39700 Universal Breakout Box
• J-47275 4th Generation TCM/VCM Breakout Harness
• J-47275-1 4th Generation TCM/VCM Magnetic Overlay
• J-46708 High Impedance Digital Multimeter
DTC Troubleshooting Step Description
Each item number description in this list correlates to the identical number shown in the DTC table "Step" column
and is meant to briefly describe the "Action" column procedures for a particular step in the table. The DTC
troubleshooting step descriptions examine the following:
1. Check for active DTC.
2. Check for CT1 and CT2 Signal State rationality.
3. Check for shorts to ground or to another wire.
4. Check for high resistance or open circuits in W117, W162, or W103.
5. Check TCM.
6. If DTC is still active, review Diagnostic Aids, begin troubleshooting again at Step 1.
Step
1
Action
1.
2.
3.
Connect Allison DOC.
Start engine and select N (Neutral).
Record snapshot using Allison DOC
showing active or inactive code(s).
4. Review failure records report from snapshot
to determine conditions when DTC occurs.
Is DTC P0504 active or present in TCM history?
Value(s)
Yes
No
Go to Step 2
Troubleshoot
any other active
DTCs if present.
If no other DTCs
are active, go
to Step 6.
Copyright © 2022 Allison Transmission, Inc. All Rights Reserved.
SIL 11-TR-22
July 25, 2022
Page 23 of 40
DTC P0504 Transmission Output Brake Switch Correlation
(SPN 11752 / FMI 7) (cont'd)
Step
Action
2
Keep engine running, transmission in
Neutral, and Allison DOC connected.
2. While watching the Signal State and
Function State parameters in Allison DOC
Data Monitor, use OEM controls to open
and close the switches that activate Input
Functions CT1 and CT2 for Output Brake.
Do the Signal States and Function States of
both inputs change as expected?
3
1.
2.
Value(s)
1.
Turn ignition OFF.
Connect J-47275 4th Generation TCM/VCM
Breakout Harnessto J-39700 Universal
Breakout Box.
3. Disconnect OEM chassis harness 80-way
connector from TCM.
4. Connect OEM chassis harness to J-47275
4th Generation TCM/VCM Breakout
Harness.
5. Do NOT connect TCM side of J-47275 4th
Generation TCM/VCM Breakout Harness
to TCM.
6. Connect 16-way bypass on J-47275 4th
Generation TCM/VCM Breakout Harness.
7. Turn ignition ON but do not start engine,
use OEM controls to OPEN the switches
on W117 and W162.
8. Turn ignition OFF and using J-46708 High
Impedance Digital Multimeter, measure
resistance between terminal 17 and every
other labeled terminal shown on J-47275-1
4th Generation TCM/VCM Magnetic
Overlay, and to chassis ground.
9. Repeat task 8 for terminal 62.
Does resistance measure 20 kΩ or more from
J-47275-1 4th Generation TCM/VCM Magnetic
Overlay terminal 17 and 62 to all other labeled
terminal locations on J-47275-1 4th Generation
TCM/VCM Magnetic Overlay, and to chassis
ground?
20 kΩ or more
Yes
No
Go to Step 6.
Go to Step 3.
Go to Step 5.
Address issue
with W103, W117
or W162 in OEM
chassis harness
or switch. Go
to Step 6 after
repairs are made.
Copyright © 2022 Allison Transmission, Inc. All Rights Reserved.
SIL 11-TR-22
July 25, 2022
Page 24 of 40
DTC P0504 Transmission Output Brake Switch Correlation
(SPN 11752 / FMI 7) (cont'd)
Step
Action
Value(s)
Yes
No
4
Turn ignition OFF.
Leave J-47275 4th Generation TCM/VCM
Breakout Harness connected to J-39700
Universal Breakout Box.
3. Leave OEM chassis harness 80-way
connected to J-47275 4th Generation
TCM/VCM Breakout Harness OEM side.
4. Leave TCM side of J-47275 4th Generation
TCM/VCM Breakout Harness disconnected
from TCM.
5. Leave 16-way bypass connected on
J-47275 4th Generation TCM/VCM
Breakout Harness.
6. Turn ignition ON but do not start engine,
use OEM controls to CLOSE the switches
on W117 and W162.
7. Install J-46708 High Impedance Digital
Multimeter between terminals 17 (CT1)
and 3 (signal return) at J-47275-1 4th
Generation TCM/VCM Magnetic Overlay.
8. Measure resistance between terminals
17 and 3 at J-47275-1 4th Generation
TCM/VCM Magnetic Overlay.
9. Repeat tasks 7 and 8 for terminals 62 (CT2)
and 3 (signal return).
Does circuit resistance for each combination
measure 4 Ω or less after tool resistance is
subtracted from J-46708 High Impedance
Digital Multimeter reading?
4 Ω or less
Address issue
with W103,
W117, or W162
in OEM chassis
harness or
switch. Go to
Step 6 after
repairs are made.
Go to Step 5.
5
1.
2.
Install a new
TCM. Go to
Step 6 after
repairs are made.
If DTC is active
with both test
TCM and
original TCM,
then reinstall
the original
TCM. Review
Diagnostic Aids.
Go to Step 1.
1.
2.
Turn ignition OFF.
Install a test TCM and tighten the bolt in
the TCM 80-way connector to 2.0-3.2 N·m
(18-28 lb in).
3. Start engine and operate equipment in the
same conditions noted from the failure
records from Step 1.
4. Using Allison DOC, check for active codes.
5. If codes are not active with test TCM
installed, then turn ignition OFF and
reinstall original TCM.
6. Restart engine, operate equipment in the
same conditions noted from the failure
records from Step 1 and check again for
active DTCs.
Is DTC P0504 still active with the original TCM
and inactive with a test TCM?
Copyright © 2022 Allison Transmission, Inc. All Rights Reserved.
SIL 11-TR-22
July 25, 2022
Page 25 of 40
DTC P0504 Transmission Output Brake Switch Correlation
(SPN 11752 / FMI 7) (cont'd)
Step
6
Action
1.
2.
Remove J-39700 Universal Breakout Box,
and all related harness adapters from
vehicle, if installed.
Install or reconnect all TCM connectors, if
needed.
NOTE: TCM 80-way connector bolt must be
tightened to 2.0-3.2 N∙m (18-28 lb in).
Value(s)
Yes
No
Review
Diagnostic
Aids for this
DTC. Begin the
diagnosis again.
Go to Step 1
System OK.
Clear inactive
DTCs and return
equipment to
service.
3.
- Mixes well with conventional fluids
- Low-moisture formula provides excellent vapor lock...
- Ideal for hydraulic and disc brakes
- Provides an extra margin of safety in extreme braking...
- Mix of polyglycol ethers ensures hot brake-system operation...
- Excellent for ABS, disc and drum brake systems
- Delivers braking power when needed by avoiding a spongy...
- Both wet and dry boiling points exceed the minimum...
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TSB/Document ID: SIL 11-TR-22
Replacement Service Bulletin Number:
MFR Communication Date: 2022-06-25
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: POWER TRAIN
MFR Component System:
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