22-TR-05EN, Rev A.

pdf 10/27/06 1:39:08 PM

Revisions to this SIL are noted 22-TR-05, Rev A

by a stripe in the left-hand margin. October, 2006
Product Code(s):
Page 1 of 4

SUBJECT: “No Engine Crank” / “No Diagnostic Tool Communication” for some 4th Generation Control TCMs

POSSIBLE EQUIPMENT AFFECTED: 1000/2000/3000/4000 Product Families Equipped with

4th Generation Controls TCMs (A40, A41, A42, A43)

Background:
Several 4th Generation TCMs have been returned to Allison Transmission with damage caused by electrical short circuits
applied to the heatsink of the TCM (see Figure 1).
Possible Symptoms:
1. TCM does not power up.
C 2. Shift selector displays cat-eyes.
M
3. TCM will not communicate with diagnostic tools (e.g. Allison DOC™ for PC).
4. Engine will not start.
5. Active Diagnostic Codes.
Y

6. Switch to Ground Input / Output Function(s) not working.

CM

MY

WARNING! Short circuits applied to the TCM heatsink are abusive to the TCM. Passing excessively high
CY

CMY
currents through the TCM or transmission is abusive. TCM damage that might occur because of
K these actions is not warrantable by Allison Transmission.
Make sure all vehicle grounds are clean and properly torqued, e.g., batteries, alternator, starter,
engine block, vehicle chassis grounds. Poor vehicle grounding practices may reroute high,
electrical currents through the TCM and other transmission, electrical systems. Any resulting
TCM damage would not be warrantable by Allison Transmission.
Do not allow electrical contact with the TCM heatsink while jump-starting the vehicle. TCM
damage may occur.
Do not allow electrical contact between the TCM heatsink and welders, battery chargers,
electrostatic painting equipment, or any other electrical devices. TCM damage may occur. When
using such equipment always disconnect the 80-way connector from the TCM.
All vehicle harness connections to circuits of the TCM, shift selector, or transmission must
comply with the latest published guidelines from Allison Transmission.

Allison Transmission
General Motors Corporation
Indianapolis, IN 46206-0894

KZ / SL5232EN

Copyright 2006 General Motors Corporation. All Rights Reserved.

 22-TR-05, Rev A
October, 2006
Product Code(s):
Page 2 of 4

PATH OF ELECTRICAL CURRENT

CAUSING DAMAGE

HEATSINK

TCM
V09005.03.00

Figure 1.

To avoid damaging a TCM in this manner, NEVER ALLOW the following:

1. Battery positive wires to touch the heatsink of the TCM (e.g when jump-starting vehicle).
2. Positive battery power chassis harness wire to pin 10 and pin 70 of the TCM to be wired without fuse protection of
10–15 amp.
3. Physical contact between heatsink and vehicle chassis or other circuit ground points.
4. Electrical grounding of devices such as arc welders, battery charger cables, electrostatic painting equipment, or
jumper cables to the TCM heatsink.
Troubleshooting:
To check for damage to TCM return circuits, do the following:
1. Switch the ignition key to the off position.
2. Install J 39700 breakout box with J 47275 TCM breakout harness adapter and J 47275-1 magnetic overlay (see Figure 2).
 22-TR-05, Rev A
October, 2006
Product Code(s):
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J 39700 BREAKOUT BOX

J 47275-1

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

17 18 19 20 21 22 23 24

25 26 27 28 29 30 31 32

33 34 35 36 37 38 39 40

41 42 43 44 45 46 47 48

49 50 51 52 53 54 55 56

57 58 59 60 61 62 63 64

65 66 67 68 69 70 71 72

73 74 75 76 77 78 79 80

Detail of
TCM Overlay
for use with
J 47275
TCM Breakout
Harness Adapter

16-Pin Bypass
Connector 80-Way Connector
To Vehicle

80-Way Connector
To TCM

TCM V09225.01.00

Figure 2.
 22-TR-05, Rev A
October, 2006
Product Code(s):
Page 4 of 4

3. Connect 80-way connector of J 47275 to the TCM. Do not connect the vehicle side 80-way connector of J 47275 to
the chassis harness.
4. Check for continuity using a digital volt-ohmmeter (multimeter) between pin 3 (digital return) and the following list
of pins: pin 9 (battery return), pin 58 (analog return), and pin 69 (battery return)—see Figure 3.
5. If there is no continuity between pin 3 and any of these pins (i.e., pin 9, 58, and 69), then the TCM is damaged. Vi-
sually inspect the TCM heatsink for surface pits and/or carbon deposits to help determine whether the damage was
caused by an electrical short through the heatsink.

58
69

80 61

60 41

40 21

20 1

3
PINOUT VIEW
TCM V09005.04.01

Figure 3.

NOTE: Typically, electrical shorts to the TCM heatsink will leave a visible mark on the heatsink,
though; it is possible to damage the TCM in this manner without an obvious, visible mark.

Repair Procedure:
1. If a no continuity condition is discovered during any of the pin-to-pin measurements made previously, then go to
repair step 2. If continuity was confirmed, in each pin-to-pin measurement, then go to step 4A for 1000/2000 or
step 4B for 3000/4000 models.
2. Eliminate or repair the source or condition that caused the TCM damage, e.g. jumper cables touching heatsink, loose
engine block ground, etc.
3. Replace the damaged TCM. Repair is complete.

1000/2000 Model
4A. Refer to Section 5 for DTCs otherwise refer to Section 7 of TS3977EN, 1000 and 2000 Product Families Trouble-
shooting Manual—Allison 4th Generation Controls.

3000/4000 Model
4B. Refer to Section 6 for DTCs otherwise refer to Section 8 of TS3989EN, 3000 and 4000 Product Families Trouble-
shooting Manual—Allison 4th Generation Controls.