PCS 4-Speed Transmission Quick Reference Guide
PCS 4-Speed Transmission Quick Reference Guide
THIS GUIDE IS FOR USE BY A TRAINED TECHNICIAN. FOR ADDITIONAL TECHNICAL SUPPORT, USE THE FOLLOWING:
+1 (804) 227-3023 gsetechs@[Link] [Link]
PREVENTATIVE MAINTENANCE
• Service interval is 1,000 hours / 12 months whichever comes first
• Filter and pan gasket should be replaced (PCS Part# TRN7090)
• Fluid must be DEXRON VI
TO COOLER TAP
within the fleet.
TRANSMISSION CASE VARIANT 1
➤
➤
➤
➤
Tapped -6ORB
(9/16-18" w/O-Ring)
➤
Recommended Fitting
➤
➤
➤
➤
OUTPUT
➤
SHAFT
CASE VARIANT 2
➤
EXTENSION
➤
SPEED
TRANS ID
SENSOR
TRANSMISSION NAMEPLATE Tapped 1/4" NPS
FILL TUBE TORQUE
VEHICLE OIL PAN HOLE CONVERTER
TRANSMISSION OIL PAN (Straight Pipe, 0.54-18")
MOUNTING PAD
TRANSMISSION CONTROL TRANSMISSION SHIFT LEVER Recommended Fitting
CONNECTOR (MANUAL SHAFT)
PCS Part #: TRN0215
HEAT SHIELD LOCATION (S)
1/4" NPS Male to -6JIC Male
ATTACHMENT
Last Four Digits Complete Trans Part # LOCATE LABEL TCM FRONT
Powertrain Control Solutions
of Trans Part #
Model: TCM-2600
Input Voltage: 8 - 18 VDC
Model #
4447
4447D717123935
TRN4447
17123 935 Sequence #
Julian Date
Located at the TCM breakout Made in USA
[Link]
(YYDDD)
READ LABEL TCM REAR
Model # Model: A-TCM2800
TCM-4635-001 PCS Part # Serial:2515
Firmware:3.160.8
4L70E 2010+ Description
Date:04/06/18
SO#:12152
Trans serial # is a 14 digit number comprised of: TO 2600 Cal: EPS J1939 With Shutdown and Fuel Level
Manufactured by Powertrain Control Solutions, LLC.
[Last 4 of Part #] + D7 + [Julian Date] + [Sequence #]
ENGINE
SIDE
+1(804) 227-3023
Verify the throttle position reading is zero • Measuring resistance between CAN H and CAN L must be 60Ω.
Throttle
when the pedal is not press and 100% when
Position Sensor:
fully depressed. LINE PRESSURE TAP
STATIONARY ENGINE RUNNING CHECKS Line pressure tap (1/8" NPT) available for diagnostics.
Start the engine and check the fluid level is 1. Remove pressure plug
Fluid Level Check: 2. Install appropriately rated pressure gauge for transmission line
sufficient.
pressure measurement. Pressures could exceed 300 PSI.
Verify the engine RPM on the software 3. Command current using PCS software
Engine RPM:
matches the actual engine RPM. 4. Start the Engine.
5. Perform test in Neutral at 1200 RPM between 100 - 200°F
DTC Check: Verify there are no diagnostic codes set.
(38 - 93°C).
TEST DRIVE (Operate the vehicle until trans is at operating temp) AMP PSI
0 170-193
Move the vehicle and verify that the vehicle
4LHD
Vehicle Speed: 0.5 135-166
speed operates properly.
1 54-80
Check proper transmission operation in all
Shifting: 0 198-227
4LHDX
gears.
0.5 154-193
*Data log recommended. For help, view "How to Datalog."
1 53-85
POST DRIVE CHECK
!
WARNING: Only perform this test in Neutral with the brakes
DTC Verification: Check for diagnostic codes. applied and engine speeds below 1500 RPM. Failure to do so may
Verify the fluid level is correct and no fluids result in extremely high pressures (in excess of 300 PSI) that could
Fluid Level Verification: damage the transmission or the gauge and result in serious injury.
are leaking from the vehicle.
[Link]
TRANSMISSION VENT TORQUE CONVERTER PULL-UP
Vent must be clear of exhaust and heat sources.
(PCS Part#: TRN7006-REV2) 1. Align and install the
bellhousing/transmission to
the engine. Before tightening
Torque Converter
rotates freely.
DIPSTICK INDICATORS
CONTAMINATED FLUID COLD: 80-90˚F (26-32˚C)
Fluid that has a cloudy or milky appearance
gsetechs@[Link]
NOTE: DTC’s may be visible on factory installed dash displays or with a J1939 code reader.
• Arrow facing out. Connect to the TCM using the software and verify the following items:
• Verify switched ignition on
pin E (10A fuse). 1. Shift lever matches reported lever position.
purposes.
➤ ➤
8.405±0.025MM
!
WARNING: Use of the diagnostic device must only be performed by a trained technician. The device will control the transmission without safety
devices or normal operating controls on the vehicle. Extreme caution must be observed. The vehicle could move suddenly and without notice.
All testing must be performed with an operator on the seat. The brakes must be functional and pressed until it is desired for the vehicle to move.
Severe injury or death could occur if safety precautions are not taken while operating the diagnostic device.
CONNECT
Step 4. With operator on seat, brakes fully pressed, start engine. The vehicle will move suddenly when commanded by the TDD.
NOTE: Gen 3 valve body vehicles will move independent of shift lever position in all tests.
GEN 2 REVERSE CLUTCH SOLENOID TEST GEN 3 REVERSE CLUTCH SOLENOID TEST
Turning the solenoid ON prevents reverse (abuse protection Turning the solenoid OFF prevents reverse (abuse protection
reverse lockout). reverse lockout).
REV FWD LINE TCC SSA SSB REV FWD LINE TCC SSA SSB
+1(804) 227-3023
OFF OFF OFF OFF ON ON OFF OFF OFF OFF ON ON
Move shift lever into Reverse with REV OFF. The vehicle Move shift lever into Reverse with REV OFF. The vehicle
Step 1. Step 1.
should move in Reverse. should not move in Reverse.
Step 2. Move shift lever into Neutral. Step 2. Move shift lever into Neutral.
Step 3. Turn REV ON. Step 3. Turn REV ON.
Step 4. Move shift lever into Reverse. Vehicle should not move. Step 4. Move shift lever into Reverse. Vehicle should move.
Turning the solenoid ON enables forward (abuse protection Increasing current to this solenoid reduces transmission
forward lockout, when OFF). pressure (softer shifts). Turning the switch ON provides 1A to the
REV FWD LINE TCC SSA SSB solenoid (minimum pressure).
OFF ON OFF OFF ON ON REV FWD LINE TCC SSA SSB
Move shift lever into Drive with FWD ON. Vehicle should OFF ON OFF OFF ON ON
Step 1.
move forward in 1st gear. Move shift lever into Drive with LINE OFF. Move forward
Step 2. Move shift lever into Neutral. Step 1. and turn OFF SSA to shift into 2nd gear. The vehicle should
Step 3. Turn FWD OFF. shift with maximum firmness.
Step 4. Move shift lever into Drive. Vehicle should not move. Step 2. Move the shift lever into Neutral.
Move the shift lever into Drive with LINE, SSA, and SSB
SHIFT SOLENOID A&B TEST Step 3. ON. Move forward and turn OFF SSA to shift into 2nd gear.
The vehicle should shift with minimum firmness.
The shift solenoids select the gear of the transmission.
REV FWD LINE TCC SSA SSB TCC SOLENOID TEST
OFF ON OFF OFF ON ON Turning the solenoid ON locks the converter clutch.
Move shift lever into Drive. The vehicle should move in 1st REV FWD LINE TCC SSA SSB
Step 1.
[Link]
gear.
OFF ON OFF OFF ON ON
At an appropriate speed, move the shift solenoids to
Step 2. Move the shift lever into Drive while firmly applying the
switch gears. Reference the table below. Step 1.
brakes.
GEAR SSA SSB
Step 2. Turn the TCC ON. The engine should stall.
1 ON ON
2 OFF ON
3 OFF OFF
4 ON OFF
P/N ON OFF ON OFF OFF OFF OFF -40 -40 90636 100707 110778
IMS P ON OFF ON OFF ON OFF ON 32 0 8481 9423 10365
G3 OFF OFF OFF ON ON ON ON 86 30 2013 2237 2461
G2 OFF ON ON ON ON OFF OFF 122 50 876 973 1070
G1 ON ON OFF OFF ON ON OFF 158 70 420 467 514
*Only for shift cable applications. 212 100 159 177 195
302 150 42.5 47.2 51.9
v1.3
DIAGNOSTIC TROUBLE CODES (DTC’s) 5
Diagnostic trouble codes (DTC’s) can be read using the PCS diagnostic software or the check transmission light installed on the dash.
If a DTC is active and the engine is running, the check transmission light will be on solid to indicate there is an active code. When the ignition
is turned on, but the engine is not running, the light will flash a pattern so the DTC can be read. The flashing will indicate both active and stored
codes.
The codes consist of two numbers. The first number is flashed at one second intervals, then a one second pause and the second number is
flashed at 350ms. There is a three second pause in between trouble codes.
EXAMPLE:
Code 24 consists of two
slow flashes followed by 3 second pause before next trouble code
gsetechs@[Link]
ACTIVE TO STORED
CODE DESCRIPTION FAIL CONDITIONS ACTION TAKEN
CONDITIONS
522744
51 TCM
Sets when Internal memory writes/reads fail, COP stops
operating or processor executes an Illegal Opcode.
2nd Gear, Max line pressure,
Inhibit TCC
Key Cycle
522736
Key Cycle or when
52 System Voltage
High Long
Sets when system voltage is greater than 16 volts for 30
minutes.
2nd Gear, Max line pressure,
Inhibit TCC
system voltage drops
522733 below 15V.
Key Cycle or when
53 System Voltage
High
Sets when system voltage is greater than 19.5 volts for 5
seconds.
2nd Gear, Max line pressure,
Inhibit TCC
system voltage drops
522734 below 18V.
When trans temp drops
58 Trans Temp High
TFT Circuit Low
Sets when Transmission Temperature Is above 151°C (304°F). Inhibit 4th/TCC below 148°C for 5
522737 seconds.
When trans temp goes
59 Trans Temp Low
TFT Circuit High
Transmission Temperature Is Below - 37°C (-34°F) for 1
second.
Inhibit 4th/TCC above -35°C for 5
522738 seconds.
Component No DTC 23, 28, 71, 74. Throttle Position is greater than 25%,
68 Slipping/TCC/4th Engine speed is 200 rpm or more than input speed for 6 Max line pressure, Inhibit 4th Key Cycle
522753 Clutch Slipping seconds when in 4th gear and TCC engaged.
No DTC 21, 22, 23, 71, 74 Sets when TCC slip is between -25
69 TCC Stuck On and 25 rpm, TCC solenoid is commanded off, TPS is greater
TCC Commanded on, Max
Line Pressure
Key Cycle
522745 than 25% for 4 seconds.
71 Engine Speed
Circuit Low
Sets when Engine speed is less than 50 RPM, transmission
range is R, D4, D3, D1 for 2 seconds.
Inhibit 4th and TCC
When Engine RPM
goes above 300 RPM
v1.3
522501
NOTE: J1939 codes, if available, can be found in the column "CODE" below the GM 2-digit code.
6 DIAGNOSTIC TROUBLE CODES (DTC’s)
ACTIVE TO STORED
CODE DESCRIPTION FAIL CONDITIONS ACTION TAKEN
CONDITIONS
No DTC 21, 22, 23, 28, 71, 74. Sets when Engine RPM is
Intermittent Max line pressure. Calculate
72 Output Shaft
greater than 300, range is D4, D3, D2, or D1, Throttle position
is greater than 25% and Output shaft speed changes more
TOSS from TISS and Key Cycle
522742 Speed commanded Gear.
than 500 rpm in one measurement period.
73 Pressure Control
Circuit
Force motor current is more than 0.16 Amps different than
commanded current for 2 seconds.
Max line pressure. Key Cycle
522746
No DTC 28. Sets when Range is not park or neutral, engine When Input Speed goes
74 Input Speed
Sensor Circuit
speed greater than 300 RPM, Output speed greater than 200
Max line pressure. Inhibit 4th/
TCC.
above 75 RPM for 2
522739 RPM, Input speed less than 50 RPM, for 2 seconds. seconds.
Sets when the ignition is on, voltage is less than the following Clears when system
conditions: voltage is greater than
75 System Voltage -40°F (-40°C) = 7.3V 2nd Gear with Max pressure. the following conditions
+1(804) 227-3023
Low 194°F (90°C) = 10.3V Inhibit TCC. for 4 seconds:-
522735 40°F (-40°C) =7.3V
302°F (150°C) = 11.7V
194°F (90°C) =10.3V
Engine Speed is greater than 300 rpm for 4 seconds. 302°F (150°C) = 11.7V
When trans temp falls
79 Transmission
Fluid Overtemp
No DTC 58 sets when transmission fluid temperature is
greater than 270°F (132°C), for 5 minutes.
None. below 266°F (130°C) for
522732 5 seconds.
Shift Solenoid Battery Voltage above 10V TCM detects an
81 B (SSB) Circuit open circuit, short to battery, short to ground, or over-current
2nd or 3rd gears only. Max
Line Pressure.
When Fault condition
removed for 2 seconds.
522750 Fault condition on the shift solenoid B circuit for 2 seconds.
Shift Solenoid Battery Voltage above 10V TCM detects an open circuit, short 2nd and 3rd gears only or 1st
82 A (SSA) Circuit to battery, short to ground, or over-current condition on the and 4th gear only. Max line
When Fault condition
removed for 2 seconds.
522748 Fault shift solenoid A circuit for 2 seconds. pressure.
Battery Voltage above 10V. TCM detects an open circuit, short
83 TCC Solenoid
Circuit Fault
to battery, short to ground, or over-current condition on the
Inhibit TCC. Inhibit 4th when
in Hot mode.
When Fault condition
removed for 2 seconds.
522752 TCC solenoid circuit.
Accelerator
Measured throttle voltage difference exceeds allowable
84 Pedal
Performance
tolerance.
Assume 0% throttle. Key Cycle
No DTC 21, 22, 23, 24, 28, 71, 72 sets when RPM is greater
85 Undefined Ratio
Error
than 300 RPM, TPS is greater than 25%, VSS is greater than
2nd gear with Max line
pressure. Inhibit TCC.
Key Cycle
522754 7 MPH, ratio falls out of range for 6 seconds.
No DTC 21, 22, 23, 24, 28, 71, 72, 74, 85 sets when RPM
Low Ratio Error is greater than 300 RPM, TPS is greater than 25%, VSS is
86 (Shift Solenoid B greater than 7 MPH, transmission ratio matches 4th when 1st
2nd gear with Max
line pressure. Inhibit TCC.
Key Cycle
522749 (SSB) Stuck On) is commanded or 3rd gear when 2nd gear is commanded, for
6 seconds.
No DTC 21, 22, 23, 24, 28, 71, 72, 74, 85 sets when RPM
High Ratio Error is greater than 300 RPM, TPS is greater than 25%, VSS is
87 (Shift Solenoid B greater than 7 MPH, transmission ratio matches 1st when 4th
2nd gear with Max
line pressure. Inhibit TCC.
Key Cycle
[Link]
522747 (SSB) Stuck Off) is commanded or 2nd gear when 3rd gear is commanded, for
6 seconds.
TPS greater than 15% or RPM greater than 800 RPM during
91 Non-Idle Inch
inching.
Transmission locked Key Cycle
Movement Not
92 Commanded
Output shaft movement detected when not commanded. Transmission locked Key Cycle
Inching Past
93 Target
Output shaft movement detected past desired stopping point. Transmission locked Key Cycle
vehicle movement.
Trans commanded to neutral;
Reverse Clutch however an electrical failure
Reverse clutch current is more than 0.16 Amps different than
95 Solenoid Circuit
Fault
commanded current for 2 seconds.
of the clutch solenoid could
result in unpredictable
Key Cycle
vehicle movement.
Valid communication
Anti-collision No communication with anti-collision module or anti-collision
98 System Fault DTC.
Disable anti-collision system received or anti-collision
fault cleared.
v1.3
NOTE: J1939 codes, if available, can be found in the column "CODE" below the GM 2-digit code.