DF 150 and 250 Transmission DIAGNOSTIC

P R O O F
Transmission Control
Unit (TCU)
Diagnostic Manual
COMPONENT TECHNICAL
MANUAL
Transmission Control Unit (TCU)
Diagnostic Manual
CTM157 15JUL05 (ENGLISH)
For complete service information also see:

P R O O F
DF150/250 Series Transmission Manual . . . CTM147

DF150 Series Transmission Manual . . . . . . . CTM148
DF250 Series Transmission Manual . . . . . . . CTM149
Funk Manufacturing Company

LITHO IN U.S.A.
P R O O F
Introduction
Foreword
This manual is written for an experienced technician. Information is organized in groups for the various
Essential tools required in performing certain service components requiring service instruction. At the
work are identified in this manual and are beginning of each group are summary listings of all
recommended for use. applicable essential tools, service equipment and tools,
other materials needed to do the job, service parts kits,
Live with safety: Read the safety messages in the specifications, wear tolerances, and torque values.
introduction of this manual and the cautions presented
throughout the text of the manual. Technical Manuals are concise guides for specific
machines. They are on-the-job guides containing only
the vital information needed for diagnosis, analysis,
This is the safety-alert symbol. When you see this
testing, and repair.
symbol on the machine or in this manual, be alert to
the potential for personal injury.
Fundamental service information is available from
other sources covering basic theory of operation,
Technical manuals are divided in two parts: repair and
fundamentals of troubleshooting, general maintenance,
operation and tests. Repair sections tell how to repair
and basic type of failures and their causes.
the components. Operation and tests sections help you
identify the majority of routine failures quickly.
DX,TMIFC 1929SEP981/1
P R O O F
CTM157 (15JUL05) DF Series TCU Analog System

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P R O O F
Contents
005
005Transmission Control Unit
Group 05Safety
Group 10General Information
Group 100Test and Troubleshooting
Group 105TCU and Accessories
INDX
Group 110Diagnostic Codes
P R O O F
All information, illustrations and specifications in this manual are based on

the latest information available at the time of publication. The right is
reserved to make changes at any time without notice.
COPYRIGHT 1999, 2004, 2005
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
CTM157 (15JUL05) i DF Series TCU Analog System

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P R O O F
Contents
005
INDX
P R O O F
CTM157 (15JUL05) ii DF Series TCU Analog System

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P R O O F
005
005
Transmission Control Unit
Contents
Page Page
Group 05Safety . . . . . . . . . . . . . . . . . . . . .005-05-1 Engine Speed Magnetic Pickup Sensor. . . .005-105-18

Cylinder Speed Magnetic Pickup Sensor. . .005-105-19
Group 10General Information Output Speed Magnetic Pickup Sensor . . . .005-105-20
Theory Of Operation . . . . . . . . . . . . . . . . . . . .005-10-1 Park Brake Pressure Switch . . . . . . . . . . . .005-105-21
Understanding The TCU Label . . . . . . . . . . . .005-10-2 Temperature Sensor . . . . . . . . . . . . . . . . . .005-105-22
Abbreviations And Acronyms. . . . . . . . . . . . . .005-10-2 Function Of Proportional Valves . . . . . . . . .005-105-23
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-3 Proportional Valve Pinouts . . . . . . . . . . . . .005-105-24
Multimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-4 Solenoid/Gear Combinations . . . . . . . . . . . .005-105-25
Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-5 Transient Voltage Protection Module. . . . . .005-105-28
High Resistance Circuit Malfunction Transmission Wiring Harness 1 of 4 . . . . . .005-105-30
Example . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-6 Transmission Wiring Harness 2 of 4
Open Circuit Malfunction Example. . . . . . . . . .005-10-8 (continued). . . . . . . . . . . . . . . . . . . . . . . .005-105-31
Grounded Circuit Malfunction Example . . . . .005-10-10 Transmission Wiring Harness 3 of 4
Shorted Circuit Malfunction Example . . . . . . .005-10-12 (continued). . . . . . . . . . . . . . . . . . . . . . . .005-105-32
Seven Step Electrical Test Procedure Transmission Wiring Harness 4 of 4
Example . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-14 (continued). . . . . . . . . . . . . . . . . . . . . . . .005-105-33
J6 Connector. . . . . . . . . . . . . . . . . . . . . . . .005-105-34
Group 100Test and Troubleshooting
Troubleshooting Introduction . . . . . . . . . . . . .005-100-1 Group 110Diagnostic Codes
Visually Inspect Electrical System . . . . . . . . .005-100-2 System Diagnostics Codes . . . . . . . . . . . . . .005-110-1
General Troubleshooting Tips . . . . . . . . . . . .005-100-3 Overview Of Diagnostic Codes . . . . . . . . . . .005-110-1
P R O O F
Troubleshooting The Gear Selector. . . . . . . .005-100-4 Code 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-5

Troubleshooting The Gear Selector with PC Code 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-7
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . .005-100-7 Code 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-9
YZ102710 RS-232 Diagnostic Cable and Code 23 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-11
J1939 Adapter . . . . . . . . . . . . . . . . . . . . . .005-100-8 Code 24 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-13
Troubleshooting The Inching Pedal Code 25 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-15
System . . . . . . . . . . . . . . . . . . . . . . . . . . .005-100-9 Code 26 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-17
Calibration. . . . . . . . . . . . . . . . . . . . . . . . . .005-100-12 Code 27 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-19
Clutch Calibration Procedure: Four Code 28 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-21
Forward Speeds and Four Reverse . . . . .005-100-13 Code 29 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-23
Clutch Calibration Procedure: Eight Code 30 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-26
Forward Speeds And Four Reverse. . . . .005-100-14 Code 30 (Continued) . . . . . . . . . . . . . . . . . .005-110-27
Code 31 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-28
Group 105TCU and Accessories Code 31 (Continued) . . . . . . . . . . . . . . . . . .005-110-29
System Components . . . . . . . . . . . . . . . . . . .005-105-1 Code 32 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-30
Transmission Control Unit (TCU). . . . . . . . . .005-105-2 Code 32 (Continued) . . . . . . . . . . . . . . . . . .005-110-31
TCU Mounting, Grounding, and Enviromental Code 33 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-32
Considerations. . . . . . . . . . . . . . . . . . . . . .005-105-3 Code 33 (Continued) . . . . . . . . . . . . . . . . . .005-110-33
J1 Connector. . . . . . . . . . . . . . . . . . . . . . . . .005-105-6 Code 34 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-34
J2 Connector. . . . . . . . . . . . . . . . . . . . . . . . .005-105-8 Code 34 (Continued) . . . . . . . . . . . . . . . . . .005-110-35
J3 Connector. . . . . . . . . . . . . . . . . . . . . . . .005-105-10 Code 35 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-36
Gear/diagnostic Indicator. . . . . . . . . . . . . . .005-105-12 Code 35 (Continued) . . . . . . . . . . . . . . . . . .005-110-37
Electronic Gear Selector . . . . . . . . . . . . . . .005-105-13 Code 36 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-38
J4 Connector. . . . . . . . . . . . . . . . . . . . . . . .005-105-15
Inching Pedal (Application Dependent) . . . .005-105-16 Continued on next page
CTM157 (15JUL05) 005-1 DF Series TCU Analog System

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Contents
005
Page Page
Code 36 (Continued) . . . . . . . . . . . . . . . . . .005-110-39 Code 108 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-150

Code 37 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-40 Code 109 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-150
Code 38 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-42 Code 111 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-151
Code 39 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-44 Code 113 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-151
Code 40 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-46 Code 115 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-152
Code 41 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-47 Code 116 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-152
Code 42 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-50 Code 117 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-152
Code 43 (For applications using disc Code 127 (For applications using disc
brakes) . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-52 brakes) . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-153
Code 43 (For applications using disc brakes) Code 127 (For applications using wet
Continued . . . . . . . . . . . . . . . . . . . . . . . .005-110-53 brakes) . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-156
Code 43 (For applications using wet Code 127 (For applications using a pressure
brakes) . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-55 switch) . . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-159
Code 44 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-58 Code 145 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-160
Code 45 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-64 Code 146 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-161
Code 48 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-70 Code 148 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-163
Code 49 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-76 Code 150 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-164
Code 50 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-78 Code 154 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-166
Code 51 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-81 Code 155 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-168
Code 52 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-84 Code 160 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-170
Code 54 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-89 Code 161 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-171
Code 56 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-90 Legal Conditions For Code 161. . . . . . . . . 005-110-172
Code 57 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-93 Code 162 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-173
Code 59 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-97 Code 163 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-175
P R O O F

Code 80 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-99 Code 171 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-177
Code 84 . . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-100 Legal Conditions For Code 171. . . . . . . . . 005-110-178
Code 85 . . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-103 Code 172 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-179
Code 87 . . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-113 Code 173 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-181
Code 89 (For applications using disc Code 175 (12 Volt System) . . . . . . . . . . . . 005-110-183
brakes) . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-120 Code 175 (24 Volt System) . . . . . . . . . . . . 005-110-185
Code 89 (For applications using wet Code 176 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-188
brakes) . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-124 Code 177 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-190
Code 90 . . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-127 Code 178 (12 Volt System) . . . . . . . . . . . . 005-110-192
Code 91 . . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-133 Code 178 (12 Volt System) -
Code 92 . . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-138 Continued . . . . . . . . . . . . . . . . . . . . . . . 005-110-193
Code 93 . . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-138 Code 178 (24 Volt System) . . . . . . . . . . . . 005-110-194
Code 98 . . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-139 Code 178 (24 Volt System) -
Code 99 . . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-140 Continued . . . . . . . . . . . . . . . . . . . . . . . 005-110-195
Code 100 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-141 Code 179 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-196
Code 101 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-143 Code 180 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-198
Code 102 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-143 Code 198 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-201
Code 103 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-144 Code 199 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-202
Code 104 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-145 Flashing ECU Message . . . . . . . . . . . . . 005-110-203
Code 105 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-147
Code 106 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-148
Code 107 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-149
CTM157 (15JUL05) 005-2 DF Series TCU Analog System

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Group 05
P R O O F
Safety
005
Recognize Safety Information 05
1
This is a safety-alert symbol. When you see this symbol

on your machine or in this manual, be alert to the
potential for personal injury.
UN07DEC88
Follow recommended precautions and safe operating
practices.
T81389
DX,ALERT 1929SEP981/1
Prepare for Emergencies
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,
UN23AUG88
hospital, and fire department near your telephone.
TS291
DX,FIRE2 1903MAR931/1
Wear Protective Clothing

P R O O F
Wear close fitting clothing and safety equipment

appropriate to the job.
Prolonged exposure to loud noise can cause impairment

or loss of hearing.
UN23AUG88
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
TS206
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating machine.
DX,WEAR 1910SEP901/1
CTM157 (15JUL05) 005-05-1 DF Series TCU Analog System

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P R O O F
Safety
005
05 Work In Ventilated Area
2
Engine exhaust fumes can cause sickness or death. If it is

necessary to run an engine in an enclosed area, remove
the exhaust fumes from the area with an exhaust pipe
extension.
UN23AUG88
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area
TS220
DX,AIR 1917FEB991/1
Work in Clean Area
Before starting a job:
Clean work area and machine.

Make sure you have all necessary tools to do your job.
UN18OCT88
Have the right parts on hand.
Read all instructions thoroughly; do not attempt
shortcuts.
T6642EJ
DX,CLEAN 1904JUN901/1
Illuminate Work Area Safely

P R O O F
Illuminate your work area adequately but safely. Use a

portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire cage.
The hot filament of an accidentally broken bulb can ignite
spilled fuel or oil.
UN23AUG88
TS223
DX,LIGHT 1904JUN901/1
Using High-Pressure Washers
IMPORTANT: Directing pressurized water at

electronic/electrical components or
connectors, bearings and hydraulic
seals, fuel injection pumps or other
UN18OCT88
sensitive parts and components may

cause product malfunctions. Reduce
pressure, and spray at a 45 or 90
degree angle.
T6642EJ
DPSG,YZ07927,186 1904MAR991/1

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P R O O F
Safety
005
Use Proper Lifting Equipment 05
3
Lifting heavy components incorrectly can cause severe

injury or machine damage.
Follow recommended procedure for removal and

installation of components in the manual.
UN23AUG88
TS226
DX,LIFT 1904JUN901/1
Use Proper Tools
Use tools appropriate to the work. Makeshift tools and

procedures can create safety hazards.
Use power tools only to loosen threaded parts and

fasteners.
UN08NOV89
For loosening and tightening hardware, use the correct
size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping
TS779
wrenches.
Use only service parts meeting John Deere specifications.

P R O O F
DX,REPAIR 1917FEB991/1
Support Machine Properly
Always lower the attachment or implement to the ground

before you work on the machine. If the work requires that
the machine or attachment be lifted, provide secure
support for them. If left in a raised position, hydraulically
supported devices can settle or leak down.
UN23AUG88
Do not support the machine on cinder blocks, hollow tiles,

or props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.
TS229
Follow recommended procedures in this manual.
When implements or attachments are used with a

machine, always follow safety precautions listed in the
implement or attachment operators manual.
DX,LOWER 1924FEB001/1

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P R O O F
Safety
005
05 Handle Fluids SafelyAvoid Fires
4
When you work around fuel, do not smoke or work near

heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not

incinerate or puncture pressurized containers.
UN23AUG88
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burn
TS227
spontaneously.
DX,FLAME 1929SEP981/1
Prevent Battery Explosions
Keep sparks, lighted matches, and open flame away from

the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object

across the posts. Use a volt-meter or hydrometer.
UN23AUG88
Do not charge a frozen battery; it may explode. Warm
P R O O F
battery to 16C (60F).
TS204
DX,SPARKS 1903MAR931/1

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P R O O F
Safety
005
Prevent Acid Burns 05
5
Sulfuric acid in battery electrolyte is poisonous. It is strong

enough to burn skin, eat holes in clothing, and cause
blindness if splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 1530 minutes. Get
medical attention immediately.
UN23AUG88
If acid is swallowed:
1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not
TS203
exceed 2 L (2 quarts).
3. Get medical attention immediately.
P R O O F
DX,POISON 1921APR931/1
Avoid Heating Near Pressurized Fluid Lines
Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders. Do not heat by welding,
soldering, or using a torch near pressurized fluid lines or
other flammable materials. Pressurized lines can
UN15MAY90
accidentally burst when heat goes beyond the immediate

flame area.
TS953
DX,TORCH 1910DEC041/1

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P R O O F
Safety
005
05 Avoid High-Pressure Fluids
6
Escaping fluid under pressure can penetrate the skin

causing serious injury.
Avoid the hazard by relieving pressure before
UN23AUG88
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands
X9811
and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid

injected into the skin must be surgically removed within a
few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable
medical source. Such information is available from Deere
& Company Medical Department in Moline, Illinois, U.S.A.
DX,FLUID 1903MAR931/1
Live With Safety

P R O O F
Before returning machine to customer, make sure

machine is functioning properly, especially the safety
systems. Install all guards and shields.
1907OCT88
TS231
DX,LIVE 1925SEP921/1

072705
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Group 10
P R O O F
General Information
005
Theory Of Operation 10
1
UN08AUG98
YZ1571
Transmission Control Unit>
The purpose of the Transmission Control Unit (TCU) is until the problem has been resolved and the gear
to control the functions of the transmission. Upshifting, selector cycled back through the neutral or park
downshifting, control of the proportional solenoids and position.
capability to communicate with a panel mounted
gear/diagnostic indicator are the main functions. The If no diagnostics code conditions are detected, based
transmissions performance is determined by the upon a combination of inputs from the gear selector
various inputs to the TCU. Based upon these inputs, and other applicable inputs, the TCU will select the
the TCU commands the transmission so that maximum proper transmission gear and command the
P R O O F
performance can be achieved under the present transmission to shift to this gear. The gear/diagnostic
operating conditions. All functions of the TCU are indicator will now show the actual transmission gear.
under software control.
The TCU uses electrohydraulic proportional valves to
Operation begins when the vehicles ignition is control the operation of the transmission. The
switched to the ON position, supplying electrical solenoids controlling the transmission clutches
power to the TCU and related system components (solenoids A through D & 1 through 4) are driven by a
from the vehicles power source. The TCU now begins signal that produces proportional pressure/flow
monitoring all inputs and outputs. If a known conflict in changes. During modulation, the solenoids are started
inputs or a fault condition is detected, the TCU will out with a low duty cycle and ramped up to full on. The
command the transmission to stay in neutral initial duty cycle is dependent upon several factors and
regardless of the gear selector position. A flashing is not a preset value. The process of modulating these
diagnostic code will be displayed on the clutches greatly enhances shift quality.
gear/diagnostic indicator, and will remain displayed
AG,YZ07927,4 1910OCT981/1

072705
PN=13
P R O O F
General Information
005
10 Understanding The TCU Label
2
NOTE: On older model TCUs, the hardware P/N is on a

sticker beneath the software P/N.
A TCU software part number

B Software revision letter
C TCU serial number
UN03MAR99
D TCU hardware part number
E Original programming date (week/year)
YZ1812
TCU Label Information
DPSG,YZ07927,185 1903MAR991/1
Abbreviations And Acronyms
BOC: Bottom of Clutch P: Park

CAN: Controller Area Network POT: Potentiometer
CCD: Chrysler Collision Detection RPM: Revolutions Per Minute
CYL: Cylinder SOL: Solenoid
DC: Direct Current TCLU: Torque Converter Lock-Up
ENG: Engine TCU: Transmission Control Unit
GND: Ground or negative battery terminal TEMP: Temperature
P R O O F
ms: Milliseconds TOC: Top of Clutch

MPU: Magnetic Pick-Up sensor. This device TVP: Transient Voltage Protection module. This
monitors the rotational speed (the engine for device conditions vehicle battery power for the TCU
example) and sends a proportional frequency signal and protects the TCU from reverse battery
to the TCU. connections and potentially harmful voltage spikes.
PWM: Pulse Width Modulation V: Volt
AG,YZ07927,31 1914OCT981/1

072705
PN=14
P R O O F
General Information
005
Glossary 10
3
Active The high voltage state of a digital signal. Legal Conditions A set or sets of input signal
Also called high or binary 1. states which will result in correct system operation;
Actual Gear The actual physical gear of the i.e. no diagnostic codes will be generated by the
transmission, regardless of shift lever position or TCU.
controller operation. Neutral Recoverable The process where a detected
Analog A signal which has a continuous range of fault is maintained and displayed by the TCU until
possible voltages. the shift lever is cycled to neutral (park on some
Bus A serial communications link which systems) and the TCU detects the proper
interconnects intelligent electronic modules. combination of inputs for a legal neutral (park)
Come-Home A hardware function which allows condition, at which time the displayed fault will be
limited vehicle motion in the event of failure of cleared. The fault code will still be stored in
certain components. memory.
Commanded Gear The gear selected by the Next Gear The next gear the controller plans to
combination of the shift lever position and the state enter. The next gear will become the current gear
of the Forward, Reverse, Neutral, and Not Neutral if no faults are detected and all conditions for
TCU inputs. The destination gear. entering the next gear are met.
Current Gear The gear the controller is currently Nonvolatile Memory Memory that retains its data
attempting to send the transmission into by the even though power to the system has been
application of current to the valves. removed.
Digital A signal which may take one of two voltage Passive The low voltage state of a digital signal.
levelsusually 0 volts and +5 volts. On/Off type Also called low or binary 0.
signals are also considered to be digital. Previous Direction The direction of vehicle motion
Downshift Inhibit The prohibiting of downshifting by before a shuttle shift is initiated
the TCU to prevent harsh and abrupt shifts or Previous Gear The previous current gear.
possible overspeed conditions of the engine. The Sequence Shift The type of shift which consists of
downshift will be inhibited until the current speed shifting from a gear to an adjacent gear.
ratio will permit the shift to take place. Shuttle Shift A shift to a gear in the opposite
Fault An abnormal condition which results in a direction of vehicle travel made by moving the shift
P R O O F
perceived performance change or in a loss of lever between the Forward and Reverse positions.
function which may result in performance loss or
system damage.
Intershift Pause Time A preprogrammed value in
the TCU which sets the minimum time delay
between shifts.
AG,YZ07927,43 1916OCT981/1

072705
PN=15
P R O O F
General Information
005
10 Multimeter
4
Multimeters are an essential troubleshooting tool. They

enable the technician to make a variety of electrical
measurements.
Multimeters vary widely in price and capability. They are

available with analog (gauge or needle) displays or
digital autoranging displays, like the unit displayed at right.
Even inexpensive multimeters have the features and

accuracy necessary for the majority of troubleshooting
tests described in this manual. However, it is important to
become familiar with the features and capabilities of your
multimeter; refer to the users guide supplied by the
manufacturer.
ADisplay
BVoltage AC (Alternating current) setting
CVoltage DC (Direct current) setting
DResistance setting
1903SEP93
EDiode test/continuity setting
FCurrent AC (Alternating current) setting
GCurrent DC (Direct current) setting
HVoltage, Resistance, Diode/continuity input (Red
T8074AA
lead)
IGround input (Black lead)
JCurrent/amps input (Red lead)
Digital Multimeter
P R O O F
AG,YZ07927,34 1909OCT981/1

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PN=16
P R O O F
General Information
005
Malfunctions 10
5
1927FEB92
T7713AD
Common Circuit Components
P R O O F
ABattery CSwitch DLight EGround

BFuse
1. There are four common circuit malfunctions. After the component.
High-Resistance Circuit Component malfunctions can easily be confused with

Open Circuit circuit malfunctions. Therefore, exercise care when
Grounded Circuit isolating the cause of a problem.
Shorted Circuit
Example: Light does not operate or is dim when switch
2. Three sections in a simple circuit where these is turned ON, until switch connector is disconnected
malfunctions can occur: and reconnected.
Before the controlling switch (C). Reason: High resistance caused by a dirty switch
Between the controlling switch and before the connector caused a voltage drop which prevented the
component, light (D). proper amount of current from flowing to the light.
AG,YZ07927,27 1908OCT981/1

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PN=17
P R O O F
General Information
005
10 High Resistance Circuit Malfunction Example
6
1926FEB92
T7713AG
High Resistance Circuit
P R O O F
ABattery DSwitch terminal FHarness connector HLight

BFuse EHigh resistance GLight terminal IGround
CSwitch
A high resistance circuit can result in slow, dim or no If less than battery voltage is measured, check again
component operation. closer to switch.
Possible Causes: If battery voltage is measured, check closer to ground

to locate point of voltage drop. The example shows
Loose, corroded, dirty or oily terminals. high resistance (E) between switch and harness
Wire size too small. connector.
Strands broken inside the wire.
Poor ground connection to frame. Repair circuit as required. In the example, strands
were broken inside the wire requiring replacement of
To locate the cause of high resistance: that section of wire.
With switch (C) ON, check for battery voltage between Repeat check-out procedure after repair.
switch and ground (I) at an easily accessible location,
like harness connector (F).
AG,YZ07927,29 1908OCT981/1

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PN=18
P R O O F
General Information
005
10
7
P R O O F

072705
PN=19
P R O O F
General Information
005
10 Open Circuit Malfunction Example
8
1927FEB92
T7713AF
Open Circuit
P R O O F
ABattery DSwitch terminal FOpen circuit HLight

BFuse EHarness connector GLight terminal IGround
CSwitch
An open circuit will result in no components operating. With switch (C) ON check for battery voltage at switch
Fuse may or may not be blown. terminal (D).
Possible Causes: If no voltage is measured, check switch, fuse and

wiring to battery.
Broken wire
Disconnected component terminal If battery voltage is measured, check for voltage closer
Pins inside a connector not making contact to ground at harness connector (E).
Blown fuse
Open circuit breaker In the example, zero voltage will be measured at the
Failed switch or component light terminal, indicating a broken wire between
Disconnected ground wire harness connector and light terminal.
To locate an open circuit: If battery voltage had been measured, the next check
for voltage would be at ground connection (I).
Check fuse. If blown, replace and operate circuit. If
fuse blows a second time, continue check.
Continued on next page AG,YZ07927,30 1908OCT981/2

072705
PN=20
P R O O F
General Information
005
Normal measured voltage at a ground connection When the problem is located, repair as needed, then 10
9
should be 0.0 to 0.5 volts. repeat the last check.
If battery voltage is measured, a poor connection to

frame or broken wire is indicated.
AG,YZ07927,30 1908OCT982/2
P R O O F

072705
PN=21
P R O O F
General Information
005
10 Grounded Circuit Malfunction Example
10
1927FEB92
T7713AE
ABattery DSwitch GHarness Connector JLight
P R O O F
BFuse ESwitch terminal HGround Circuit KGround

CFuse terminal FHarness Connector ILight (component) terminal
If no component operates, the fuse is blown and connector (F), turn switch (D) ON, and check for
replacement fuses blow immediately or the circuit continuity to the ground at harness connector (F). This
breaker is open and reopens when reset, a grounded will check the harness from the harness connector to
circuit exists. the fuse.
Possible Causes: If continuity to ground is measured, there is a pinched

or bare wire between the fuse (C) and harness
A power wire contacting another metal component connector (F).
due to a pinched wire or worn insulation.
If continuity to ground does not exist, disconnect
To isolate the location of a grounded circuit: ground (K) from the frame. Measure continuity to
ground at harness connector (G). This checks the
If the circuit is grounded between the battery and fuse, harness from the harness connector to the ground
the wire will be burned and circuit will be open; the terminal. In the example, continuity to ground will exist
fuse will not be blown. because the circuit is grounded (wire is pinched) at
(H).
If the fuse is blown, remove it from the circuit.
Disconnect the circuit near its center at harness

072705
PN=22
P R O O F
General Information
005
If continuity exists, disconnect the circuit at the light Repeat check-out procedure after repair. 10
11
terminal (I) and measure continuity to ground on the
light terminal. In the example continuity will not exist,
indicating a grounded circuit between the light and
harness connector (G).
AG,YZ07927,31 1908OCT982/2
P R O O F

072705
PN=23
P R O O F
General Information
005
10 Shorted Circuit Malfunction Example
12
1927FEB92
T7713AH
Shorted Circuit
P R O O F
ABattery ESwitch terminal IHarness connector LLight

BFuse FSwitch JLight MGround
CFuse GHarness Connector KLight terminal NGround
DSwitch HShorted Circuit
A shorted circuit causes components in separate Turn switch (F) ON. Both lights (J and L) will be ON;
circuits to operate when a switch in either circuit is only light (L) should be ON.
turned ON.
Disconnect the wire from switch of the component that
Example: should not be ON. In the example, disconnect wire
from terminal (E) at switch (D). Light (J) remains ON.
Both lights (J and L) will be ON when either switch
(D or F) is ON.> Disconnect the circuit at convenient places like
harness connectors (G), (I) and light terminal (K) until
Possible Causes: light (J) goes OFF.
Two harnesses rubbing together until insulation is The short circuit will be between the last two places
worn through allowing bare wires to touch). the circuit was disconnected. In the example, it is
Components can also become shorted. However, between harness connectors (G and I). Light (J) will go
shorted components will usually blow the fuse. OFF when harness connector (I) is disconnected.
Inspect harness between connectors (G and I).
To locate a shorted circuit:

072705
PN=24
P R O O F
General Information
005
Repair or replace wires and harnesses as needed. Repeat check-out procedure after repair. 10
13
Install tie bands and clamps on harnesses as required
to prevent future failures.
AG,YZ07927,33 1909OCT982/2
P R O O F

072705
PN=25
P R O O F
General Information
005
10 Seven Step Electrical Test Procedure Example
14
1905MAR92
T7719AA
Seven Step Electrical Test Procedure
P R O O F
ABattery ground DFuse or circuit breaker GBattery side of component IGround side of component
BBattery EComponent side of fuse or terminal terminal
CBattery side of fuse or circuit breaker HLight (Component) JComponent ground
circuit breaker FSwitch

072705
PN=26
P R O O F
General Information
005
Step 1Switch ON 10
15
Check battery side of circuit breaker (C) for battery voltage Battery voltage normal. Go to step 2.
Low voltage, repair high resistance.
Open circuit from battery
Step 2Switch OFF
Check component side of circuit breaker for battery voltage Battery voltage normal. Go to step 4.
No voltage. Go to step 3.
Step 3Switch OFF
Check component side of circuit breaker for continuity to ground Continuity to ground. Repair grounded circuit at or before switch.
No continuity to ground, replace circuit breaker.
Step 4Switch ON
Check component side of circuit breaker for battery voltage Battery voltage normal. Go to step 6.
No voltage. Go to step 5.
Step 5
Disconnect wire at battery side of component (G). Switch ON. Check Battery voltage, repair component.
wire at (G) for battery voltage
No voltage, repair grounded or open circuit at or after switch.
Step 6Switch ON
Check lead to component at (G) for battery voltage Battery voltage normal. Go to step 7.
Low voltage, repair high resistance in circuit between fuse and
component.
No voltage, repair high resistance or open circuit between fuse and
component.
Step 7Switch ON
Check ground wire of component at (I) for voltage No voltage, good continuity to ground.
P R O O F
Repair component.
Voltage, poor continuity to ground. Repair high resistance or open
ground circuit.
AG,YZ07927,36 1909OCT982/2

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PN=27
P R O O F
General Information
005
10
16
P R O O F

072705
PN=28
Group 100
P R O O F
Test and Troubleshooting
005
Troubleshooting Introduction 100
1
This introduction is written to initiate an understanding Magnetic pickups (speed sensors)

of a strategy which can be used toward solving Temperature sensor
problems in the vehicle driveline system. The preferred Transmission control unit (TCU)
technique used in solving problems is to exchange Transmission control valves
components. An understanding of the total system and Transmission hydraulic system (pump, relief valves,
an elimination process leading to identification of the lines, etc.)
problem component is absolutely necessary before Transmission mechanical system (clutches, gears,
starting the exchange activity. shafts, seals, etc.)
Transient Voltage Protection module (TVP)
Reduce the random exchange of components by Wiring harness
carefully analyzing the symptoms and then conducting
tests which will help determine which component in the Because the TCU is a relatively complex and
system is likely to be the problem. unfamiliar component, it is often the first component
targeted for exchange. However, TCU malfunctions are
The transmission system consists of the following relatively rare. In addition, the TCU has internal
components linked together to form a functioning diagnostics capabilities which are usually helpful in
system: isolating an operational problem. If the TCU responds
to commands and does not provide a diagnostic code
Gear selector indicating a problem with the TCU itself, the likelihood
Gear/Diagnostic indicator of the problem being internal to the TCU is remote.
Inching pedal (application dependent)
P R O O F
AG,YZ07927,2 1918NOV981/1

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P R O O F
005
100 Visually Inspect Electrical System
2
Make the following visual electrical inspection prior to 6. After machine has been shut down for five minutes
starting the vehicle. inspect for overheated parts.
1. Look for bare wires that could ground a component 7. If your visual inspection does not indicate the
or short across to another component. possible malfunction, turn the key to the ON
position. Visually check out the accessory circuits,
2. Look for missing or worn conduit. indicator lights, gauge lights. Look for sparks or
smoke which might indicate a possible short.
3. Look for loose or broken connectors and wires.
8. Start machine. Check all gauges for good operation
4. Inspect batteries for: and check to see if system is charging or
discharging.
Corroded terminals
Loose terminals or battery posts Many electrical failures cannot be detected even if the
Dirty condition machine is started. Therefore, a systematic and
Damp condition complete inspection of the electrical system is
necessary.
5. Check alternator belt tension.
DPSG,YZ07927,187 1915MAR991/1
P R O O F

072705
PN=30
P R O O F
005
General Troubleshooting Tips 100
3
1. Troubleshoot with the vehicle engine off. 7. If using the vehicle frame as a ground reference
during electrical measurements, make certain that it
2. During the troubleshooting process, be sure to is in fact ground. If in doubt, use the negative
check the integrity of all connector pins. Replace or battery terminal.
repair any broken or damaged pins as needed.
8. Whenever checking a device (switch, etc.) remotely
3. Check for damaged connectors. through a wire harness, dont forget to rule out the
possibility that the problem is in the wiring rather
4. Verify that wires are connected to the correct than the device being tested.
harness or device pins.
Assumptions:
5. When troubleshooting at a connector with many
pins, take special care to correctly identify and 1. Correct battery voltage is available to the TVP
accurately probe the pins of interest. Probing the module (except for Code 60-low supply voltage).
correct pins is crucial to solving the problem. Look
for wire labels on wiring harness. 2. Only single-point failures are considered.
6. When using the multimeter, take care not to 3. An application-specific wiring diagram is available
damage female terminals by forcing in a probe, for reference.
especially one with a diameter larger than the
terminals are designed for. This can lead to open 4. If a short to GND caused a fuse to blow, the TCU
circuits or bad connections after the troubleshooting would not be operational. Troubleshooting would
process is completed. have to proceed without the added benefit of
diagnostic codes.
IMPORTANT: Always use the correct terminals
when making repairs or
replacements.
P R O O F
DPSG,YZ07927,188 1915MAR991/1

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P R O O F
005
100 Troubleshooting The Gear Selector
4
NOTE: (This procedure applies only to FUNK 12V 3. Check integrity and cleanliness of the terminal pins
gear selector p/n YZ102155 and 24V gear on both the harness and the gear selector. Check
selector p/n YZ102827) gear selector pins to insure that the connector pins
have not been pushed up into the connector.
Several of the diagnostic codes involve signals that
come from the gear selector. With this simple list of 4. Connect the black multimeter lead to the black
tests, it can be checked out in just a few minutes. The common jack on the multimeter.
only tool required is a multimeter.
5. Connect the red multimeter lead to the red
1. Turn the ignition to the "OFF" position. volts/ohms "V-ohms" jack on the multimeter.
2. Remove the round J4 connector from the bottom of 6. Proceed with the tests in Table A:
the gear selector. (Testing will go even faster if the Troubleshooting the Gear Selector, taking careful
gear selector is removed from its mounting point, note of the pin letter designations on the connector.
since the connector pins are more easily accessible
when the gear selector is completely detached from
the vehicle.)
Continued on next page DPSG,YZ07927,169 1901DEC981/3

P R O O F

072705
PN=32
P R O O F
005
100
5
UN23SEP98
YZ1805
J4 Gear Selector Pinout
GEAR SELECTOR PINOUT
J4 CONNECTOR PIN TCU PIN DESCRIPTION

A J3-A1 +12/24V
B J2-A2 NOT NEUTRAL/shift code (B)
C J2-A1 NEUTRAL
D J1-H3 DOWNSHIFT/shift code (D)
E J1-H2 UPSHIFT/shift code (E)
F J1-J2 REVERSE
P R O O F
G J1-J1 FORWARD
H J1-A2 Ground
J S1-A Neutral start

072705
PN=33
P R O O F
005
100 Table A: Troubleshooting the Gear Selector
6
To Check Multimeter Mode Multimeter Gear Selector Expected Reading Faulty Gear
Connections Position for Good Gear Selector Reading
Selector
*NEUTRAL relay coil Diode check Black lead on pin A Neutral 0.4 to 0.7 V Open circuit ("OL")
diode Red lead on pin H or short circuit (0 V)
*NOT NEUTRAL Diode check Same as previous Not neutral 0.4 to 0.7 V Open circuit ("OL") or
relay coil diode step. short circuit (0 V)
*NOT NEUTRAL Resistance Same as previous Not neutral 12V: 640 to 800 Infinite resistance
relay coil step. ohms (open circuit)
24V: 2600 to 3180
ohms
*NEUTRAL relay coil Resistance Same as previous Neutral 12V: 640 to 800 Infinite resistance
step. ohms (open circuit)
24V: 2600 to 3180
ohms
DOWNSHIFT switch Resistance or Black lead on pin A Downshift Less than 2 ohms, More than 2 ohms,
audible continuity Red lead on pin D or "beep." or no "beep."
Resistance or Black lead on pin A Not downshift More than 2 ohms, Less than 2 ohms, or
DOWNSHIFT switch
audible continuity Red lead on pin D or no "beep." "beep."
UPSHIFT switch Resistance or Black lead on pin A Upshift Less than 2 ohms, More than 2 ohms,
audible continuity Red lead on pin E or "beep." or no "beep."
Resistance or Black lead on pin A Not upshift More than 2 ohms, Less than 2 ohms, or
UPSHIFT switch
audible continuity Red lead on pin E or no "beep." "beep."
REVERSE switch Resistance or Black lead on pin A Reverse Less than 2 ohms, More than 2 ohms,
audible continuity Red lead on pin F or "beep." or no "beep."
REVERSE switch Resistance or Black lead on pin A Not reverse More than 2 ohms, Less than 2 ohms, or
audible continuity Red lead on pin F or no "beep." "beep."
FORWARD switch Resistance or Black lead on pin A Forward Less than 2 ohms, More than 2 ohms,
audible continuity Red lead on pin G or "beep." or no "beep."
Resistance or Black lead on pin A Not forward More than 2 ohms, Less than 2 ohms, or
P R O O F
FORWARD switch
audible continuity Red lead on pin G or no "beep." "beep."
*NOT NEUTRAL Diode check Black lead on pin B Any 0.4 to 0.7 V Open circuit ("OL") or
diode Red lead on pin H short circuit (0 V)
*NEUTRAL diode Diode check Black lead on pin C Any 0.4 to 0.7 V Open circuit ("OL") or
Red lead on pin H short circuit (0 V)
*All the tests in the above table were done with the without connecting system battery voltage to the gear
ignition "OFF." The gear selectors NEUTRAL and selector.
NOT NEUTRAL signal outputs cannot be checked
DPSG,YZ07927,169 1901DEC983/3

072705
PN=34
P R O O F
005
Troubleshooting The Gear Selector with PC Diagnostics 100
7
The Funk gear selectors can be checked using the The table below summarizes the states that should be
FGDIAG diagnostic software running on a laptop PC. observed for each gear selector position. A blank entry
in the table represents an OFF signal state.
1. Connect the diagnostic cable between the PCs
serial port and 3-pin harness diagnostic connector If one or more of the signal states is not correct for a
S6. particular gear selector position, the diagnostics
2. Turn the ignition to the ON position, but do not software should provide an indication, and the gear
start the engine. This is to ensure that system selector may be faulty. In this case, replace it with a
battery voltage is supplied to the gear selector. known good selector if one is available.
3. Start the diagnostic software.
4. Select menu item 2, Display input & output status. IMPORTANT: If gear selector handle is moved too
5. Select 1 to view the present state of each of the slowly between neutral and forward
TCUs digital inputs. The TCU pins are labeled, and positions or between neutral and
next to each pin is an ON or OFF indication. reverse, a false diagnostic code may
ON means the TCU is seeing system battery occur. This is not an indication that
voltage on that pin. OFF means the TCU is seeing the gear selector is faulty. Handle
zero volts. movement must be crisp.
Gear Selector Position

Gear Selector TCU Forward Neutral Reverse Forward Forward Neutral Neutral Reverse Reverse
Output Signal PIN Upshift Downshift Upshift Downshift Upshift Downshift
UPSHIFT J1-H2 - - - ON - ON - ON -
DOWNSHIFT J1-H3 - - - - ON - ON - ON
FORWARD J1-J1 ON - - ON ON - - - -
REVERSE J1-J2 - - ON - - - - ON ON
NEUTRAL J2-A1 - ON - - - ON ON - -
P R O O F
NOT J2-A2 ON - ON ON ON - - ON ON
NEUTRAL
DPSG,YZ07927,180 1911FEB991/1

072705
PN=35
P R O O F
005
100 YZ102710 RS-232 Diagnostic Cable and J1939 Adapter
8
UN08JUN04
YZ5181
P R O O F
AConnect to Serial Port on BStandard DB-9 Connector, C3-Pin Weather Pack Tower, DW/P Tower 1201 5792,
Laptop PC Female Terminals Female Terminals Terminals 1208 9188, Seals
1201 5323
YZ07927,0000307 1908JUN041/1

072705
PN=36
P R O O F
005
Troubleshooting The Inching Pedal System 100
9
NOTE: (This procedure written for FUNK pedal, p/n 5. Check integrity of pins on TCU, inching pedal, and
YZ103310) harness mating connectors. Repair or replace any
pins that are bent, missing, or damaged.
If laptop diagnostic capability is available, inching
pedal function and the operation of the BOC and TOC Three requirements must be met for proper inching
(if present) switches can be quickly verified. pedal operation:
If laptop diagnostics are not available, this procedure 1. All signal lines between the TCU and the pedal
may be used. must be intact and wired correctly, with no short or
open circuits.
With this list of tests, the inching pedal system can be
checked out in just a few minutes. The only tools 2. The inching pedal must be working properly.
required are a multimeter and a 1/4" nut driver.
3. The TCU must supply the correct voltage to the
1. Turn the ignition to the "OFF" position. inching pedal.
2. Remove the inching pedal mounting bolts. To check that these requirements are met, perform
each test listed in the tables below. Each table
3. At the pedal, disconnect the wiring harness from addresses one of the three requirements listed above.
the inching pedal. If any test fails, replace or repair wire or part (TCU or
pedal) as necessary.
4. At the TCU, disconnect connector J1.
P R O O F

072705
PN=37
P R O O F
005
100
10
UN17FEB99
YZ1813
Inching Pedal Connector
IMPORTANT: Pedal pin A is the pin closest to the

pedals mounting bracket.
P R O O F
Table A: Check Integrity of Signal Lines Between TCU and Inching Pedal
To Check Multimeter Mode Multimeter Connections Expected Reading for Good
Pedal
Continuity of inching pedal "HI" Resistance or audio continuity One lead on harness pin J1-F2, Less than 10 ohms, or "beep."
reference voltage line other lead on pedals mating
harness pin C.
Continuity of inching pedal signal Resistance or audio continuity One lead on harness pin J1-F3, Less than 10 ohms, or "beep."
line other lead on pedals mating
harness pin A.
Continuity of inching pedal "LO" Resistance or audio continuity One lead on harness pin J1-G1, Less than 10 ohms, or "beep."
reference voltage line other lead on pedals mating
harness pin B.
Continuity of "NOT BOC" signal Resistance or audio continuity One lead on harness pin J1-K2, Less than 10 ohms, or "beep."
line other lead on pedals mating
harness pin E.
Continuity of system battery Resistance or audio continuity One lead on harness pin J2-F2, Less than 10 ohms, or "beep."
voltage supply line other lead on pedals mating
harness pin F.
For shorts between any two Resistance or audio continuity One lead on pedals mating Infinite resistance, or no "beep"
signal lines, or between a signal harness pin A, other lead on pin for all pin combinations.
line and ground B, then C, then E, then F, then
ground. Repeat for all other
combinations of pins and ground.

072705
PN=38
P R O O F
005
Table B: Verify Operation of Inching Pedal 100
11
To Check Multimeter Mode Multimeter Connections Pedal Position Expected Reading for
Good Pedal
Total potentiometer One lead on pedal pin B,
Resistance Fully up 2000 to 3000 ohms
resistance other lead on pedal pin C.
Total potentiometer One lead on pedal pin B,
Resistance Fully depressed 2000 to 3000 ohms
resistance other lead on pedal pin C.
Output variation with One lead on pedal pin A,
pedal travel other lead on pedal pin B.
Output variation with One lead on pedal pin A,
Resistance Fully depressed 2000 to 3000 ohms
pedal travel other lead on pedal pin B.
Double-check output One lead on pedal pin A,
variation with pedal travel other lead on pedal pin C.
Double-check output One lead on pedal pin A, 150 to 450
Resistance Fully depressed
variation with pedal travel other lead on pedal pin C. ohms
"BOTTOM OF CLUTCH" Resistance or audio One lead on pedal pin E,
Fully depressed Open circuit, "no beep."
switch continuity other lead on pedal pin F.
"BOTTOM OF CLUTCH" Resistance or audio One lead on pedal pin E, Less than 100 ohms, or
Not fully depressed
switch continuity other lead on pedal pin F. "beep."
Reattach connector J1 to the TCU and turn ignition to

"ON" position before proceeding with Table C. (Dont
proceed with Table C until first completing Table A.)
Table C: Verify TCU is Supplying Correct Voltage to Inching Pedal

To Check Multimeter Mode Multimeter Connections Expected Reading for Good
Pedal
Voltage differential supplied to Voltage Black lead on harness pin B, 3.20 to 3.90 V
pedal Red lead on harness pin C.
Upper voltage on inching Voltage Black lead on frame or good 3.96 to 4.59 V
P R O O F
potentiometer ground point, Red lead on

harness pin C.
Lower voltage on inching Voltage Black lead on frame or good 0.57 to 0.91 V
potentiometer ground point, Red lead on
harness pin B.
Presence of TCUs internal Resistance Turn ignition back to "OFF" 475 to 530 ohms
resistor (low side). position for this test. One lead on
frame or good ground point, one
on harness pin B.
DPSG,YZ07927,170 1915DEC983/3

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P R O O F
005
100 Calibration
12
Reasons to Calibrate
Matches Transmission Control Unit (TCU) to

Transmission.
Default values for the clutch fill and hold levels are
factory preset in the TCU. Calibration adjusts these
values to match a particular transmission, automatically
compensating for part differences due to manufacturing
tolerances.
Provides For Consistency Between Machines.
The calibration routine makes sure each transmission
clutch starts from the same spot just prior to clutch
engagement.
When to Calibrate
a.) If solenoid valve assemblies are changed.
b.) After repairs involving transmission clutches.
c.) If the TCU is replaced.
d.) If shift quality deteriorates.

P R O O F
AG,YZ07927,5 1910OCT981/1

072705
PN=40
P R O O F
005
Clutch Calibration Procedure: Four Forward Speeds and Four Reverse 100
13
For Funk analog system DF150 or DF250 Series 4. Power up the TCU by turning on the vehicle
Transmissions. ignition. The display should show "CAL".
5. Start and hold the engine speed at 1600 RPM. The
IMPORTANT: Attempting to calibrate with sump engine governor must hold the engine speed 50
temperature below minimum RPM.
calibration temperature (120F for 6. Move the gear selector to the forward position.
converter drives and 90F for most 7. During the first few seconds of the calibration
direct drives) will trigger the process, the display will show "---" while testing the
"warm-up" mode. This mode will cylinder speed and response.
show "---" on the display as the 8. At this time the clutch calibration process starts.
transmission warms to the minimum a. Directional and Speed Clutch Holds. The display
calibration temperature at which time will show C1H, C2H, C3H, C4H, CAH, and
the calibration process will CBH while acquiring the respective "hold" level
automatically begin. Temperatures of each clutch.
below 50F will result in "sump b. Directional and Speed Clutch Fills. The display
temperature too cold" diagnostic will show C1F, C2F, C3F, C4F, CAF, and CBF
code 100. while acquiring the respective "fill" level of each
clutch.
1. Bring the transmission oil temperature up to 140 to
160F (60 to 71C) for optimum calibration. 9. The display will show END when the routine is
2. With the vehicle ignition off, apply the park brake. finished. At that time move the gear selector back
3. Plug a jumper plug (which connects pin A to pin B) to the neutral position.
in the calibration connector (S16) on the vehicle 10. Shut the vehicles ignition OFF, which will power
harness. down the TCU.
11. Remove the jumper plug from the calibration
IMPORTANT: Any diagnostics code that appear connector (S16).
during calibration will cause the
procedure to terminate, and you will The calibration is complete.
P R O O F
have to start the calibration over

from the beginning.
AG,YZ07927,6 1910OCT981/1

072705
PN=41
P R O O F
005
100 Clutch Calibration Procedure: Eight Forward Speeds And Four Reverse
14
For Funk analog system DF150 or DF250 Series 4. Power up the TCU by turning on the vehicle
Transmissions. ignition. The display should show "CAL".
5. Start and hold the engine speed at 1600 RPM. The
IMPORTANT: Attempting to calibrate with sump engine governor must hold the engine speed 50
temperature below minimum RPM.
calibration temperature (120F for 6. Move the gear selector to the forward position.
converter drives and 90F for most 7. During the first few seconds of the calibration
direct drives) will trigger the process, the display will show "---" while testing the
"warm-up" mode. This mode will cylinder speed and response.
show "---" on the display as the 8. At this time the clutch calibration process starts.
transmission warms to the minimum a. Directional and Speed Clutch Holds. The display
calibration temperature at which time will show C1H, C2H, C3H, CAH, CBH, CCH
the calibration process will and CDH while acquiring the respective "hold"
automatically begin. Temperatures level of each clutch.
below 50F will result in "sump b. Directional and Speed Clutch Fills. The display
temperature too cold" diagnostic will show C1F, C2F, C3F, CAF, CBF, CCF and
code 100. CDF while acquiring the respective "fill" level of
each clutch.
1. Bring the transmission oil temperature up to 140 to
160F (60 to 71C) for optimum calibration. 9. The display will show END when the routine is
2. With the vehicle ignition off, apply the park brake. finished. At that time move the gear selector back
3. Plug a jumper plug (which connects pin A to pin B) to the Neutral position.
in the calibration connector (S16) on the vehicle 10. Shut the vehicles ignition OFF, which will power
harness. down the TCU.
11. Remove the jumper plug from the calibration
IMPORTANT: Any diagnostics code that appear connector (S16).
during calibration will cause the
procedure to terminate, and you will The calibration is complete.
P R O O F
have to start the calibration over

from the beginning.
AG,YZ07927,7 1912OCT981/1

072705
PN=42
Group 105
P R O O F
TCU and Accessories
005
System Components 105
1
Transmission Control Unit (TCU)

Gear/Diagnostic Indicator
Gear Selector
Inching Pedal (Optional, depending on application.)
Engine Speed Magnetic Pickup Sensor (Input speed)
Cylinder Magnetic Pickup Sensor (MPU)
Output Speed Magnetic Pickup Sensor (MPU)
Pressure Switch (Optional, used on applications having
wet brakes)
Temperature Sensor
Proportional Valves
Transient Voltage Protection (TVP) Module
Transmission Wiring Harness
AG,YZ07927,8 1912OCT981/1
P R O O F

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P R O O F
TCU and Accessories
005
105 Transmission Control Unit (TCU)
2
FUNCTION
UN08AUG98
The TCU is the "brain" of the system. It is responsible for
the logic, computation, and decision-making processes of
the transmission based on calculations. TCU operation is
determined by software programmed into the TCUs
YZ1576
memory. This software is tailored to meet the
requirements of the vehicle manufacturer, and is based on
a vehicle performance analysis. It is application specific; Transmission Control Unit
therefore TCUs from different types of vehicles are not
interchangeable. TCUs can only be interchanged on
vehicles which are identical in all ways (same
engine/drivetrain combination, wiring, gear selector,
vehicle voltage, etc.)
MOUNTING
The TCU must be mounted inside the vehicle cab or other

enclosed area which will not exceed an ambient
temperature range of (-40C to +85C). It must be
mounted to ensure good electrical grounding between the
TCU and the vehicle chassis, although a ground wire from
battery negative to the TCU is required. It must not be
mounted by any method which would electrically isolate
the TCU from the vehicle chassis. If it is mounted on
shock absorbing materials, a grounding strap must be
utilized to ensure proper grounding.
P R O O F
IMPORTANT: Do not weld on vehicle with battery and

TCU connected or the WARRANTY
WILL BE VOID.
IMPORTANT: The only way to adequately protect the

TCU from damage caused by high
voltage and amperage is to completely
remove all three wiring harness
connectors (J1, J2 and J3) and any
ground strap from the TCU prior to
welding. Disconnecting the battery
supply alone is not sufficient to protect
the TCU from ground voltage feeding
back through the wiring harness.
AG,YZ07927,9 1912OCT981/1

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P R O O F
TCU and Accessories
005
TCU Mounting, Grounding, and Enviromental 105
3
Considerations
Location
The Transmission Control Unit, or TCU, (also called an

ECU, or Electronic Control Unit) must be mounted
inside the vehicle cab or other enclosed area. Mounting
the TCU outside the cab where there is an increased
risk of exposure to the elements is not recommended.
Operational Temperature Range
The TCU should be mounted in a location which will not

exceed an ambient temperature range of -40C to
+85C.
Orientation
Mounting orientation of the TCU should be such that

moisture will naturally run off the TCU rather than into
and around the connectors. The TCU should be
oriented so that when facing it, the connectors are
pointing to the left and right (horizontal), as shown in
Figures 1 and 2 below. If possible, wiring harnesses
should be routed downward to prevent moisture from
accumulating near the connector.
P R O O F
YZ07927,0000306 1902JUN041/4
UN08JUN04
YZ5179
Continued on next page YZ07927,0000306 1902JUN042/4

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PN=45
P R O O F
TCU and Accessories
005
105 Under no circumstances should the TCU be mounted
4
with the connectors pointing up and down (vertical).
Examples of non-recommended mounting orientations
are shown in the photograph:
UN08JUN04
NOTE: Vertical mounting moisture can collect around or
wick toward connectors. Vertical mounting
YZ5180
moisture can follow harness to connector.
Unused Pin Locations
All empty terminal holes in the harness mating

connectors are to be filled with the proper cavity plugs
(Delphi-Packard P/N 12034413) to prevent moisture
from entering the connector through them. Wiring
insulation should be of sufficient diameter to provide a
moisture-tight seal where each individual wire passes
through the connector seal.
Moisture
The TCU is designed to be resistant to occasional

contact with moisture, but is not hermetically sealed.
Occasional contact includes condensation, cleaning
with a shop towel, and infrequent exposure to rainfall,
especially if the mounting precautions above are
followed. Mounting the TCU where it will be repeatedly
exposed to rainfall, buildup of snow and ice, or partial or
P R O O F
complete immersion is not recommended.

The TCU should never be subjected to direct spray
from any form of washing, especially under high
pressure. Doing so risks damage to the connector seals
or the enclosure gasket.
Welding
Do not weld on the vehicle with the battery and TCU

connected. Doing so voids the TCU warranty.
The best way to protect the TCU from potentially
damaging voltage and current is to completely
disconnect all three harness connectors from the TCU,
as well as any TCU grounding strap prior to welding,
and remove the TCU from the vehicle. Disconnecting
the battery alone is not sufficient, as there may be
feedback through the wiring harness.
Continued on next page YZ07927,0000306 1902JUN043/4

072705
PN=46
P R O O F
TCU and Accessories
005
Grounding 105
5
A ground wire from the negative battery terminal to the

TCU is required, and in addition, the TCU should be
mounted to ensure good electrical grounding between
the TCU and the vehicle chassis. It must not be
mounted by any method that would electrically isolate
the TCU from the vehicle chassis. If rubber mounted for
shock protection, a grounding strap must be utilized to
ensure proper grounding.
YZ07927,0000306 1902JUN044/4
P R O O F

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P R O O F
TCU and Accessories
005
105 J1 Connector
6
UN09SEP98
YZ1589
J1 and Mating Connector
Mating connector for J1 is:

P R O O F
Metri-Pack 150 series 30-way sealed P2S connector

Delphi/Packard part number: 12034398
Mating terminals for J1 are Delphi/Packard
terminals: 12103881
Tighten connector to TCU 0.81.5 Nm (7.113.3
lb-in)

072705
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P R O O F
TCU and Accessories
005
CONNECTOR PINOUT 105
7
J1 CONECTOR PIN DESCRIPTION
A1 Main battery 1 (TCU Power, +12/24V)
A2 Ground 1
A3 Output speed magnetic pickup sensor input (frequency input)
B1 Engine speed magnetic pickup sensor input (frequency input)
B2 Cylinder speed magnetic pickup sensor input (frequency input)
B3 Spare magnetic pickup sensor input (frequency input)
C1 Fuel Flow (input)
C2 MPU sensor ground
C3 Temperature sensor (analog voltage input)
D1 Temperature sensor ground
D2 Rear-steer HI (voltage reference output)
D3 Rear-steer position (analog voltage input)
E1 Rear-steer LO (voltage reference output)
E2 Load sense HI (voltage reference output)
E3 Load sense (analog voltage input)
F1 Load sense LO (voltage reference output)
F2 Inching pedal HI (voltage reference output)
F3 Inching pedal position (analog voltage input)
G1 Inching pedal LO (voltage reference output)
G2 Spare ground
G3 Spare ground
H1 Magnetic pickup sensor shield
H2 UPSHIFT (shift code E), (digital input)
H3 DOWNSHIFT (shift code D), (digital input)
P R O O F
J1 FORWARD (digital input)

J2 REVERSE (digital input)
J3 Spare input (digital input)
K1 NOT PARK (digital input)
K2 NOT BOTTOM OF CLUTCH (digital input)
K3 TOP OF CLUTCH (digital input)
NOTE: Connector pinouts reference the wiring vehicle manufacturers wiring harness diagram
harness diagram in this group. Reference the for your application.
AG,YZ07927,21 1913OCT982/2

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PN=49
P R O O F
TCU and Accessories
005
105 J2 Connector
8
UN10AUG98
YZ1590
P R O O F

terminals: 12103881
lb-in)

072705
PN=50
P R O O F
TCU and Accessories
005
9
J2 CONNECTOR PIN DESCRIPTION
A1 NEUTRAL (digital input)
A2 NOT NEUTRAL (shift code B), (digital input)
A3 Brake cutoff (shift code C), (digital input)
B1 Program (shift code A), (digital input)
B2 Start (digital input)
B3 Park or park brake pressure (digital input)
C1 Auto / manual mode select (digital input)
C2 Calibrate (digital input)
C3 Disconnect (digital input)
D1 CAN HI (communication input/output)
D2 CAN LO (communication input/output)
D3 RS232 TxD (serial communication output)
E1 RS232 RxD (serial communication input)
E2 CCD Bus+ (gear/diagnostic indicator communication input/output)
E3 CCD Bus- (gear/diagnostic indicator communication input/output)
F1 Bus ground for communication lines
F2 +12/24 supply voltage output (supply voltage output)
F3 +12/24 supply voltage output (supply voltage output)
P R O O F
AG,YZ07927,22 1914OCT982/2

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PN=51
P R O O F
TCU and Accessories
005
105 J3 Connector
10
UN11AUG98
YZ1591

P R O O F

terminals: 12103881
lb-in)
Continued on next page AG,YZ07927,21CONV1 1913OCT981/2

072705
PN=52
P R O O F
TCU and Accessories
005
11
J3 CONNECTOR PIN DESCRIPTION
A1 Main battery 2 (TCU power +12/24V)
A2 Ground 2
A3 Solenoid 1 (PWM output)
B1 Solenoid 1 return (current sense input)
B2 Solenoid 2 (PWM output)
B3 Solenoid 2 return (current sense input)
C1 Solenoid 3 (PWM output)
C2 Solenoid 3 return (current sense input)
C3 Solenoid 4 (PWM output)
D1 Solenoid 4 return (curent sense input)
D2 Solenoid A (PWM output)
D3 Solenoid A return (current sense input)
E1 Solenoid B (PWM output)
E2 Solenoid B return (current sense input)
E3 Solenoid C (PWM output)
F1 Solenoid C return (current sense input)
F2 Solenoid D (PWM output)
F3 Solenoid D return (current sense input)
G1 Driver 9 (PWM output)
G2 Driver 9 return (current sense input)
G3 Torque converter lock-up solenoid (PWM output)
H1 Torque converter lock-up solenoid return (current sense input)
H2 Disconnect solenoid (PWM output)
H3 Disconnect solenoid return (current sense input)
P R O O F
J1 Spare solenoid driver (PWM output)

J2 Spare solenoid return (current sense input)
J3 Speedometer output
K1 Speedometer return
K2 Ground
K3 Ground
AG,YZ07927,21CONV1 1913OCT982/2

072705
PN=53
P R O O F
TCU and Accessories
005
105 Gear/diagnostic Indicator
12
The gear/diagnostic indicator can be used on both 12 and

24 volt applications. It is powered by the TCU. It has a
3-digit LCD display which is used to provide present gear
status and diagnostic code information.
CONNECTOR PINOUT
UN30JUN98
YZ1574
Gear/Diagnostic Indicator
SIGNAL DESCRIPTION CONNECTOR AND PIN TCU PIN

+12V/+24V S5A J3A1
GROUND S5B J2F1
CCD BUS+ S5C J2E2
CCD BUS- S5D J2E3
AG,YZ07927,16 1912OCT981/1
P R O O F

072705
PN=54
P R O O F
TCU and Accessories
005
Electronic Gear Selector 105
13
The electronic gear selector is a "bump" handle which

operates in an "I" pattern with a horizontal bar in the
middle. Neutral position is in the middle of the pattern
along the horizontal bar. While in neutral, the handle can
be moved right to request a higher pre-selected gear or
left to request a lower pre-selected gear.
The handle can be moved forward to request a forward

gear or moved back to request a reverse gear. The
UN30JUN98
release ring under the handle knob must be pulled up to
release the neutral lock.
When in the forward or reverse position the handle can be
YZ1572
"bumped" to the right to request an upshift or to the left to
request a downshift.
Electronic Gear Selector
The handle can be moved back to the neutral position at

any time without moving the release ring under the handle
knob.
The gear selector is available in both 12V or 24V

versions.
P R O O F

072705
PN=55
P R O O F
TCU and Accessories
005
105
14
UN12FEB99
YZ1501A
Gear Selector Shift Pattern
AG,YZ07927,14 1912OCT982/2
P R O O F

072705
PN=56
P R O O F
TCU and Accessories
005
J4 Connector 105
15
UN23SEP98
YZ1805
J4 Gear Selector Pinout
GEAR SELECTOR PINOUT

A J3-A1 +12/24V
B J2-A2 NOT NEUTRAL/shift code (B)
C J2-A1 NEUTRAL
D J1-H3 DOWNSHIFT/shift code (D)
E J1-H2 UPSHIFT/shift code (E)
P R O O F
F J1-J2 REVERSE
G J1-J1 FORWARD
H J1-A2 Ground
J S1-A Neutral start
AG,YZ07927,23 1914OCT981/1

072705
PN=57
P R O O F
TCU and Accessories
005
105 Inching Pedal (Application Dependent)
16
The inching pedal provides the operator a means of

controlling modulation of the transmission clutches when
desired. With the pedal fully depressed, the transmission
remains in neutral regardless of gear selector position.
Releasing the inching pedal engages the transmission.
The more the pedal is released, the more the clutches
engage, causing the vehicle to inch. When the pedal is
fully released, the transmission clutches are fully engaged.
UN30JUN98
CONNECTOR PINOUT
YZ1575
Inching Pedal
SIGNAL DESCRIPTION CONNECTOR AND PIN TCU PIN

VAGND (ANALOG GROUND) T11B J1G1
VAREF (ANALOG VOLTAGE REFERENCE) T11C J1F2
PEDAL POSITION T11A J1F3
TOC INPUT (TOP OF CLUTCH) User provided, (optional) J1K3
NOT BOC INPUT (BOTTOM OF CLUTCH) T11E J1K2
+12V/+24V T11F J2F2
The pedal position output, or "inching" signal, comes from

the 2.5K-ohm potentiometer attached to the pedal. The
potentiometers angle changes proportionally with the
degree of pedal depression. The potentiometer has an
P R O O F
analog ground (VAGND, pin T11-B) and a 5V DC

reference (VAREF, pin T11-C), both provided by the TCU.
The pedals output signal to the TCU (pin T11-A) varies
between the ground and reference levels. The output
signal voltage increases as the pedal is depressed.
A normally closed switch integral to the pedal provides the

"NOT BOTTOM OF CLUTCH" signal (pin T11-E) to the
TCU. The switch contacts open when the pedal is fully
depressed, and are closed for all other pedal positions.
The TCU sees an active (+12 or +24V) signal on J1-K2
whenever the pedal is NOT at the bottom of its travel
range.
The "TOP OF CLUTCH" signal to the TCU is present only

in those applications where it is required, and where a
separate switch has been installed for that purpose. (The
switch is not part of the inching pedal itself.)

072705
PN=58
P R O O F
TCU and Accessories
005
There is no connection to inching pedal pin D (pin T11-D). 105
17
AG,YZ07927,18 1913OCT982/3
P R O O F
UN16MAR99
YZ1594
Inching Pedal
AG,YZ07927,18 1913OCT983/3

072705
PN=59
P R O O F
TCU and Accessories
005
105 Engine Speed Magnetic Pickup Sensor
18
The engine speed magnetic pickup (A) reads engine, or

input, RPM by measuring the number of pulses per
minute generated from the teeth of the charge pump idler
gear, which is in mesh with the input gear.
UN01JUL98
Input RPM is calculated by pulses per minute divided by
the number of teeth on the input gear.
YZ1577
Engine Speed Magnetic Pickup Sensor
AG,YZ07927,11 1912OCT981/2
YZ1809 UN11FEB99
CAUTION: Sensors become hot during vehicle

operation. To prevent potential burns care must
be exercised when troubleshooting.
CONNECTOR PINOUT
Sensor Connector
P R O O F
SIGNAL DESCRIPTION SENSOR PIN TRANSMISSION CONNECTOR TCU PIN

PIN
ENGINE MPU A J629 J1B1
ENGINE MPU GND B J628 J1C2
AG,YZ07927,11 1912OCT982/2

072705
PN=60
P R O O F
TCU and Accessories
005
Cylinder Speed Magnetic Pickup Sensor 105
19
The cylinder speed magnetic pickup (C) reads cylinder

RPM by measuring the number of pulses per minute
generated from the teeth of the cylinder gear.
UN09FEB99
Cylinder RPM is calculated by pulses per minute divided
by the number of teeth on the cylinder gear.
YZ1734A
Cylinder Speed Magnetic Pickup Sensor
AG,YZ07927,12 1912OCT981/2
YZ1809 UN11FEB99

CONNECTOR PINOUT
Sensor Connector
P R O O F

PIN
CYLINDER MPU A J69 J1B2
CYLINDER MPU GND B J616 J1C2
AG,YZ07927,12 1912OCT982/2

072705
PN=61
P R O O F
TCU and Accessories
005
105 Output Speed Magnetic Pickup Sensor
20
The output speed magnetic pickup sensor (E) reads

output RPM by measuring the number of pulses per
minute generated from the teeth of the sixth stage gear.
The sixth stage gear is on the same shaft as the sixth
UN10FEB99
stage pinion which drives the output gear.
YZ1733A
Output Speed Magnetic Pickup Sensor
AG,YZ07927,13 1912OCT981/2
YZ1809 UN11FEB99

CONNECTOR PINOUT
Sensor Connector
P R O O F

PIN
OUTPUT MPU A J618 J1A3
OUTPUT MPU GND B J630 J1C2
AG,YZ07927,13 1912OCT982/2

072705
PN=62
P R O O F
TCU and Accessories
005
Park Brake Pressure Switch 105
21
The park brake pressure switch is used on applications

having wet brakes to indicate to the TCU when the park
brake is engaged or disengaged.
UN23FEB99
YZ1810
Park Brake Pressure Switch
DPSG,YZ07927,181 1911FEB991/2
YZ1809 UN11FEB99

CONNECTOR PINOUT
Sensor Connector
P R O O F
Signal Description Switch Pin Transmission Connector Pin TCU Pin

PARK BRAKE SW +12/24V A J6-20 J1-A1
PARK BRAKE PRESSURE B J6-21 J2-B3
DPSG,YZ07927,181 1911FEB992/2

072705
PN=63
P R O O F
TCU and Accessories
005
105 Temperature Sensor
22
The temperature sensor sends transmission fluid

temperature data to the TCU.
UN06NOV98
YZ1808
Temperature Sensor
AG,YZ07927,15 1912OCT981/2
YZ1809 UN11FEB99
CONNECTOR PINOUT
Sensor Connector
P R O O F

PIN
TEMPERATURE SENSOR A J624 J1C3
TEMPERATURE SENSOR GND B J625 J1D1
AG,YZ07927,15 1912OCT982/2

072705
PN=64
P R O O F
TCU and Accessories
005
Function Of Proportional Valves 105
23
Each clutch in the transmission is controlled by a

solenoid-actuated proportional valve. The valve has a
main spool that is moved in one direction by clutch
pressure and a spring acting together, and in the other
direction by force generated due to current flow in the
solenoid.
UN16FEB99
Proportional valves differ from on/off valves in that the
spool is not just fully on or off, but may also be controlled
to an intermediate position using a solenoid capable of
generating a variable force. The proportional valve is pilot
YZ1811
operated. The pilot section is the part of the valve that
forces the spool open against the spring. It is a chamber
Proportional Valve
within which the spool moves like a hydraulic cylinder.
There are two openings in the chamber; one is an inlet
from system pressure, the other is an outlet. The outlet
opening may be shut off by a small poppet that is
normally held away from the opening by fluid exiting the
chamber. The poppet is forced shut against the outlet by
the solenoid, increasing pilot pressure and forcing the
valve spool against the spring and bringing the valve on.
As the spool moves against the spring, the clutch is
increasingly open to system pressure and less open to
sump. The pressure forces the clutch piston against the
friction plates, engaging the clutch.
The variable solenoid force is created with a pulse-width

modulated (PWM) signal which is supplied and controlled
P R O O F
by the TCU. The PWM signal is a square wave with a

fixed frequency but varying duty cycle. "Duty cycle" is that
percentage of the signal period that the voltage is "on."
For example, a duty cycle of 25% at a frequency of 50
cycles per second (a 20 millisecond period) means that
the solenoid sees full voltage for 5 milliseconds and zero
volts for the remaining 15 milliseconds of each period.
The frequency used is higher than the frequency at which
the solenoid can respond, so the solenoid "averages out"
the current to some intermediate value. The "average"
current and solenoid force increase with the duty cycle.
AG,YZ07927,28 1914OCT981/1

072705
PN=65
P R O O F
TCU and Accessories
005
105 Proportional Valve Pinouts
24
SIGNAL DESCRIPTION TRANSMISSION CONNECTOR PIN TCU PIN
SOLENOID 1 J6-2 J3-A3
SOLENOID 1 RETURN J6-1 J3-B1
SOLENOID 2 J6-3 J3-B2
SOLENOID 2 RETURN J6-15 J3-B3
SOLENOID 3 J6-4 J3-C1
SOLENOID 3 RETURN J6-19 J3-C2
SOLENOID 4 J6-5 J3-C3
SOLENOID 4 RETURN J6-6 J3-D1
SOLENOID A J6-10 J3-D2
SOLENOID A RETURN J6-17 J3-D3
SOLENOID B J6-12 J3-E1
SOLENOID B RETURN J6-11 J3-E2
SOLENOID C J6-23 J3-E3
SOLENOID C RETURN J6-22 J3-F1
SOLENOID D J6-8 J3-F2
SOLENOID D RETURN J6-7 J3-F3
AG,YZ07927,29 1914OCT981/1
P R O O F

072705
PN=66
P R O O F
TCU and Accessories
005
Solenoid/Gear Combinations 105
25
UN04MAR99
YZ734B
Solenoids and Valve Port Locations
P R O O F
DF Series Transmission Eight Speeds Forward and Four Reverse

GEAR ENGAGED ACTIVE SOLENOIDS
F 8th 2 and D
F 7th 1 and D
F 6th 2 and B
F 5th 1 and B
F 4th 2 and C
F 3rd 1 and C
F 2nd 2 and A
F 1st 1 and A
Neutral
R 1st 3 and A
R 2nd 3 and C
R 3rd 3 and B
R 4th 3 and D
Continued on next page DPSG,YZ07927,174 1928JAN991/2

072705
PN=67
P R O O F
TCU and Accessories
005
105 DF Series Transmission Four Speeds Forward and Four Reverse
26
GEAR ENGAGED ACTIVE SOLENOIDS
F 4th 2 and B
F 3rd 1 and B
F 2nd 2 and A
F 1st 1 and A
Neutral
R 1st 3 and A
R 2nd 4 and A
R 3rd 3 and B
R 4th 4 and B
DPSG,YZ07927,174 1928JAN992/2
P R O O F

072705
PN=68
P R O O F
TCU and Accessories
005
105
27
P R O O F

072705
PN=69
P R O O F
TCU and Accessories
005
105 Transient Voltage Protection Module
28
The TVP (Transient Voltage Protection) Module is

available in either a 12V or a 24V version, based on the
vehicle battery voltage. It has two important functions:
Supply electrical power to the system.

Protect the electrical system against electrical
conditions that might otherwise be potentially damaging,
such as load dump and reverse battery connection.
Protection is provided only when the ignition switch is on,

thus energizing an internal relay which provides an
electrical connection between the vehicle battery and the
protective device inside the TVP.
UN30JUN98
YZ1573
Transient Voltage Protection (TVP) Module
TVP Module Connector Pinout

S7 CONNECTOR PIN DESCRIPTION
A +12/24V system voltage input
B +12/24V system voltage input
P R O O F
C +12/24V output (transient protected)

D +12/24V output (transient protected)
E RUN/START signal from ignition switch
F RUN/START return (GND, or negative battery terminal)

072705
PN=70
P R O O F
TCU and Accessories
005
105
29
UN08JUN04
YZ5182
IMPORTANT: A and B are tied together inside the D1, D2 = 1N4005 diode rectifier
TVP. C and D are tied together inside D3 = Sussex zener diode (John Deere P/N
the TVP. RE10019)
K1 = Fairchild ND012/01CS relay (John Deere P/N
The schematic for the 12V TVP Module, John Deere R91911B)
P/N RE30711.
CB1 = Wagner 20A resettable circuit breaker (John

Deere P/N AR56671)
AG,YZ07927,20 1913OCT982/3
P R O O F
UN09JUN04
YZ5183
The schematic for the 24V TVP Module, Funk P/N D3 = PRZ95T060 zener diode
YZ102080. K1 = Fairchild 57ND24-N relay
D1, D2 = Diode rectifier
AG,YZ07927,20 1913OCT983/3

072705
PN=71
P R O O F
TCU and Accessories
005
105 Transmission Wiring Harness 1 of 4
30
This drawing represents a generic harness only. Specific

applications may vary; reference the vehicle
manufacturers harness diagram.
AG,YZ07927,25 1914OCT981/2
P R O O F
UN19SEP98
YZ1596
Part 1 of 4
NOTE: Letters A,B,C,D,E,F are labels linking to the

following three pages.
AG,YZ07927,25 1914OCT982/2

072705
PN=72
P R O O F
TCU and Accessories
005
Transmission Wiring Harness 2 of 4 (continued) 105
31
P R O O F
UN04MAR99
YZ1597
Part 2 of 4
AG,YZ07927,25CONV1 1914OCT981/1

072705
PN=73
P R O O F
TCU and Accessories
005
105 Transmission Wiring Harness 3 of 4 (continued)
32
P R O O F
UN04MAR99
YZ1598
Part 3 of 4
AG,YZ07927,26 1914OCT981/1

072705
PN=74
P R O O F
TCU and Accessories
005
Transmission Wiring Harness 4 of 4 (continued) 105
33
UN30MAR99
P R O O F
YZ1599
Part 4 of 4
AG,YZ07927,27 1914OCT981/1

072705
PN=75
P R O O F
TCU and Accessories
005
105 J6 Connector
34
UN24SEP98
YZ1806
J6 Connector Pinout

P R O O F

072705
PN=76
P R O O F
TCU and Accessories
005
NOTE: The J6 connector is located on the 105
35
transmission.
CONNECTOR PINOUT
1 J3-B1 Solenoid 1 return
2 J3-A3 Solenoid 1 output
3 J3-B2 Solenoid 2 output
4 J3-C1 Solenoid 3 output
5 J3-C3 Solenoid 4 output
6 J3-D1 Solenoid 4 return
7 J3-F3 Solenoid D return
8 J3-F2 Solenoid D output
9 J1-B2 Cylinder speed MPU input
10 J3-D2 Solenoid A output
11 J3-E2 Solenoid B return
12 J3-E1 Solenoid B output
13 J3-H2 Disconnect solenoid output
14 J3-G3 Torque converter lockup solenoid output
15 J3-B3 Solenoid 2 return
16 J1-G3 Cylinder speed MPU sensor ground
17 J3-D3 Solenoid A return
18 J1-A3 Output speed MPU input
19 J3-C2 Solenoid 3 return
20 J1-A1 Main battery 1 (TCU power, +12/24V)
21 J2-B3 Park brake pressure switch input
P R O O F
22 J3-F1 Solenoid C return

23 J3-E3 Solenoid C output
24 J1-C3 Temperature sensor input
25 J1-D1 Temperature sensor ground
26 J3-H3 Disconnect solenoid return
27 J3-H1 Torque converter lockup solenoid return
28 J1-C2 Engine speed MPU sensor ground
29 J1-B1 Engine speed MPU signal input
30 J1-G2 Output speed MPU sensor ground
31 - Shield
AG,YZ07927,24 1914OCT982/2

072705
PN=77
P R O O F
TCU and Accessories
005
105
36
P R O O F

072705
PN=78
Group 110
P R O O F
Diagnostic Codes
005
System Diagnostics Codes 110
1
The TCU provides troubleshooting assistance in the causing the diagnostics code
form of diagnostic codes. prevents the TCU from detecting a
legal neutral condition. After a
Diagnostic codes may appear due to a number of neutral recovery, the shift lever may
causes, including: be placed back into a legal forward
or reverse position. If the condition
Pinched or broken wiring causing the diagnostics code still
Shorted or open solenoids exists, the diagnostics code will
Bad connections again be detected and displayed.
Shorted wiring (to either ground or vehicle voltage)
Invalid signal combinations from the gear selector. The TCU retains the last eight non-repeating
Magnetic pickup sensor failures diagnostics codes in nonvolatile memory in the order in
which they have occurred. These codes are available
IMPORTANT: All diagnostics codes are neutral for future retrieval, except in the earliest-model TCUs.
recoverable, unless the condition
AG,YZ07927,30 1914OCT981/1
Overview Of Diagnostic Codes

P R O O F
The following are those diagnostic codes that can be

logically grouped by similarities. (Not all codes are
included in this list.)
Codes 20-29, 175-177: Low or no current in a solenoid.

Codes 30-39, 178-180: Solenoid current too high.
Codes 50-57, 59: Gear selector related.
Codes 91-99: Application specific codes.
Codes 100-127: Calibration related.
Codes 145, 148: Inching voltage related.
Codes 154, 155: Speed sensor related.
The following table describes all diagnostic codes in

summary form.
Continued on next page DPSG,YZ07927,189 1930MAR991/4

072705
PN=79
P R O O F
Diagnostic Codes
005
110 Diagnostic Codes in Summary Form
2
Codes Description
20 Solenoid 1, low or no current
24 Solenoid A, low or no current
25 Solenoid B, low or no current
26 Solenoid C, low or no current
27 Solenoid D, low or no current
28 Driver 9, low or no current
29 TCLU Solenoid, low or no current
30 Solenoid 1, current too high
34 Solenoid A, current too high
35 Solenoid B, current too high
36 Solenoid C, current too high
37 Solenoid D, current too high
38 Driver 9, current too high
39 TCLU solenoid, current too high
40 Undefined shift request
41 No NEUTRAL signal since power-up
42 BOC signal passive
43 NOT PARK, PARK PRESSURE simultaneously passive
P R O O F
44 NOT PARK, NEUTRAL simultaneously passive

45 PARK active, NEUTRAL passive
48 NOT PARK, PARK PRESSURE simultaneously active
49 PARK active, PARK PRESSURE passive
50 UPSHIFT, DOWNSHIFT simultaneously active
51 FORWARD, REVERSE simultaneously active
52 FORWARD, NEUTRAL, REVERSE simultaneously passive
54 Invalid requested gear calculation
56 NEUTRAL, FORWARD simultaneously active
57 NEUTRAL, REVERSE simultaneously active
58 START signal active
59 Invalid 5-bit selector code from discrete gear selector
60 System supply voltage too low
84 Undefined vehicle mode
85 PARK active, NEUTRAL passive

072705
PN=80
P R O O F
Diagnostic Codes
005
Diagnostic Codes in Summary Form 110
3
Codes Description
86 TOC active, BOC passive
87 PARK and FORWARD simultaneously active
88 PARK and REVERSE simultaneously active
89 NOT PARK, PARK simultaneously passive
90 NOT PARK, PARK simultaneously active
91 Seat switch signal and NEUTRAL simultaneously passive
92 Engine speed approaching engine warranty maximum
93 Engine speed too high for neutral-to-gear engagement
98 WHEELS-UP and WHEELS-DOWN inputs simultaneously active
99 Wheels mode change attempted when not in neutral
100 Sump temperature too low for calibration
101 Engine speed too high for calibration
102 Engine speed too low for calibration
103 Output speed detected during calibration
104 No cylinder speed detected during calibration
105 Forward cylinder speed ratio incorrect
106 Reverse cylinder speed ratio incorrect
107 Cylinder speed will not drop below the start count speed
108 Holding clutch pressure exceeds 90 psi
109 Clutch 1 fast fill time exceeds 300 ms
113 Clutch A fast fill time exceeds 300 ms
P R O O F
114 Clutch B fast fill time exceeds 300 ms

115 Clutch C fast fill time exceeds 300 ms
116 Clutch D fast fill time exceeds 300 ms
117 Calibrating clutch hold pressure exceeds 90 psi
127 Calibration without applying park brake
145 Inching voltage is too low
146 Temperature sensor value out of range
148 Inching voltage is too high
154 Engine speed sensor open or resistance too high
155 Output speed sensor open or resistance too high
160 Cant obtain shift parameters from memory
161 Group one enable signal passive; should be active
162 Group two enable signal passive; should be active
163 Group three enable signal passive; should be active
171 Group one enable signal active; should be passive

072705
PN=81
P R O O F
Diagnostic Codes
005
110 Diagnostic Codes in Summary Form
4
Codes Description
172 Group two enable signal active; should be passive
173 Group three enable signal active; should be passive
175 Solenoid driver 11, low or no current
178 Solenoid driver 11, current too high
198 CCD communications link failure between master and slave TCUs
199 Non-functional base TCU
DPSG,YZ07927,189 1930MAR994/4
P R O O F

072705
PN=82
P R O O F
Diagnostic Codes
005
Code 20 110
5
Symptom Problem Solution
Solenoid 1 cannot get up to Solenoid disconnected. Verify harness is connected to

requested current. solenoid.
There is a problem in the pin

J3-A3 (output) to pin J3-B1
(return) circuit path.
Open circuit in wiring to solenoid. 1. Inspect wiring in solenoid circuit

between solenoid and TCU for cuts,
frayed areas, splayed pins, or
pinched spots.
2. Replace or repair wire(s) as

necessary.
Solenoid return line shorted to GND 1. Disconnect connector J3 from

or vehicle frame. TCU.
2. Check continuity between return

pin J3-B1 and common GND pin
J3-A2.
3. If continuity is found, a short

exists; inspect and repair.
P R O O F
4. Visually inspect return line for

damaged insulation and verify that it
is not shorted to the vehicle frame.

072705
PN=83
P R O O F
Diagnostic Codes
005
110 Symptom Problem Solution
6
Solenoid output line shorted to GND 1. Disconnect connector J3 from

2. Check continuity between output

pin J3-A3 and common GND pin
J3-A2.

4. Visually inspect output line for

Open circuit in solenoid. 1. Disconnect solenoid from harness.
2. Check continuity of solenoid.
3. If an open circuit is indicated, or a

resistance measurement indicates
more than 70 ohms, replace
solenoid.
Solenoid is incorrect voltage type. 1. Disconnect solenoid from harness.

(12V vs. 24V)
2. Measure solenoid resistance.
3. Resistance should be
P R O O F
approximately 10 ohms for a 12V

system (may range from 7 to 14
ohms depending on solenoid
temperature), and approximately 40
ohms for a 24V system (may range
from 30 to 65 ohms depending on
solenoid temperature).
4. If resistance is incorrect, replace

solenoid.
Faulty TCU. After all other possible causes have

been eliminated, replace TCU.
AG,YZ07927,35 1915OCT982/2

072705
PN=84
P R O O F
Diagnostic Codes
005
Code 21 110
7


J3-B2 (output) to pin J3-B3

pinched spots.

necessary.


J3-A2.

P R O O F


072705
PN=85
P R O O F
Diagnostic Codes
005
8


J3-A2.



solenoid.

(12V vs. 24V)
P R O O F


solenoid.

AG,YZ07927,36 1915OCT982/2

072705
PN=86
P R O O F
Diagnostic Codes
005
Code 22 110
9


J3-C1 (output) to pin J3-C2

pinched spots.

necessary.


pin J3-C2 and common GND pin
J3-A2.

P R O O F


072705
PN=87
P R O O F
Diagnostic Codes
005
10


J3-A2.



solenoid.

(12V vs. 24V)
P R O O F


solenoid.

AG,YZ07927,40 1916OCT982/2

072705
PN=88
P R O O F
Diagnostic Codes
005
Code 23 110
11


J3-C3 (output) to pin J3-D1

pinched spots.

necessary.


pin J3-D1 and common GND pin
J3-A2.

P R O O F


072705
PN=89
P R O O F
Diagnostic Codes
005
12


J3-A2.



solenoid.

(12V vs. 24V)
P R O O F


solenoid.

AG,YZ07927,44 1916OCT982/2

072705
PN=90
P R O O F
Diagnostic Codes
005
Code 24 110
13
Solenoid A cannot get up to Solenoid disconnected. Verify harness is connected to


J3-D2 (output) to pin J3-D3

pinched spots.

necessary.


J3-A2.

P R O O F


072705
PN=91
P R O O F
Diagnostic Codes
005
14


J3-A2.



solenoid.

(12V vs. 24V)
P R O O F


solenoid.

AG,YZ07927,46 1916OCT982/2

072705
PN=92
P R O O F
Diagnostic Codes
005
Code 25 110
15
Solenoid B cannot get up to Solenoid disconnected. Verify harness is connected to


J3-E1 (output) to pin J3-E2

pinched spots.

necessary.


pin J3-E2 and common GND pin
J3-A2.

P R O O F


072705
PN=93
P R O O F
Diagnostic Codes
005
16


J3-A2.



solenoid.

(12V vs. 24V)
P R O O F


solenoid.

AG,YZ07927,47 1916OCT982/2

072705
PN=94
P R O O F
Diagnostic Codes
005
Code 26 110
17
Solenoid C cannot get up to Solenoid disconnected. Verify harness is connected to


J3-E3 (output) to pin J3-F1

pinched spots.

necessary.


pin J3-F1 and common GND pin
J3-A2.

P R O O F


072705
PN=95
P R O O F
Diagnostic Codes
005
18


J3-A2.



solenoid.

(12V vs. 24V)
P R O O F


solenoid.

AG,YZ07927,49 1916OCT982/2

072705
PN=96
P R O O F
Diagnostic Codes
005
Code 27 110
19
Solenoid D cannot get up to Solenoid disconnected. Verify harness is connected to


J3-F2 (output) to pin J3-F3

pinched spots.

necessary.


J3-A2.

P R O O F


072705
PN=97
P R O O F
Diagnostic Codes
005
20


J3-A2.



solenoid.

(12V vs. 24V)
P R O O F


solenoid.

AG,YZ07927,51 1916OCT982/2

072705
PN=98
P R O O F
Diagnostic Codes
005
Code 28 110
21
Driver 9 cannot get up to Solenoid disconnected. Verify harness is connected to


J3-G1 (output) to pin J3-G2

pinched spots.

necessary.


pin J3-G2 and common GND pin
J3-A2.

P R O O F


072705
PN=99
P R O O F
Diagnostic Codes
005
22


J3-A2.



solenoid.

(12V vs. 24V)
P R O O F


solenoid.

AG,YZ07927,52 1916OCT982/2

072705
PN=100
P R O O F
Diagnostic Codes
005
Code 29 110
23
TCLU (Torque-Converter Solenoid disconnected. Verify harness is connected to

Lock-Up) solenoid (Driver 10) solenoid.
cannot get up to requested
current.

J3-G3 (output) to pin J3-H1

pinched spots.

necessary.


pin J3-H1 and common GND pin
J3-A2.
P R O O F



072705
PN=101
P R O O F
Diagnostic Codes
005
24


J3-A2.



solenoid.

(12V vs. 24V)
P R O O F


solenoid.

AG,YZ07927,54 1916OCT982/2

072705
PN=102
P R O O F
Diagnostic Codes
005
110
25
P R O O F

072705
PN=103
P R O O F
Diagnostic Codes
005
110 Code 30
26
Solenoid 1 cannot drop to Short circuit in solenoid, or solenoid 1. Disconnect solenoid from harness.
requested current. has low resistance.
-
There is a problem in the pin approximately 10 ohms for a 12V
J3-A3 (output) to pin J3-B1 system (may range from 7 to 14
(return) circuit path. ohms depending on solenoid
4. If a direct short (less than 1 ohm)

or low resistance is indicated,
replace solenoid. See Continuity
Measurement Note below.
NOTE: Continuity Measurement:

Some multimeters have an
audio continuity indication
feature. Getting the "beep"
during a continuity check
does not mean a direct short
circuit exists! Rely on the
actual resistance value
P R O O F
during the measurement

rather than going by the
beep. (For example: the
continuity beep may sound
when performing a
measurement on a perfectly
good solenoid.)
AG,YZ07927,55 1916OCT981/1

072705
PN=104
P R O O F
Diagnostic Codes
005
Code 30 (Continued) 110
27
Solenoid 1 cannot drop to Short circuit in wiring to solenoid. 1. Disconnect connector J3 from the
requested current. (Output line shorted to return line in TCU.
harness.)
- 2. Disconnect solenoid from harness.
There is a problem in the pin 3. On the harness, check for

J3-A3 (output) to pin J3-B1 continuity between the J3-A3 output
(return) circuit path. pin and the J3-B1 return pin.
4. Normally, there should be an

open circuit between these pins.
Continuity indicates a short circuit.
5. Inspect wiring in solenoid circuit

between solenoid and TCU to locate
short.

necessary.
Output line shorted to supply 1. Disconnect connector J3 from the

voltage. TCU.
2. Check for continuity between the

J3-A3 output pin and all other pins in
the J3 connector, excluding return
P R O O F
pin J3-B1.
3. Continuity for any measurement

indicates a short circuit.
4. Inspect wiring to locate short.

necessary.

YZ07927,00000B9 1930APR031/1

072705
PN=105
P R O O F
Diagnostic Codes
005
110 Code 31
28
-
J3-B2 (output) to pin J3-B3 system (may range from 7 to 14


P R O O F

when performing a
good solenoid.)
AG,YZ07927,56 1916OCT981/1

072705
PN=106
P R O O F
Diagnostic Codes
005
29
harness)

J3-B2 (output) to pin J3-B3 continuity between the J3-B2 output
(return) circuit path. pin and the J3-B3 return pin.


short.

necessary.

voltage. TCU.

J3-B2 output pin and all other pins in
P R O O F
pin J3-B3.


necessary.

YZ07927,00000BA 1930APR031/1

072705
PN=107
P R O O F
Diagnostic Codes
005
110 Code 32
30
-
J3-C1 (output) to pin J3-C2 system (may range from 7 to 14


P R O O F

when performing a
good solenoid.)
AG,YZ07927,57 1916OCT981/1

072705
PN=108
P R O O F
Diagnostic Codes
005
31
harness.)

J3-C1 (output) to pin J3-C2 continuity between the J3-C1 output
(return) circuit path. pin and the J3-C2 return pin.


short.

necessary.

voltage. TCU.

J3-C1 output pin and all other pins in
P R O O F
pin J3-C2.


necessary.

YZ07927,00000BB 1930APR031/1

072705
PN=109
P R O O F
Diagnostic Codes
005
110 Code 33
32
-
J3-C3 (output) to pin J3-D1 system (may range from 7 to 14


P R O O F

when performing a
good solenoid.)
AG,YZ07927,58 1916OCT981/1

072705
PN=110
P R O O F
Diagnostic Codes
005
33
harness.)

J3-C3 (output) to pin J3-D1 continuity between the J3-C3 output
(return) circuit path. pin and the J3-D1 return pin.


short.

necessary.

voltage. TCU.

J3-C3 output pin and all other pins in
P R O O F
pin J3-D1.


necessary.

YZ07927,00000BC 1930APR031/1

072705
PN=111
P R O O F
Diagnostic Codes
005
110 Code 34
34
Solenoid A cannot drop to Short circuit in solenoid, or solenoid 1. Disconnect solenoid from harness.
-
J3-D2 (output) to pin J3-D3 system (may range from 7 to 14

replace solenoid. *See Continuity

P R O O F

when performing a
good solenoid.)
AG,YZ07927,59 1919OCT981/1

072705
PN=112
P R O O F
Diagnostic Codes
005
35
Solenoid A cannot drop to Short circuit in wiring to solenoid. 1. Disconnect connector J3 from the
harness.)

J3-D2 (output) to pin J3-D3 continuity between the J3-D2 output
(return) circuit path. pin and the J3-D3 return pin.


short.

necessary.

voltage. TCU.

J3-D2 output pin and all other pins in
P R O O F
pin J3-D3.


necessary.

YZ07927,00000BD 1930APR031/1

072705
PN=113
P R O O F
Diagnostic Codes
005
110 Code 35
36
Solenoid B cannot drop to Short circuit in solenoid, or solenoid 1. Disconnect solenoid from harness.
-
J3-E1 (output) to pin J3-E2 system (may range from 7 to 14


P R O O F

when performing a
good solenoid.)
AG,YZ07927,60 1919OCT981/1

072705
PN=114
P R O O F
Diagnostic Codes
005
37
Solenoid B cannot drop to Short circuit in wiring to solenoid. 1. Disconnect connector J3 from the
harness.)

J3-E1 (output) to pin J3-E2 continuity between the J3-E1 output
(return) circuit path. pin and the J3-E2 return pin.


short.

necessary.

voltage. TCU.

J3-E1 output pin and all other pins in
P R O O F
pin J3-E2.


necessary.

YZ07927,00000BE 1930APR031/1

072705
PN=115
P R O O F
Diagnostic Codes
005
110 Code 36
38
Solenoid C cannot drop to Short circuit in solenoid, or solenoid 1. Disconnect solenoid from harness.
-
J3-E3 (output) to pin J3-F1 system (may range from 7 to 14


P R O O F

when performing a
good solenoid.)
AG,YZ07927,61 1919OCT981/1

072705
PN=116
P R O O F
Diagnostic Codes
005
39
Solenoid C cannot drop to Short circuit in wiring to solenoid. 1. Disconnect connector J3 from the
harness.)

J3-E3 (output) to pin J3-F1 continuity between the J3-E3 output
(return) circuit path. pin and the J3-F1 return pin.


short.

necessary.

voltage. TCU.

J3-E3 output pin and all other pins in
P R O O F
pin J3-F1.


necessary.

YZ07927,00000BF 1930APR031/1

072705
PN=117
P R O O F
Diagnostic Codes
005
110 Code 37
40
Solenoid D cannot drop to Short circuit in solenoid, or solenoid 1. Disconnect solenoid from harness.
-
J3-F2 (output) to pin J3-F3 system (may range from 7 to 14


P R O O F

when performing a
good solenoid.)
AG,YZ07927,62 1920OCT981/1

072705
PN=118
P R O O F
Diagnostic Codes
005
41
Solenoid D cannot drop to Short circuit in wiring to solenoid. 1. Disconnect connector J3 from the
harness.)

J3-F2 (output) to pin J3-F3 continuity between the J3-F2 output
(return) circuit path. pin and the J3-F3 return pin.


short.

necessary.

voltage. TCU.

J3-F2 output pin and all other pins in
P R O O F
pin J3-F3.


necessary.

YZ07927,00000C0 1930APR031/1

072705
PN=119
P R O O F
Diagnostic Codes
005
110 Code 38
42
Driver 9 cannot drop to Short circuit in solenoid, or solenoid 1. Disconnect solenoid from harness.
-
J3-G1 (output) to pin J3-G2 system (may range from 7 to 14


P R O O F

when performing a
good solenoid.)
AG,YZ07927,63 1920OCT981/1

072705
PN=120
P R O O F
Diagnostic Codes
005
43
Driver 9 cannot drop to Short circuit in wiring to solenoid. 1. Disconnect connector J3 from the
harness.)

J3-G1 (output) to pin J3-G2 continuity between the J3-G1 output
(return) circuit path. pin and the J3-G2 return pin.


short.

necessary.

voltage. TCU.

J3-G1 output pin and all other pins
in the J3 connector, excluding
P R O O F
return pin J3-G2.


necessary.

YZ07927,00000C1 1930APR031/1

072705
PN=121
P R O O F
Diagnostic Codes
005
110 Code 39
44
TCLU (Torque Converter Short circuit in solenoid, or solenoid 1. Disconnect solenoid from harness.
Lock-Up) solenoid (Driver 10) has low resistance.
cannot drop to requested 2. Measure solenoid resistance.
current.
- approximately 10 ohms for a 12V
There is a problem in the pin ohms depending on solenoid
J3-G3 (output) to pin J3-H1 temperature), and approximately 40
(return) circuit path. ohms for a 24V system (may range


P R O O F

when performing a
good solenoid.)
AG,YZ07927,64 1920OCT981/1

072705
PN=122
P R O O F
Diagnostic Codes
005
45
TCLU (Torque Converter Short circuit in wiring to solenoid. 1. Disconnect connector J3 from the
Lock-Up) solenoid (Driver 10) (Output line shorted to return line in TCU.
cannot drop to requested harness.)
current. 2. Disconnect solenoid from harness.
- 3. On the harness, check for

continuity between the J3-G3 output
There is a problem in the pin pin and the J3-H1 return pin.
J3-G3 (output) to pin J3-H1
(return) circuit path. 4. Normally, there should be an

short.

necessary.

voltage. TCU.

J3-G3 output pin and all other pins
in the J3 connector, excluding
P R O O F
return pin J3-H1.


necessary.

YZ07927,00000C2 1930APR031/1

072705
PN=123
P R O O F
Diagnostic Codes
005
110 Code 40
46
Request for an undefined shift is Internal TCU diagnostics code. 1. Turn ignition to "OFF" position.
being made.
2. Restart vehicle with gear selector
- in neutral.
This diagnostic code is typically 3. If Code 40 persists, replace TCU

not field serviceable. or contact Field Service.
AG,YZ07927,65 1920OCT981/1
P R O O F

072705
PN=124
P R O O F
Diagnostic Codes
005
Code 41 110
47
No NEUTRAL signal since initial Gear selector is out of neutral Move gear selector to neutral
system power-up. position. position.
The TCU is not receiving the

expected active signal on pin
J2-A1 (NEUTRAL) during
power-up.
LEGAL CONDITIONS: The

NEUTRAL signal coming from
the gear selector should be
active during system power-up
when the vehicle is in neutral.
This diagnostic code description

applies to the Funk 12V and 24V
gear selector. If using a different
gear selector the description will
change in regards to selector
pinouts.
P R O O F

072705
PN=125
P R O O F
Diagnostic Codes
005
48
NEUTRAL signal line between gear 1. Disconnect connector J2 from

selector and TCU has faulty TCU.
connection or is open.
2. Disconnect connector J4 from
gear selector.
3. Check for continuity between

harness pins J2-A1 and J4-C.
4. If measurement indicates no
continuity, inspect and repair or
replace NEUTRAL signal line.
5. If measurement indicates
continuity, NEUTRAL signal line is
OK.
Open in system battery voltage line 1. With ignition switch in "OFF"

between TVP module and gear position, disconnect connector T7
selector. from TVP module.

gear selector.

harness pins T7-C and J4-A.
4. If measurement indicates no
P R O O F
continuity, inspect and repair or

replace system battery voltage line
between TVP module and gear
selector.
5. If measurement indicates
continuity, system battery voltage
line is OK.

072705
PN=126
P R O O F
Diagnostic Codes
005
Symptom Problem Solution 110
49
Faulty gear selector. Attach connector J4 to the gear

selector, and disconnect J2 from the
TCU. The ignition should be in the
"ON" position. (The engine should
not be running.)
Replace the gear selector if and only

if all of the following are true:
1. NEUTRAL signal line is OK. (see

above)
2. System battery voltage line

selector is OK. (see above)
3. The voltage on harness pin J2-A1

does not alternate between 0 volts
and system battery voltage as the
gear selector is moved in and out of
neutral.
If all these tests are true, it indicates

that the gear selector is getting
power, but is incapable of providing
an active NEUTRAL output signal.
IMPORTANT: For more

P R O O F
information refer to
TROUBLESHOOTING
THE GEAR
SELECTOR in
Group 100 (Test and
Troubleshooting).
System battery voltage dropping 1. Check voltage at vehicle battery

below required level after system terminals.
has been operating normally.
2. If measurement is below 8 volts
on a 12V system or below 17 volts
on a 24V system, verify that
alternator is charging battery.
3. If alternator is OK, replace or

recharge battery.

AG,YZ07927,66 1920OCT983/3

072705
PN=127
P R O O F
Diagnostic Codes
005
110 Code 42
50
BOTTOM Of CLUTCH signal is No jumper wire between BOC input 1. Visually examine TCU connector
passive. and system battery voltage. J1 and verify the presence of a wire
connected to the J1-K2 input.
-
2. If no wire is present, install one
The TCU expects the BOTTOM between J1-K2 and system battery
OF CLUTCH (BOC) input line at voltage. (TCU pins J2-F2 or J2-F3
J1-K2 to be active on are system battery voltage.)
applications which do not utilize
an inching function.
LEGAL CONDITIONS: The BOC

discrete input signal must be tied
to system battery voltage.
Jumper wire between BOC input and 1. Disconnect connector J1 from the
system battery voltage is open. TCU.
2. Trace the J1-K2 line from this

connector to its opposite end,
disconnecting the connector, if any,
on the opposite end.

P R O O F
harness pin J1-K2 and the pin on

the other end of the jumper.
4. If no continuity, repair or replace

the open jumper wire.
5. If continuity is indicated, BOC

jumper wire is OK.

072705
PN=128
P R O O F
Diagnostic Codes
005
51
Jumper wire connected to wrong 1. Trace the J1-K2 line from the
pins. TCU to its opposite end.
2. At the opposite end, make certain

that this point supplies system
battery voltage.

AG,YZ07927,67 1920OCT982/2
P R O O F

072705
PN=129
P R O O F
Diagnostic Codes
005
110 Code 43 (For applications using disc brakes)
52
NOT PARK and PARK signals Faulty park switch. 1. Turn ignition to "OFF" position.
simultaneously passive at TCU.
2. Disconnect connector T9 from the
- park switch or park switch harness.
The TCU expects the J1-K1 NOT 3. Testing directly at switch pins,
PARK input and the J2-B3 PARK check for continuity between switch
input to have opposite states. pins A and B while actuating switch.
- 4. Repeat continuity check, this time

between switch pins A and C.
LEGAL CONDITIONS:
5. If for either test 3 or 4, continuity
1. NOT PARK active and PARK fails to toggle as the switch is
passive. actuated, replace the switch.
2. NOT PARK passive and PARK IMPORTANT: If testing switch

active. through wiring, be
sure to rule out
possible open
circuits in the
wiring between S9
and the park switch
before replacing
switch. (See below)
P R O O F
YZ07927,00003E3 1908MAR051/1

072705
PN=130
P R O O F
Diagnostic Codes
005
Code 43 (For applications using disc brakes) 110
53
Continued
NOT PARK and PARK signals Open in wiring between park switch 1. Disconnect connector T9 from the
simultaneously passive at TCU. connector S9 and park switch. park switch or park switch harness.
- 2. Inspect wires to park switch for

possible open circuits due to pinches
The TCU expects the J1-K1 NOT or cuts.
PARK input and the J2-B3 PARK
input to have opposite states. 3. Wiring can be verified as OK if the
park brake is set and continuity is
- indicated between pins S9-A and
S9-B. However, if continuity is not
LEGAL CONDITIONS: indicated, the park switch remains a
possible cause.
1. NOT PARK active and PARK
passive. 4. If the wiring harness can be
detached from the park switch
2. NOT PARK passive and PARK directly at the switch, test continuity
active. of all wires between connector S9
and the switch.
5. Replace or repair open wires as

needed.
Open in PARK signal line. 1. Disconnect connector T9 from the

park switch.
P R O O F
2. Disconnect connector J2 from the

TCU.

harness pins J2-B3 and T9-B.
4. If no continuity is indicated,
inspect this line for an open circuit,
and repair or replace as needed.
5. If continuity is indicated, PARK

signal line is OK.
Continued on next page AG,YZ07927,68 1908MAR051/2

072705
PN=131
P R O O F
Diagnostic Codes
005
54
Open in NOT PARK signal line. 1. Disconnect connector T9 from the

park switch.

TCU.

harness pins J1-K1 and T9-C.
5. If continuity is indicated, NOT

PARK signal line is OK.
Open in system battery voltage 1. With ignition in "OFF" position,

supply line between TVP and park disconnect connector T7 from the
switch. TVP module.

park switch.

harness pins T9-A and T7-C.
4. If no continuity is indicated, the

park switch is not getting power.
P R O O F
Inspect this line for an open circuit,

5. If continuity is indicated, system

battery voltage supply line to park
switch is OK.

AG,YZ07927,68 1908MAR052/2

072705
PN=132
P R O O F
Diagnostic Codes
005
Code 43 (For applications using wet brakes) 110
55
Possible causes for a wet brake Faulty park brake pressure switch. The park brake pressure switch is
system: normally closed; it is closed
(providing an active signal to the
TCU) when the park brake is
applied. With the park brake
disengaged, the wet brake relay is
energized, which in turn energizes
the wet brake solenoid, which then
opens the park brake pressure
switch, allowing the vehicle to move.
1. Disconnect harness from park

brake pressure switch.
2. With ignition in "ON" position,

check for continuity between the two
switch pins while the park brake is
engaged, then disengaged.
3. If continuity does not change with

park brake engagement and
disengagement, replace switch.
4. If continuity does change with

disengagement, park brake pressure
P R O O F
switch is OK.

072705
PN=133
P R O O F
Diagnostic Codes
005
56
Open in PARK signal line. (Park 1. Disconnect connector J6 from the

brake pressure switch input line) transmission.

TCU.

harness pins J6-21 and J2-B3.
5. If continuity is indicated, park

brake pressure switch input line is
OK.

park switch. (Not the park brake
pressure switch.)

TCU.

harness pins J1-K1 and T9-B.
P R O O F



072705
PN=134
P R O O F
Diagnostic Codes
005
57
Open in system battery voltage 1. Disconnect connector J6 from the

supply line between TVP and park transmission.
TVP module.
3. With ignition in "OFF" position,

check for continuity between harness
pins J6-20 and T7-C.

brake pressure switch is OK.

DPSG,YZ07927,172 1905JAN993/3
P R O O F

072705
PN=135
P R O O F
Diagnostic Codes
005
110 Code 44
58
NOT PARK and NEUTRAL Faulty park switch. With ignition in "OFF" position,
signals simultaneously passive disconnect connector T9 from the
at TCU. park switch.
The TCU expects the J1-K1 NOT

PARK input and the J2-A1
NEUTRAL input to have opposite
states.
LEGAL CONDITIONS:
1. NOT PARK active and

NEUTRAL passive.
2. NOT PARK passive and

NEUTRAL active.

P R O O F

pinouts.
For a disc brake system only: 1. Check for continuity between

switch pins A and B while actuating
switch.
2. Repeat continuity check, this time


fails to alternate as the switch is
actuated, replace the switch.

072705
PN=136
P R O O F
Diagnostic Codes
005
59
For a wet brake system only: 1. Check for continuity between

switch.
2. If continuity fails to alternate as

the switch is actuated, replace the
switch.
NOTE: If testing switch through

wiring, be sure to rule out
possible open circuits in the
wiring between S9 and the
park switch before replacing
switch. (See below)
Open in wiring between park switch 1. Disconnect connector T9 from the

connector S9 and park switch. park switch or park switch harness.
2. Inspect wires to park switch for

or cuts.
3. Wiring can be verified as OK if the

indicated between pins S9-A and
S9-B (for wet brake systems) or
S9-A and S9-C (for disc brake
systems). However, if continuity is
P R O O F
not indicated, the park switch

remains a possible cause.
4. If the wiring harness can be

directly at the switch, test continuity
of all wires between connector S9
and the switch.

needed.

072705
PN=137
P R O O F
Diagnostic Codes
005
60
Open in NOT PARK signal line. For 1. Disconnect connector T9 from the
a disc brake system only: park switch.

TCU.

harness pins J1-K1 and T9-C.
5. If continuity is indicated, the NOT

For a wet brake system: 1. Disconnect connector T9 from the

park switch. (Not the pressure
switch.)

TCU.

harness pins J1-K1 and T9-B.
P R O O F


072705
PN=138
P R O O F
Diagnostic Codes
005
61
Open in NEUTRAL signal line. 1. Disconnect connector J4 from the

gear selector.

TCU.

harness pins J4-C and J2-A1.
5. If continuity is indicated,
NEUTRAL signal line is OK.
Open in system battery voltage line 1. Turn ignition to "OFF" position.

between TVP and park switch.
TVP module.

park switch.

harness pins T9-A and T7-C.
5. If no continuity is indicated, park

P R O O F
switch is not getting power--inspect

this line for an open circuit, and
repair or replace as needed.

battery voltage line to park switch is
OK.

072705
PN=139
P R O O F
Diagnostic Codes
005
62
Open in system battery voltage line 1. Turn ignition to "OFF" position.

between TVP and gear selector.
TVP module.

gear selector. Check for continuity
between pins J4-A and T7-C.
4. If no continuity is indicated, gear

selector is not getting power-inspect

battery voltage line to gear selector
is OK.

P R O O F

072705
PN=140
P R O O F
Diagnostic Codes
005
63

"ON" position.


above)


neutral.

IMPORTANT: For more

P R O O F
TROUBLESHOOTING
THE GEAR
SELECTOR in
Group 100 (Test and
Troubleshooting).

AG,YZ07927,72 1923OCT986/6

072705
PN=141
P R O O F
Diagnostic Codes
005
110 Code 45
64
PARK signal is active and Faulty park switch. For a disc brake With ignition in "OFF" position,
NEUTRAL signal is passive at system only: disconnect connector T9 from the
TCU. park switch.
- 1. Check for continuity between

The TCU sees a conflict; the switch.
passive NEUTRAL signal on pin
J2-A1 claims that the vehicle is 2. Repeat continuity check, this time
in gear, yet the active PARK between switch pins A and C.
signal on pin J2-B3 says the
vehicle is parked. 3. If for either test 1 or 2, continuity
- actuated, replace the switch.
LEGAL CONDITIONS:
1. PARK active and NEUTRAL

active. (Park brake is set and
gear selector is in NEUTRAL)
2. PARK passive and NEUTRAL

active. (Park brake is off and
gear selector is in gear)
3. PARK passive and NEUTRAL

P R O O F
passive (Park brake is off and

gear selector is in NEUTRAL).

pinouts.

072705
PN=142
P R O O F
Diagnostic Codes
005
65
For a wet brake system only: 1. Check for continuity between

switch.

switch.
Faulty park brake pressure switch. 1. Disconnect park brake pressure

For a wet brake system only: switch from harness.

switch pins while actuating switch.

switch.
Faulty wet brake relay. For a wet Replace relay.

brake system only:
Wet brake solenoid disconnected. Verify that harness is connected to

For a wet brake system only: solenoid.
Open in NOT PARK signal line. For 1. Disconnect connector T9 from

a wet brake system only: park switch.
2. Disconnect connector S35 from

P R O O F
wet brake relay.

harness pins T9-B and S35-A.
inspect wire for open circuit, and
replace or repair as needed.

072705
PN=143
P R O O F
Diagnostic Codes
005
66
Open in NOT PARK signal line 1. Disconnect connector S35 from

between T35 connector and wet wet brake relay harness connector
brake relay. For a wet brake T35.
system only:
2. Check for continuity from harness
pin T35-A and the wet brake relay.
Open in system battery voltage 1. Locate the system battery voltage

supply line to wet brake relay. For a supply line at the wet brake relay.
wet brake system only:
2. Verify that there is system battery
voltage on this line.
3. If not, inspect line for open circuit

and replace or repair as necessary.
Open wet brake solenoid. For a wet 1. Disconnect the wet brake solenoid
brake system only: from its harness.
2. Check resistance between the

solenoids pins.
3. If an open circuit is indicated,

replace the solenoid.
P R O O F
Faulty pressure switch. For a 1. Disconnect pressure switch from

pressure switch system only: harness.


switch.

072705
PN=144
P R O O F
Diagnostic Codes
005
67

gear selector.

TCU.
3. Check for continuity between pins

J4-C and J2-A1.
Open in system battery voltage 1. Turn ignition to "OFF" position.

supply line between TVP module
and gear selector. 2. Disconnect connector T7 from the
TVP module.

gear selector.

harness pins J4-A and T7-C.

P R O O F
selector is not getting power. Inspect


is OK.

072705
PN=145
P R O O F
Diagnostic Codes
005
68
Short to system battery voltage in 1. Turn ignition to "OFF" position.

PARK signal line. For disc brake
systems: 2. Disconnect connector J2 from the
TCU.

TCU.
CAUTION: Make sure

vehicle will not roll.
4. Disengage park brake.

harness pins J2-B3 and J1-A1.
6. If continuity is indicated, inspect

these lines for a short circuit and
replace or repair as necessary.
For wet brake systems or 1. Disconnect connector J6 at

pressure switch systems: transmission.
2. Verify that harness pins J6-20

(system battery voltage) and J6-21
(PARK signal) are not in contact; if
so, repair or replace.
P R O O F
3. Make sure there is no conductive

path between the two pins via
contamination by a foreign
substance; clean pins if necessary.
4. Disconnect connector J3 at TCU.
5. Check for continuity between pin

J3-A1 and J6-21.

lines to locate short; repair or
replace wires as necessary.

072705
PN=146
P R O O F
Diagnostic Codes
005
69

"ON" position. (Engine not running.)


above)


neutral.


P R O O F
AG,YZ07927,73 1923OCT986/6

072705
PN=147
P R O O F
Diagnostic Codes
005
110 Code 48
70
NOT PARK and PARK signals Faulty park switch. For a disc brake With ignition in "OFF" position,
simultaneously active at TCU. system only: disconnect connector T9 from the
park switch.
-
The TCU expects the J1-K1 NOT switch pins A and B while actuating
PARK input and the J2-B3 PARK switch.
input to have opposite states.
- between switch pins A and C.
LEGAL CONDITIONS: 3. If for either test 1 or 2, continuity

1. NOT PARK active and PARK actuated, replace the switch.
passive.
IMPORTANT: If testing switch
2. NOT PARK passive and PARK through wiring, be
active. sure to rule out
possible short
circuits to system
battery voltage in
the wiring between
S9 and the park
switch before
replacing switch.
P R O O F
Faulty park brake pressure switch. The park brake pressure switch is
For a wet brake system only: normally closed; it is closed

072705
PN=148
P R O O F
Diagnostic Codes
005
71
CAUTION: Make sure

2. With engine OFF turn ignition to

"ON" position, check for continuity
between the two switch pins while
the park brake is engaged, then
disengaged.


switch is OK.
NOT PARK and PARK signal lines 1. Turn ignition to "OFF" position.
shorted together between connector
S9 and park switch. For a disc 2. Disconnect connector S9 from T9.
brake system only:
S9-B and S9-C.

these lines for a short, and replace
or repair wire(s) as necessary.
P R O O F

072705
PN=149
P R O O F
Diagnostic Codes
005
72
T9 and TCU. For a disc brake 2. Disconnect connector S9 from T9.
system only:
TCU.

TCU.

harness pins J1-K1 and J2-B3.


P R O O F

072705
PN=150
P R O O F
Diagnostic Codes
005
73

TCU.

TCU.
CAUTION: Make sure


J2-B3 and J1-A1.

For wet brake systems: 1. Disconnect connector J6 at

transmission.

P R O O F


J3-A1 and J6-21.


072705
PN=151
P R O O F
Diagnostic Codes
005
74

NOT PARK signal line.
2. Disconnect connector S9 from T9.
For a disc brake system only:
harness pins T9-A (system battery
voltage) and T9-C (NOT PARK).

replace wire(s) as necessary.
For a wet brake system only: 1. Turn ignition to "OFF" position.
2. Disconnect connector S9 from T9.

voltage) and T9-B (NOT PARK).

Faulty wet brake relay. For a wet Specific installations will vary;
brake system only: consult wiring diagram for the
application.
P R O O F
Replace relay.
Disconnected wet brake solenoid. Verify that harness is connected to


solenoids pins.


072705
PN=152
P R O O F
Diagnostic Codes
005
75
Open circuit in wiring between park Specific installations will vary;

switch and wet brake solenoid. For consult wiring diagram for the
a wet brake system only: application.
Check continuity in wiring between

park switch and wet brake solenoid.
Open in system supply voltage line Specific installations will vary;

to wet brake relay. For a wet brake consult wiring diagram for the
system only: application.
1. Turn ignition to "ON" position.
2. Verify that system supply voltage

is present at the appropriate relay
terminal.
3. If system supply voltage is not

present, trace the supply voltage line
from the relay back towards the
voltage source.

P R O O F
AG,YZ07927,76 1923OCT986/6

072705
PN=153
P R O O F
Diagnostic Codes
005
110 Code 49
76
Signals coming from gear Faulty park brake pressure switch. The park brake pressure switch is
selector indicate park but PARK normally closed; it is closed
PRESSURE is passive at TCU. (providing an active signal to the
- applied. With the park brake
The TCU sees a conflict; the gear energized, which in turn energizes
selector indicates park, but the the wet brake solenoid, which then
PARK PRESSURE signal input at opens the park brake pressure
J2-B3 indicates the vehicle is out switch, allowing the vehicle to move.
of park.
- brake pressure switch.
LEGAL CONDITIONS:
CAUTION: Make sure
1. PARK PRESSURE signal
active while gear selector is in
2. With engine off and ignition in
park position.
2. PARK PRESSURE signal
passive while gear selector is in
disengaged.
gear.
-
P R O O F
This code occurs only for

non-Funk gear selectors.
switch is OK.
Open in PARK PRESSURE signal 1. Disconnect connector J6 from the

line. transmission.

TCU.

J6-21 and J2-B3.

072705
PN=154
P R O O F
Diagnostic Codes
005
77

OK.


TVP module.


Faulty gear selector. Troubleshoot (consult manufacturers

P R O O F
information) or replace gear selector.

AG,YZ07927,77 1924OCT982/2

072705
PN=155
P R O O F
Diagnostic Codes
005
110 Code 50
78
LEGAL CONDITIONS:
1. UPSHIFT and DOWNSHIFT both passive (no new gear

being requested by operator
2. UPSHIFT active, DOWNSHIFT passive (higher gear

being requested by operator)
3. UPSHIFT passive, DOWNSHIFT active (lower gear

being requested by operator).

P R O O F

072705
PN=156
P R O O F
Diagnostic Codes
005
79
UPSHIFT and DOWNSHIFT Faulty gear selector. 1. Disconnect connector J4 from the
signals are simultaneously active gear selector.
at TCU.
- J4-D (DOWNSHIFT) and J4-E
(UPSHIFT) when selector is in the
Code 50 applicable only to upshift position.
systems with a FUNK gear
selector handle. 3. Hold selector in the downshift
position and repeat continuity check.
-
4. If continuity is indicated in either
The TCU sees a conflict; it measurement, replace gear selector.
cannot instruct the transmission
to upshift and downshift at the IMPORTANT: For more
same time. During a requested information refer to
shift, it expects the UPSHIFT TROUBLESHOOTING
input at J1-H2 and the THE GEAR
DOWNSHIFT input at J1-H3 to SELECTOR in
have opposite states. Group 100 (Test and
Troubleshooting).
-
UPSHIFT and DOWNSHIFT signal 1. Disconnect connector J4 from the

lines shorted together. gear selector.

harness pins J4-D (DOWNSHIFT)
P R O O F
and J4-E. (UPSHIFT)
3. If continuity is indicated, trace

both lines back to the J1 connector
on the TCU, inspecting for a short.
Replace or repair as needed.

072705
PN=157
P R O O F
Diagnostic Codes
005
80
Short to system battery voltage in 1. Disconnect connector J4 from the

UPSHIFT signal line. gear selector.

harness pins J4-A (system voltage)
and J4-E (UPSHIFT).

lines for short and replace or repair
as needed.
4. If continuity is not indicated,

UPSHIFT line is OK.

DOWNSHIFT signal line. gear selector.

J4-A (System voltage) and J4-D
(DOWNSHIFT).

as needed.

DOWNSHIFT line is OK.
P R O O F

AG,YZ07927,78 1924OCT983/3

072705
PN=158
P R O O F
Diagnostic Codes
005
Code 51 110
81
LEGAL CONDITIONS:
1. FORWARD and REVERSE both passive (selector in

neutral).
2. FORWARD active, REVERSE passive (selector in

forward).
3. FORWARD passive, REVERSE active (selector in

reverse).
This diagnostic code description applies to the Funk 12V

and 24V gear selector. If using a different gear selector
the description will change in regard to selector pinout.

P R O O F

072705
PN=159
P R O O F
Diagnostic Codes
005
82
FORWARD and REVERSE Faulty gear selector. 1. Disconnect connector J4 from the
signals are simultaneously active gear selector.
at TCU.
- J4-F (REVERSE) and J4-G
(FORWARD) when selector is in the
The TCU sees a conflict; it reverse position.
cannot instruct the transmission
to move forward and reverse at 3. Hold selector in the forward
the same time. While the vehicle position and repeat continuity check.
is in gear, it expects the
FORWARD input at J1-J1 and the 4. If continuity is indicated in either
REVERSE input at J1-J2 to have measurement, replace gear selector.
opposite states.
IMPORTANT: For more
- information refer to
TROUBLESHOOTING
THE ELECTRONIC
GEAR SELECTOR
in Group 100 (Test
and
Troubleshooting).
FORWARD and REVERSE signal 1. Disconnect connector J4 from the

lines shorted together. gear selector.

J4-F (REVERSE) and J4-G.
P R O O F
(FORWARD)
3. If continuity is indicated, trace

both lines back to the J1 connector
on the TCU, inspecting for a short.
Replace or repair as needed.

072705
PN=160
P R O O F
Diagnostic Codes
005
83

FORWARD signal line. gear selector.

J4-A (system voltage) and J4-G
(FORWARD).

as needed.

FORWARD line is OK.

REVERSE signal line. gear selector.

J4-A (system voltage) and J4-F
(REVERSE).

as needed.

REVERSE line is OK.
P R O O F

AG,YZ07927,79 1924OCT983/3

072705
PN=161
P R O O F
Diagnostic Codes
005
110 Code 52
84
FORWARD, NEUTRAL, and Open in FORWARD signal line. 1. Disconnect connector J4 from the
REVERSE signals are all gear selector.
- TCU.
The TCU always expects a 3. Check for continuity between pins

commanded transmission state J4-G and J1-J1.
from the gear selector, and it is
not seeing any one of the 4. If no continuity is indicated,
possible choices [FORWARD inspect this line for an open circuit
(J1-J1), NEUTRAL (J2-A1), or and replace or repair as needed.
REVERSE (J1-J2)] as an active
signal. 5. If continuity is indicated,
FORWARD line is OK.
-
LEGAL CONDITIONS:
In a properly operating system,

one and only one of the three
signals must be active at all
times.
-
P R O O F

change in regard to selector
pinout.

072705
PN=162
P R O O F
Diagnostic Codes
005
85
Open in REVERSE signal line. 1. Disconnect connector J4 from the

gear selector.

TCU.

J4-F and J1-J2.
inspect this line for an open circuit
and replace or repair as needed.
REVERSE line is OK.

gear selector.

TCU.

J4-C and J2-A1.
and replace or repair as needed.
P R O O F
NEUTRAL line is OK.

072705
PN=163
P R O O F
Diagnostic Codes
005
86

TVP module.

gear selector.

J4-A and T7-C.


is OK.

P R O O F

072705
PN=164
P R O O F
Diagnostic Codes
005
87
Faulty gear selector. 1. Disconnect connector J4 from the

gear selector.
2. With engine off, turn the ignition to

the "ON" position.
3. Measure the voltage at pin J4-A.
4. If measurement indicates system

battery voltage, it indicates that the
gear selector is powered. Proceed
with step 6.
5. If measurement does not indicate

system battery voltage, a fault in the
wiring between the TVP module and
the gear selector is likely, or the TVP
module may be faulty. Troubleshoot
accordingly.

TCU.

TCU.
8. Verify NEUTRAL signal line is OK

(See above).
P R O O F
9. Verify FORWARD signal line is

OK (See above).
10. Verify REVERSE signal line is

OK (See above).
11. Attach connector J4 to the gear

selector.

072705
PN=165
P R O O F
Diagnostic Codes
005
88
Replace the gear selector if any

one of the following are true:
1. The voltage on pin J2-A1

(NEUTRAL) does not alternate
between 0 volts and system battery
voltage as the gear selector is
moved in and out of neutral.
2. The voltage on pin J1-J1

(FORWARD) does not alternate
moved in and out of forward.
3. The voltage on pin J1-J2

(REVERSE) does not alternate
moved in and out of reverse.

P R O O F
AG,YZ07927,81 1924OCT985/5

072705
PN=166
P R O O F
Diagnostic Codes
005
Code 54 110
89
Invalid requested gear Requested gear is an invalid value. 1. Turn ignition to "OFF" position.
calculation.
- in neutral.
The result of an internal 3. If Code 54 persists, replace TCU

calculation for the requested or contact Field Service.
gear is an invalid value.
IMPORTANT: This diagnostic

code is typically
not field
serviceable.
AG,YZ07927,82 1924OCT981/1
P R O O F

072705
PN=167
P R O O F
Diagnostic Codes
005
110 Code 56
90
NEUTRAL and FORWARD inputs Short to system battery voltage in 1. Turn ignition to "OFF" position.
simultaneously active at TCU. NEUTRAL signal line.
- gear selector.
The TCU sees a conflict; it 3. Check for continuity between pins

cannot instruct the transmission J4-A (system battery voltage) and
to move forward and stay in J4-C (NEUTRAL).
neutral at the same time. It
expects the J2-A1 NEUTRAL 4. If continuity is indicated, inspect
input and the J1-J1 FORWARD these lines for a short, and replace
input to have opposite states. or repair as needed.
- 5. If no continuity is indicated,
LEGAL CONDITIONS:
1. NEUTRAL active and

FORWARD passive.
2. NEUTRAL passive and

FORWARD active.

P R O O F

pinout.

072705
PN=168
P R O O F
Diagnostic Codes
005
91

FORWARD signal line.
gear selector.

J4-A (system battery voltage) and
J4-G (FORWARD).

or repair as needed.
FORWARD signal line is OK.
NEUTRAL and FORWARD signal 1. Turn ignition to "OFF" position.

lines shorted together.
gear selector.

J4-C (NEUTRAL) and J4-G
(FORWARD).

P R O O F

072705
PN=169
P R O O F
Diagnostic Codes
005
92
Faulty gear selector. 1. Turn ignition to "OFF" position.

gear selector.
3. Move gear selector to neutral

position.
4. Check for continuity between gear

selector pins J4-C (NEUTRAL) and
J4-G (FORWARD).

selector pins J4-A (system battery
voltage) and J4-G.
6. Disconnect meter leads from gear

selector.
7. Move gear selector to forward

position.

selector pins J4-C and J4-G.
9. If continuity is indicated for any of

the tests 4, 5, or 8, replace the gear
selector.
P R O O F

AG,YZ07927,83 1924OCT983/3

072705
PN=170
P R O O F
Diagnostic Codes
005
Code 57 110
93
NEUTRAL and REVERSE inputs Short to system battery voltage in 1. Turn ignition to "OFF" position.
simultaneously active at TCU. NEUTRAL signal line.
- gear selector.
The TCU sees a conflict; it 3. Check for continuity between pins

cannot instruct the transmission J4-A (system battery voltage) and
to move forward and stay in J4-C (NEUTRAL).
neutral at the same time. It
expects the J2-A1 NEUTRAL 4. If continuity is indicated, inspect
input and the J1-J2 REVERSE these lines for a short, and replace
input to have opposite states. or repair as needed.
- 5. If no continuity is indicated,
LEGAL CONDITIONS:
1. NEUTRAL active and

REVERSE passive.
2. NEUTRAL passive and

REVERSE active.

P R O O F

pinout.

072705
PN=171
P R O O F
Diagnostic Codes
005
94

REVERSE signal line.
gear selector.

J4-F (REVERSE).

REVERSE signal line is OK.
NEUTRAL and REVERSE signal 1. Turn ignition to OFF position.

lines shorted together.
gear selector.

J4-C (NEUTRAL) and J4-F
(REVERSE).

P R O O F

072705
PN=172
P R O O F
Diagnostic Codes
005
95
Faulty gear selector. 1. Turn ignition to "OFF" position.

gear selector.
3. Move gear selector to neutral

position.

J4-C (NEUTRAL) and J4-F
(REVERSE).

J4-F.
6. Disconnect meter leads from gear

selector.
7. Move gear selector to reverse

position.

J4-C and J4-F.
9. If continuity is indicated for any of

the tests 4, 5, or 8, replace the gear
selector.
P R O O F

AG,YZ07927,84 1924OCT983/3

072705
PN=173
P R O O F
Diagnostic Codes
005
110 Code 58
96
START signal went active at Ignition turned to "START" position Do not crank starter once vehicle
TCU. after vehicle is running. has started.
The TCU sees an active START

signal on pin J2-B2.
This condition causes the

internal solenoid power to be
disabled.
LEGAL CONDITIONS:
START signal should be active

only when ignition is in "START"
position and vehicle starter is
cranking.

P R O O F
AG,YZ07927,85 1924OCT981/1

072705
PN=174
P R O O F
Diagnostic Codes
005
Code 59 110
97
Invalid 5-bit selector code. Faulty wiring between gear selector Refer to gear selector documentation
and TCU. and application wiring diagram.
- Check for miswiring, shorted or open
lines between the gear selector and
The TCU does not recognize the the TCU.
code being sent by the gear
selector.
Faulty gear selector. Refer to gear selector

documentation. Replace gear
selector if necessary.
Faulty TCU. 1. Turn ignition to "OFF" position.

in neutral. If Code 59 persists,
replace TCU or contact Field
Service.
AG,YZ07927,86 1924OCT981/1
P R O O F

072705
PN=175
P R O O F
Diagnostic Codes
005
110 Code 60
98
Valve driver supply voltage too Insufficient vehicle battery voltage. System battery supply voltage must
low. be above 8 volts on a 12V system,
or above 17 volts on a 24V system.
-
1. Check voltage at vehicle battery
There is insufficient voltage to terminals.
properly operate the solenoids.
2. If measurement is below 8 volts
on a 12V system or below 17 volts
on a 24V system, recharge or
replace battery.
Open in system battery voltage 1. Disconnect connector T7 from the

supply line between TVP module TVP module.
and TCU.
TCU.

harness pins T7-C and J3-A1.

P R O O F
AG,YZ07927,87 1924OCT981/1

072705
PN=176
P R O O F
Diagnostic Codes
005
Code 80 110
99
NOTE: This error code is typically only associated with a

dual engine / transmission application and is
normally a result of one of the engines not
running. It is not generated as a result of electrical
problems with the MPU or its associated circuit or
wiring and will only occur when there are no other
TCU related faults in the system.
Engine speed MPU signal Dual Engine/Transmission Start second engine.

missing or frequency is too low. application
Basic Problem: The TCU is not

seeing the expected engine speed
signal on input pin J1-B1.
Ignition is on, but engine has not Start engine.

been started.
Engine speed MPU sensor out of Verify that sensor is tightened

adjustment. securely and has not loosened from
the transmission housing.
Wrong sensor in the engine speed Verify the sensor has not been
sensor port. accidentally exchanged with the
cylinder speed or transmission
output speed MPU sensor.
P R O O F
Faulty engine speed MPU sensor. 1) Remove and inspect MPU. Look
for physical damage.
2) Replace MPU.
No engine speed MPU sensor. Verify that an engine speed MPU

sensor is installed on the
transmission, and install one if
needed.
Faulty TCU After all other possible causes have

YZ07927,0000436 1928APR051/1

072705
PN=177
P R O O F
Diagnostic Codes
005
110 Code 84
,100
LEGAL CONDITIONS:
1. TRANSPORT MODE signal active, DRILL MODE signal

passive. (vehicle is in transport mode
2. TRANSPORT MODE signal passive, DRILL MODE

signal active. (vehicle is in drill mode)
IMPORTANT: This code applies to customers who

use the TCUs discrete inputs.
Incorrect or undefined vehicle Open in DRILL MODE signal line. 1. Turn the ignition to the "OFF"
mode. position.
- 2. Disconnect connector J2 from the

TCU.
The TCU is not seeing one of the
expected combinations of 3. Check continuity of this signal line
application-specific vehicle mode between pin J2-B1 and the DRILL
signals. Discrete inputs DRILL MODE signal source.
MODE (pin J2-B1) and
TRANSPORT MODE (pin J2-C3) 4. If continuity is not indicated,
must have opposite states. inspect this line for an open circuit
and replace or repair wire.
P R O O F
Open in TRANSPORT MODE signal 1. Turn the ignition to the "OFF"

line. position.

TCU.
3. Check continuity of this signal line

between pin J2-C3 and the
TRANSPORT MODE signal source.

and replace or repair wire.

072705
PN=178
P R O O F
Diagnostic Codes
005
,101
Short to system battery voltage in 1. Turn the ignition to the "OFF"

DRILL MODE signal line. position.

TCU.

TCU.

J2-B1 and pin J1-A1 (system battery
voltage).

this line for a short circuit and
Short to system battery voltage in 1. Turn the ignition to the OFF

TRANSPORT MODE signal line. position.

TCU.

TCU.

J2-C3 and pin J1-A1 (system battery
P R O O F
voltage).


072705
PN=179
P R O O F
Diagnostic Codes
005
,102
TRANSPORT MODE and DRILL 1. Turn the ignition to the "OFF"

MODE signal lines shorted together. position.

TCU.

J2-B1 and J2-C3.

these lines for a short circuit, and
repair or replace wire(s) as
necessary.

AG,YZ07927,92 1924OCT983/3
P R O O F

072705
PN=180
P R O O F
Diagnostic Codes
005
Code 85 110
,103
LEGAL CONDITIONS:
1. PARK active and NEUTRAL active. (Park brake is set

and gear selector is in NEUTRAL)
2. PARK passive and NEUTRAL active. (Park brake is off

and gear selector is in gear)
3. PARK passive and NEUTRAL passive. (Park brake is

off and gear selector is in NEUTRAL)
NOTE: In some applications, where the capability to

warm up the transmission by stalling out the
torque converter is desired, the combination of
active PARK and passive NEUTRAL is legal.
PARK signal is active and Faulty park switch. For a disc brake With ignition in "OFF" position,
NEUTRAL signal is passive at system only: disconnect connector T9 from the
TCU. park switch.

The TCU sees a conflict; the switch.
passive NEUTRAL signal on pin
P R O O F
J2-A1 indicates that the vehicle 2. Repeat continuity check, this time
is in gear, yet the active PARK between switch pins A and C.
signal on pin J2-B3 indicates the
vehicle is parked. 3. If for either test 3 or 4, continuity
- actuated, replace the switch.



switch.

072705
PN=181
P R O O F
Diagnostic Codes
005
,104
Faulty wet brake relay. For a wet Replace relay.

brake system only:
Wet brake solenoid disconnected. Verify that harness is connected to

Open in NOT PARK signal line. For 1. Disconnect connector T9 from

a wet brake system only: park switch.
2. Disconnect connector S35 from

wet brake relay.

T9-B and S35-A.
Open in NOT PARK signal line 1. Disconnect connector S35 from

between T35 connector and wet wet brake relay harness connector
brake relay. For a wet brake T35.
system only:
2. Check for continuity from harness
pin T35-A and the wet brake relay.
P R O O F
Open in system battery voltage 1. Locate the system battery voltage

supply line to wet brake relay. For a supply line at the wet brake relay.
wet brake system only:
2. Verify that there is system battery
voltage on this line.
3. If not, inspect line for open circuit


072705
PN=182
P R O O F
Diagnostic Codes
005
,105

solenoids pins.




switch.

gear selector.

TCU.

J4-C and J2-A1.
P R O O F

072705
PN=183
P R O O F
Diagnostic Codes
005
,106

TVP module.

gear selector.

J4-A and T7-C.


is OK.

P R O O F

072705
PN=184
P R O O F
Diagnostic Codes
005
,107

TCU.

TCU.
CAUTION: Make sure


J2-B3 and J1-A1.



P R O O F


J3-A1 and J6-21.


072705
PN=185
P R O O F
Diagnostic Codes
005
,108

"ON" position. (Engine not running.)


above)

3. The voltage on pin J2-A1 does

not alternate between 0 volts and
system battery voltage as the gear
selector is moved in and out of
neutral.

IMPORTANT: For more

P R O O F
TROUBLESHOOTING
THE GEAR
SELECTOR in
Group 100 (Test and
Troubleshooting).

AG,YZ07927,93 1924OCT986/6

072705
PN=186
P R O O F
Diagnostic Codes
005
Code 86 110
,109
Inching pedal TOP OF CLUTCH Faulty TOC switch 1. Disconnect connector T21 from
signal is active but BOTTOM OF TOC switch.
CLUTCH signal is passive at
TCU. 2. Check for continuity between pins
S21-A and S21-B as switch is
- actuated.
The TCU is reading the TOP OF 3. If continuity fails to alternate as

CLUTCH (TOC) switch as closed the switch is actuated, replace
on input J1-K3, but BOTTOM OF switch.
CLUTCH (BOC) switch as open
on input J1-K2. Under normal
conditions, this is an impossible
signal state.
LEGAL CONDITIONS:
1. TOC closed (active) and BOC

closed (active). This state occurs
when the inching pedal is fully
up.
2. TOC open (passive) and BOC

closed (active). This state occurs
P R O O F
when the inching pedal is

somewhere between its fully up
and fully down positions.
3. TOC open (passive) and BOC

open (passive). This state occurs
when the inching pedal is fully
depressed.
Faulty BOC switch. 1. Disconnect the inching pedal.

pedal pins E and F as the pedal is
actuated.
Continued on next page DPSG,YZ07927,94 1906NOV981/4

072705
PN=187
P R O O F
Diagnostic Codes
005
,110
3. There should be continuity (or

resistance less than 100 ohms)
except when the pedal is fully
depressed. If not, replace the inching
pedal.
BOC signal line open between T11 1. Disconnect connector J1 from the
connector and TCU. TCU.
2. Disconnect connector T11 from

the inching pedal.

T11-E and J1-K2.

BOC signal line open between S11 1. Disconnect connector from the
connector and BOC switch. inching pedal.
2. Disconnect connectors T11 and

S11.

S11-E and pin E of the pedals
mating connector.
P R O O F


072705
PN=188
P R O O F
Diagnostic Codes
005
,111
Supply voltage line to BOC switch 1. Disconnect connector J1 from the

open between T11 connector and TCU.
TCU.
2. Disconnect connector T11 from
the inching pedal.

T11-F and J2-F2 (system battery
voltage).

Supply voltage line to BOC switch 1. Disconnect connector from the

open between S11 connector and inching pedal.
BOC switch.
S11.

S11-F and pin F of the pedals
mating connector.

P R O O F

072705
PN=189
P R O O F
Diagnostic Codes
005
,112
TOC signal line shorted to system 1. Disconnect connector J1 from the

battery voltage. TCU.

TCU.

S21.

J1-K3 and J2-F3.

J1-K3 and J1-A1.
6. If continuity is indicated for either

test, inspect the lines for a short
circuit, and replace or repair wire(s)
as necessary.

P R O O F
DPSG,YZ07927,94 1906NOV984/4

072705
PN=190
P R O O F
Diagnostic Codes
005
Code 87 110
,113
PARK and FORWARD signals are Faulty park switch. For a disc brake With ignition in "OFF" position,
park switch.
-
The TCU sees a conflict; the switch pins A and B while actuating
active PARK signal on pin J2-B3 switch.
indicates that the vehicle is
parked, yet the active FORWARD 2. Repeat continuity check, this time
signal on pin J1-J1 says the between switch pins A and C.
vehicle is in gear.
- fails to alternate as the switch is
LEGAL CONDITIONS:
1. PARK active and FORWARD

passive. (Park brake is set and
gear selector is not in a forward
gear)
2. PARK passive and FORWARD

gear selector is in a forward
gear)
P R O O F
3. PARK passive and FORWARD

passive. (Park brake is off and
gear selector is not in a forward
gear)



switch.

072705
PN=191
P R O O F
Diagnostic Codes
005
,114



switch.
Short to system battery voltage in 1. Turn ignition to OFF position.

FORWARD signal line.
gear selector.

J4-G and J4-A.

P R O O F

072705
PN=192
P R O O F
Diagnostic Codes
005
,115

TCU.

TCU.
CAUTION: Make sure


J2-B3 and J1-A1.

For wet brake systems or

pressure switch systems:
1. Disconnect connector J6 at
transmission.
2. Verify that pins J6-20 (system

battery voltage) and J6-21 (PARK
P R O O F
signal) are not in contact; if so,

repair or replace.


J3-A1 and J6-21.


072705
PN=193
P R O O F
Diagnostic Codes
005
,116
Faulty gear selector. IMPORTANT: For more

TROUBLESHOOTING
THE GEAR
SELECTOR in
Group 100 (Test and
Troubleshooting).

DPSG,YZ07927,96 1909NOV984/4
P R O O F

072705
PN=194
P R O O F
Diagnostic Codes
005
Code 88 110
,117
PARK and REVERSE signals are Faulty park switch. For a disc brake With ignition in "OFF" position,
park switch.
-
The TCU sees a conflict; the switch pins A and B while actuating
active PARK signal on pin J2-B3 switch.
indicates that the vehicle is
parked, yet the active REVERSE 2. Repeat continuity check, this time
signal on pin J1-J2 indicates the between switch pins A and C.
vehicle is in gear.
- fails to alternate as the switch is
LEGAL CONDITIONS:
1. PARK active and REVERSE

passive. (Park brake is set and
gear selector is not in a reverse
gear)
2. PARK passive and REVERSE

gear selector is in a reverse
gear)
P R O O F
3. PARK passive and REVERSE

passive. (Park brake is off and
gear selector is notin a reverse
gear)

pinouts.

072705
PN=195
P R O O F
Diagnostic Codes
005
,118



switch.



switch.

REVERSE signal line.
gear selector.

J4-G and J4-A.
P R O O F


072705
PN=196
P R O O F
Diagnostic Codes
005
,119

TCU.

TCU.
CAUTION: Make sure


J2-B3 and J1-A1.



repair or replace.
P R O O F


J3-A1 and J6-21.


072705
PN=197
P R O O F
Diagnostic Codes
005
,120
Faulty gear selector. IMPORTANT: For more

TROUBLESHOOTING
THE GEAR
SELECTOR in
Group 100 (Test and
Troubleshooting).

DPSG,YZ07927,97 1909NOV984/4
Code 89 (For applications using disc brakes)

NOT PARK and PARK signals Faulty park switch. 1. Turn ignition to "OFF" position.
- park switch or park switch harness.
P R O O F
The TCU expects the J1-K1 NOT 3. Testing directly at switch pins,
PARK input and the J2-B3 PARK check for continuity between switch
input to have opposite states. pins A and B while actuating switch.
- 4. Repeat continuity check, this time

LEGAL CONDITIONS:
1. NOT PARK active and PARK fails to toggle as the switch is
passive. actuated, replace the switch.
2. NOT PARK passive and PARK

active.

072705
PN=198
P R O O F
Diagnostic Codes
005
,121
IMPORTANT: NOTE: If testing

switch through
wiring, be sure to
rule out possible
open circuits in the
wiring between S9
and the park switch
before replacing
switch. (See below)


or cuts.

indicated, the park switch remains a
possible cause.

P R O O F
and the switch.

needed.

072705
PN=199
P R O O F
Diagnostic Codes
005
,122
Open in PARK signal line. 1. Disconnect connector T9 from the

park switch.

TCU.

harness pins J2-B3 and T9-B.

signal line is OK.

park switch.

TCU.

J1-K1 and T9-C.
P R O O F


072705
PN=200
P R O O F
Diagnostic Codes
005
,123

switch. TVP module.

park switch.

T9-A and T7-C.


switch is OK.

P R O O F
DPSG,YZ07927,98 1909NOV984/4

072705
PN=201
P R O O F
Diagnostic Codes
005
110 Code 89 (For applications using wet brakes)
,124
Possible causes for a wet brake Faulty park brake pressure switch. The park brake pressure switch is
system. normally closed; it is closed

2. With ignition in "ON" position,

check for continuity between the two
switch pins while the park brake is
engaged, then disengaged.


P R O O F
switch is OK.

072705
PN=202
P R O O F
Diagnostic Codes
005
,125

brake pressure switch input line.) transmission.

TCU.

J6-21 and J2-B3.

OK.

park switch. (Not the park brake
pressure switch.)

TCU.

J1-K1 and T9-B.
P R O O F



072705
PN=203
P R O O F
Diagnostic Codes
005
,126

TVP module.



DPSG,YZ07927,184 1903MAR993/3
P R O O F

072705
PN=204
P R O O F
Diagnostic Codes
005
Code 90 110
,127
NOT PARK and PARK signals Faulty park switch. For a disc brake With ignition in "OFF" position,
park switch.
-
The TCU expects the J1-K1 NOT switch pins A and B while actuating
PARK input and the J2-B3 PARK switch.
input to have opposite states.
- between switch pins A and C.
LEGAL CONDITIONS: 3. If for either test 3 or 4, continuity

1. NOT PARK active and PARK actuated, replace the switch.
passive.
2. NOT PARK passive and PARK through wiring, be
active. sure to rule out
possible short
circuits to system
battery voltage in
the wiring between
S9 and the park
switch before
replacing switch.
P R O O F
Faulty park brake pressure switch. The park brake pressure switch is
For a wet brake system only: normally closed; it is closed


072705
PN=205
P R O O F
Diagnostic Codes
005
,128
CAUTION: Make sure

2. With engine OFF turn ignition to

disengaged.


switch is OK.
S9 and park switch. For a disc 2. Disconnect connectors S9 and T9.
brake system only:
S9-B and S9-C.

P R O O F


072705
PN=206
P R O O F
Diagnostic Codes
005
,129
T9 and TCU. For a disc brake 2. Disconnect connectors S9 and T9.
system only:
TCU.

TCU.

J1-K1 and J2-B3.


P R O O F

072705
PN=207
P R O O F
Diagnostic Codes
005
,130

TCU.

TCU.
CAUTION: Make sure


J2-B3 and J1-A1.

Short to system battery voltage in 1. Disconnect connector J6 at

PARK signal line. For wet brake transmission.
systems:
repair or replace.
P R O O F


J3-A1 and J6-21.


072705
PN=208
P R O O F
Diagnostic Codes
005
,131
For a disc brake system only: 1. Turn ignition to "OFF" position.
2. Disconnect connectors S9 and T9.

T9-A (system battery voltage) and
T9-C (NOT PARK).


NOT PARK signal line.
For a wet brake system only:
voltage) and T9-B (NOT PARK).

Faulty wet brake relay. For a wet Specific installations will vary;
brake system only: consult wiring diagram for the
application.
P R O O F
Replace relay.
Disconnected wet brake solenoid. Verify that harness is connected to


solenoids pins.


072705
PN=209
P R O O F
Diagnostic Codes
005
,132
Open circuit in wiring between park Specific installations will vary;

switch and wet brake solenoid. For consult wiring diagram for the
a wet brake system only: application.
Check continuity in wiring between

park switch and wet brake solenoid.
Open in system supply voltage line Specific installations will vary;

to wet brake relay. For a wet brake consult wiring diagram for the
system only: application.
1. Turn ignition to "ON" position.
2. Verify that system supply voltage

is present at the appropriate relay
terminal.
3. If system supply voltage is not

present, trace the supply voltage line
from the relay back towards the
voltage source.

P R O O F
DPSG,YZ07927,99 1913NOV986/6

072705
PN=210
P R O O F
Diagnostic Codes
005
Code 91 110
,133
LEGAL CONDITIONS:
1. Seat switch signal active, NEUTRAL signal active.

(Operator at controls, vehicle in neutral)
2. Seat switch signal active, NEUTRAL signal passive.

(Operator at controls, vehicle in gear)
3. Seat switch signal passive, NEUTRAL signal active.

(No operator, vehicle in neutral)
This diagnostic code description applies to the Funk 12V

and 24V gear selector. If using a different gear selector
the description will change in regards to selector pinouts.

P R O O F

072705
PN=211
P R O O F
Diagnostic Codes
005
,134
Seat switch signal and NEUTRAL Faulty seat switch. 1. Disconnect seat switch from
signal are simultaneously wiring harness.
passive at TCU.
2. Check continuity between switch
- pins as the switch is actuated.
The passive seat switch signal at 3. If continuity does not alternate

TCU pin J2-C3 indicates that with seat switch state, replace
there may not be an operator at switch.
the controls, and the passive
NEUTRAL signal at TCU pin IMPORTANT: If testing switch
J2-A1 indicates the vehicle is in through wiring, be
gear. sure to rule out
possible open
- circuits in the
wiring between the
test point and the
switch before
replacing switch.
Open in seat switch signal line. 1. Disconnect seat switch connector

S15 from T15.

TCU.

S15-B and J2-C3.
P R O O F

072705
PN=212
P R O O F
Diagnostic Codes
005
,135
Open in system battery voltage 1. Disconnect seat switch connector

supply line to seat switch. S15 from T15.

TCU.

S15-A and J1-A1.

gear selector.

TCU.

J4-C and J2-A1.
P R O O F

072705
PN=213
P R O O F
Diagnostic Codes
005
,136

TVP module.

gear selector.

J4-A and T7-C.


is OK.

P R O O F

072705
PN=214
P R O O F
Diagnostic Codes
005
,137

NOTE: Ignition needs to be "ON" to TCU. The ignition should be in the
power the gear selector "ON" position. (Engine not running)
relay in order to verify
NEUTRAL signal operation. Replace the gear selector if and only

above)

3. The voltage on pin J2-A1 does

not alternate between 0 volts and
system battery voltage as the gear
selector is moved in and out of
neutral.

IMPORTANT: For more

P R O O F
TROUBLESHOOTING
THE GEAR
SELECTOR in
Group 100 (Test and
Troubleshooting).

DPSG,YZ07927,100 1913NOV985/5

072705
PN=215
P R O O F
Diagnostic Codes
005
110 Code 92
,138
Engine speed is at or near Engine speed too high. Reduce engine speed.
manufacturers warranty void
level.
Engine speed is too high.

DPSG,YZ07927,101 1913NOV981/1
Code 93
Engine speed too high for Engine speed too high. Reduce engine speed below the
neutral-to-gear engagement. neutral-to-gear engagement
threshold specified for the vehicle.
P R O O F
DPSG,YZ07927,102 1913NOV981/1

072705
PN=216
P R O O F
Diagnostic Codes
005
Code 98 110
,139
WHEELS-UP and Short to system battery voltage in 1. Turn ignition to OFF position.
WHEELS-DOWN inputs are WHEELS-UP signal line.
simultaneously active at TCU. 2. Disconnect connector J1 from
TCU.
-
The TCU expects the TCU.
WHEELS-UP input signal on pin
J1-H1 and the WHEELS-DOWN 4. Check for continuity between
input signal on pin J1-H2 to have harness pins J3-A1 (system battery
opposite states. voltage) and J1-H1.

harness pins J1-A1 (system battery
LEGAL CONDITIONS: voltage) and J1-H1.
1. WHEELS-UP active and 6. If continuity is found for either

WHEELS-DOWN passive. test, a short circuit is indicated;
inspect the appropriate lines and
2. WHEELS-UP passive and replace or repair as needed.
WHEELS-DOWN active.
Short to system battery voltage in 1. Turn ignition to OFF position.

WHEELS-DOWN signal line
TCU.
P R O O F

TCU.

voltage) and J1-H2.

voltage) and J1-H2.
6. If continuity is found for either

test, a short circuit is indicated;
inspect the appropriate lines and

072705
PN=217
P R O O F
Diagnostic Codes
005
,140
Fault in hardware responsible for 1. Verify that the device(s) supplying

generating WHEELS-UP and/or the WHEELS-UP and
WHEELS-DOWN signal. WHEELS-DOWN signal are
operating correctly.
2. Replace or repair as needed.

DPSG,YZ07927,107 1920NOV982/2
Code 99
Attempt to change wheels mode An attempt was made to change Change wheels mode only when
while vehicle is not in neutral. wheels mode while vehicle was out vehicle is neutral.
of neutral.
-
P R O O F
The TCU must detect an active

NEUTRAL signal before
permitting a change in the
wheels mode.

DPSG,YZ07927,108 1920NOV981/1

072705
PN=218
P R O O F
Diagnostic Codes
005
Code 100 110
,141
Sump temperature too low for Cold transmission. Warm transmission to above 50
calibration. degrees F. (10 degrees C)
Calibration cannot be performed

until transmission is above 50
degrees F. (10 degrees C).
Temperature sensor disconnected. Verify that temperature sensor is

connected to wiring harness.
Open in temperature sensor signal 1. Disconnect connector J1 from the

line between TCU and connector J6. TCU.

transmission.

J1-C3 and J6-25.

and repair or replace as necessary.
Open in temperature sensor GND 1. Disconnect connector J1 from the

P R O O F

transmission.

J1-D1 and J6-24.


072705
PN=219
P R O O F
Diagnostic Codes
005
,142

line between connector J6 and transmission.
sensor.
2. Disconnect the sensor from the
wiring harness.

J6-25 and sensor pin A.


line between TCU and sensor. transmission.

wiring harness.

J6-24 and sensor pin B.

Faulty temperature sensor. 1. Disconnect the temperature

sensor from the wiring harness.
P R O O F
2. Measure the resistance across

sensor pins A and B.
3. If the resistance is greater than

100,000 ohms, replace the sensor.

DPSG,YZ07927,109 1920NOV982/2

072705
PN=220
P R O O F
Diagnostic Codes
005
Code 101 110
,143
Engine speed too high for Engine speed too high. Reduce engine speed below 1700
calibration. RPM, preferably 1600 RPM.

until engine speed is between
1500 and 1700 RPM. (Preferably
1600 RPM.)

DPSG,YZ07927,110 1920NOV981/1
Code 102
Engine speed too low for Engine speed too low. Increase engine speed above 1500
calibration. RPM, preferably 1600 RPM.
-
P R O O F

until engine speed is between
1500 and 1700 RPM. (Preferably
1600 RPM.)

DPSG,YZ07927,111 1920NOV981/1

072705
PN=221
P R O O F
Diagnostic Codes
005
110 Code 103
,144
Output speed sensed during Vehicle is moving during calibration. Set vehicle park brake, and verify
calibration. that it is properly adjusted.

while transmission has an output
speed.
Driveline wrap-up may be significant

CAUTION: Unplug output
enough to produce a detectable
speed MPU sensor ONLY if
transmission output speed.
vehicle is not moving.
Unplug output speed MPU sensor

from harness during calibration.
(Dont forget to reconnect it when
calibration is complete.)

P R O O F
DPSG,YZ07927,112 1920NOV981/1

072705
PN=222
P R O O F
Diagnostic Codes
005
Code 104 110
,145
No cylinder speed during Cylinder speed MPU sensor Verify that cylinder speed MPU is
calibration. disconnected. connected to the wiring harness.
The TCU does not detect a

cylinder speed signal during
calibration.
Controlling valve is not functioning Replace valve 1 and/or valve 2.

properly. (slow or no response)
Open in cylinder speed MPU sensor 1. Turn ignition to the "OFF" position.
signal line between TCU and
connector J6. 2. Disconnect connector J1 from the
TCU.
3. Disconnect connector J6 at the

transmission.

J1-B2 and J6-9.
P R O O F
ground line between TCU and
TCU.

transmission.

J1-C2 and J6-16.

072705
PN=223
P R O O F
Diagnostic Codes
005
,146
signal line between connector J6
and the cylinder speed MPU sensor. 2. Disconnect the engine cylinder
MPU sensor from the harness.

transmission.

J6-9 and sensor mating harness pin
A.
ground line between connector J6
and the cylinder speed MPU sensor. 2. Disconnect the engine cylinder

transmission.

J6-16 and sensor mating harness
pin B.
P R O O F
and replace or repair as necessary
Cylinder speed MPU sensor not Verify that sensor and cover is
seated properly. tightened securely and has not
loosened from the transmission
housing.
Wrong sensor in the cylinder speed Verify that sensor has not been
sensor port. accidentally exchanged with the
engine speed or transmission output
speed MPU sensor.

072705
PN=224
P R O O F
Diagnostic Codes
005
,147
Cylinder speed MPU sensor signal 1. Disconnect connector J1 from the

and ground lines shorted together. TCU.

J1-B2 and J1-C2.

these lines for a short and repair or
Faulty cylinder speed MPU sensor. 1. Measure resistance between the

pins of the sensor.
approximately 515 ohms (may range
from 200 to 600 ohms).
3. If open circuit or short circuit is

indicated, replace sensor.

P R O O F
DPSG,YZ07927,113 1920NOV983/3
Code 105
Incorrect FWD cylinder ratio. Oil temperature too low. Increase oil temperature and retry. If
Converter-driven units only. problem persists at sump
temperatures above 120 degrees F,
(49 degrees C) then another solution
is needed.
Controlling valve is not functioning Replace valve 1.

properly. (slow)

DPSG,YZ07927,114 1920NOV981/1

072705
PN=225
P R O O F
Diagnostic Codes
005
110 Code 106
,148
Incorrect REV cylinder ratio. Oil temperature too low. Increase oil temperature and retry. If
Converter-driven units only. problem persists at sump
temperatures above 120 degrees F,
(49 degrees C) then another solution
is needed.
Controlling valve is not functioning Replace valve 2.

properly. (slow)

DPSG,YZ07927,115 1920NOV981/1
P R O O F

072705
PN=226
P R O O F
Diagnostic Codes
005
Code 107 110
,149
Cylinder speed will not drop New clutches need to be exercised. Retry calibration three times, noting
below start count speed. the message being displayed just
previous to getting the diagnostic
code message.
Excess drag in the REV clutches. 1. Exercise REV clutches by

(Message "C1H" or "C2H.") operating in reverse for a reasonable
time.
2. If applicable, also use inching

pedal.
3. Retry calibration.
4. Replace valve 3 (R1) and retry.
5. Replace valve 4 (R2) if applicable,

and retry.
Excess drag in the FWD clutches. 1. Exercise FWD clutches by

operating in forward for a reasonable
time.
2. If applicable, also use inching

pedal.
P R O O F
3. Retry calibration.
4. Replace valve 1 (F1) and retry.
5. Replace valve 2 (F2) if applicable,

and retry.
DPSG,YZ07927,116 1920NOV981/1

072705
PN=227
P R O O F
Diagnostic Codes
005
110 Code 108
,150
Holding clutch hold pressure Holding clutch valve not performing If the message displayed previous to
exceeding 90 psi. properly. the diagnostics code is "C3F" or
"C4F," then replace valve 1 and retry
calibration.
Holding clutch valve not performing If the message displayed previous to

properly. the diagnostics code is something
other than "C3F" or "C4F," then
replace valve 3 and retry calibration.

DPSG,YZ07927,118 1920NOV981/1
Code 109
Fast fill time for clutch 1 exceeds Valve 1 is not performing properly. Replace valve 1.
300ms.

P R O O F
DPSG,YZ07927,119 1920NOV981/1
Code 110
Fast fill time for clutch 2 exceeds Valve 2 is not performing properly. Replace valve 2.
300ms.

DPSG,YZ07927,120 1920NOV981/1

072705
PN=228
P R O O F
Diagnostic Codes
005
Code 111 110
,151
Fast fill time for clutch 3 exceeds Valve 3 not performing properly. Replace valve 3.
300ms.

DPSG,YZ07927,121 1920NOV981/1
Code 112
Fast fill time for clutch 4 exceeds Valve 4 (R2) is not performing Replace valve 4.
300ms. properly.

DPSG,YZ07927,122 1920NOV981/1
Code 113
P R O O F
Fast fill time for clutch A Valve A is not performing properly. Replace valve A.
exceeds 300ms.
Replace valve A. After all other possible causes have

DPSG,YZ07927,123 1920NOV981/1
Code 114
Fast fill time for clutch B Valve B is not performing properly. Replace valve B.
exceeds 300ms.

DPSG,YZ07927,124 1920NOV981/1

072705
PN=229
P R O O F
Diagnostic Codes
005
110 Code 115
,152
Fast fill time for clutch C Valve C is not performing properly. Replace valve C.
exceeds 300ms.

DPSG,YZ07927,125 1920NOV981/1
Code 116
Fast fill time for clutch D Valve D is not performing properly. Replace valve D.
exceeds 300ms.

DPSG,YZ07927,126 1920NOV981/1
Code 117
P R O O F
Calibrating clutch hold pressure Valve being calibrated is not Replace valve that was being
exceeds 90 psi. performing properly. calibrated at the time the diagnostics
code was indicated.

DPSG,YZ07927,127 1920NOV981/1

072705
PN=230
P R O O F
Diagnostic Codes
005
Code 127 (For applications using disc 110
,153
brakes)
Calibrating without park brake Park brake is not set. Set the park brake.
set.
The park brake must be set

during calibration. The TCU is
not reading an active PARK
signal on input J2-B3.
Faulty park switch. 1. Turn ignition to "OFF" position.

park switch or park switch harness.
3. Testing directly at switch pins,

check for continuity between switch
pins A and B while actuating switch.


fails to toggle as the switch is
P R O O F

072705
PN=231
P R O O F
Diagnostic Codes
005
,154

through wiring, be
sure to rule out
possible open
circuits in the
wiring between S9
and the park switch
before replacing
switch. (See below)


or cuts.

indicated, the park switch remains a
possible cause.

P R O O F
and the switch.

needed.

072705
PN=232
P R O O F
Diagnostic Codes
005
,155
Open in PARK signal line between 1. Disconnect connector T9 from the

connector T9 and TCU. park switch.

TCU.

J2-B3 and T9-B.

signal line is OK.

switch. TVP module.

park switch.

T9-A and T7-C.

P R O O F


switch is OK.

DPSG,YZ07927,132 1920NOV983/3

072705
PN=233
P R O O F
Diagnostic Codes
005
110 Code 127 (For applications using wet brakes)
,156
Calibrating without park brake Faulty park brake pressure switch. 1. Disconnect harness from park
set. brake pressure switch.
- 2. With engine OFF and ignition in

The park brake must be set between the two switch pins while
during calibration. The TCU is the park brake is engaged, then
not reading an active PARK disengaged.

switch is OK.
Continued on next page DPSG,YZ07927,175 1905FEB991/3

P R O O F

072705
PN=234
P R O O F
Diagnostic Codes
005
,157
Faulty park switch. 1. Turn ignition to "OFF" position.

3. Testing directly at switch pins,

check for continuity between switch
pins A and B while actuating switch.
4. If continuity fails to toggle as the

switch is actuated, replace the
switch.

through wiring, be
sure to rule out
possible short
circuits in the
wiring between S9
and the park switch
before replacing
switch.

NOT PARK signal line between
connector T9 and the TCU. 2. Disconnect connector T9 from the
P R O O F

T9-A and T9-B.

replace or repair wire(s) as
necessary.

072705
PN=235
P R O O F
Diagnostic Codes
005
,158

brake pressure switch input line.) transmission.

TCU.

harness pins J6-21 and J2-B3.

OK.

TVP module.

P R O O F


Faulty TCU. Faulty TCU. After all other possible

causes have been eliminated,
replace TCU.
DPSG,YZ07927,175 1905FEB993/3

072705
PN=236
P R O O F
Diagnostic Codes
005
Code 127 (For applications using a pressure 110
,159
switch)
Calibrating without park brake Faulty pressure switch. 1. Disconnect harness from pressure
set. switch.
- 2. With engine OFF and ignition in

The park brake must be set between the two switch pins while
during calibration. The TCU is the park brake is engaged, then
not reading an active PARK disengaged.

disengagement, pressure switch is
OK.
Open in PARK signal line. (Pressure 1. Disconnect connector J6 from the

switch input line.) transmission.

TCU.

P R O O F
J6-21 and J2-B3.

pressure switch input line is OK.

072705
PN=237
P R O O F
Diagnostic Codes
005
,160

supply line between TVP and transmission.
pressure switch.
TVP module.

check for continuity between pins
J6-20 and T7-C.

battery voltage supply line to
pressure switch is OK.

DPSG,YZ07927,182 1919FEB992/2
Code 145
P R O O F
Analog inching voltage is too Faulty inching pedal. IMPORTANT: For more
low. information refer to
TROUBLESHOOTING
- THE GEAR
SELECTOR in
The analog inching signal Group 100 (Test and
voltage at pin J1-F3 is below the Troubleshooting).
minimum level required by the
TCU.

DPSG,YZ07927,135 1920NOV981/1

072705
PN=238
P R O O F
Diagnostic Codes
005
Code 146 110
,161
Temperature sensor circuit is Temperature sensor disconnected. Verify that temperature sensor is
shorted or open. connected to wiring harness.
There is a problem in the circuit

from the J1-C3 SENSE input to
the J1-D1 GND input causing an
out-of-range temperature reading
in the TCU.


transmission.

J1-C3 and J6-25.


P R O O F

transmission.

J1-D1 and J6-24.


072705
PN=239
P R O O F
Diagnostic Codes
005
,162

line between connector J6 and transmission.
sensor.
wiring harness.

J6-25 and sensor pin A.


line between TCU and sensor. transmission.

wiring harness.

J6-24 and sensor pin B.

Temperature sensor signal and GND 1. Disconnect connector J1 from the

lines shorted together. TCU.
P R O O F

J1-C3 and J1-D1.

repair or replace as necessary.

072705
PN=240
P R O O F
Diagnostic Codes
005
,163
Temperature sensor signal line 1. Disconnect connector J1 from the

shorted to GND. TCU.

J1-C3 and J1-A2.

repair or replace as necessary
Faulty temperature sensor. 1. Disconnect the temperature

sensor from the wiring harness.
2. Measure the resistance across

sensor pins A and B.
3. If the resistance is greater than

100,000 ohms, replace the sensor.

P R O O F
DPSG,YZ07927,136 1920NOV983/3
Code 148
Analog inching voltage is too Faulty inching pedal. IMPORTANT: For more
high. information refer to
TROUBLESHOOTING
- THE GEAR
SELECTOR in
The analog inching signal Group 100 (Test and
voltage at pin J1-F3 is above the Troubleshooting).
maximum level allowed by the
TCU.

DPSG,YZ07927,137 1920NOV981/1

072705
PN=241
P R O O F
Diagnostic Codes
005
110 Code 150
,164
Transmission temperature is too Transmission temperature is too 1. Stop the vehicle.

high. high.
2. Check transmission fluid level.
- Add fluid if necessary.
The temperature signal voltage at 3. Check transmission fluid cooling

TCU pin J1-C3 indicates that the system.
transmission temperature is too
high. 4. Rule out possible mechanical
problems that may contribute to
overheating.
5. If code 150 is not present at cold

start and occurs only after a period
of vehicle operation, the cause is
likely to be mechanical rather than
electrical.
6. If code 150 occurs at cold start,

the cause is electrical.
Temperature signal lines shorted 1. Turn ignition to the OFF position.

between TCU and transmission.
TCU.
P R O O F

transmission.

harness pins J1-C3 and J1-D1.

exists in this section of the harness.
6. Inspect harness to locate and

repair short.

072705
PN=242
P R O O F
Diagnostic Codes
005
,165
Temperature signal lines shorted 1. Turn ignition to the OFF position.

between transmission connector and
temperature sensor. 2. Disconnect connector J6 from the
transmission.
3. Disconnect the harness at the

temperature sensor.

harness pins.

exists in this section of the harness.
6. Inspect harness to locate and

repair short.
Temperature sensor shorted or 1. Turn ignition to the OFF position.

faulty.
2. Allow the transmission to cool for
an hour.
3. Disconnect the harness at the

temperature sensor.
4. Check resistance of the

temperature sensor.
P R O O F
5. If resistance measures less than

100 ohms, replace the temperature
sensor.

DPSG,YZ07927,183 1903MAR992/2

072705
PN=243
P R O O F
Diagnostic Codes
005
110 Code 154
,166
Engine speed circuit is open. Engine speed MPU sensor Verify that the engine speed MPU
disconnected. sensor is connected to the wiring
- harness.
The TCU is detecting an

improper signal from the engine
speed MPU sensor.
Open in engine speed MPU sensor 1. Turn ignition to the "OFF" position.
signal line between TCU and
TCU.

transmission.

J1-B1 and J6-29.
ground line between TCU and
P R O O F
TCU.

transmission.

J1-C2 and J6-28.

072705
PN=244
P R O O F
Diagnostic Codes
005
,167
signal line between connector J6
and the engine speed MPU sensor. 2. Disconnect the engine speed

transmission.

pin A.
ground line between connector J6
and the engine speed MPU sensor. 2. Disconnect the engine speed

transmission.

pin B.
P R O O F
Faulty engine speed MPU sensor. 1. Measure resistance between the

pins of the sensor.
3. If open circuit is indicated, replace

sensor.

DPSG,YZ07927,140 1930NOV982/2

072705
PN=245
P R O O F
Diagnostic Codes
005
110 Code 155
,168
Transmission output speed Transmission output speed MPU Verify that the transmission output
circuit is open. sensor disconnected. speed MPU sensor is connected to
the wiring harness.
-
The TCU is detecting an

improper signal from the
transmission output speed MPU
sensor.
Open in transmission output speed 1. Turn ignition to the "OFF" position.

MPU sensor signal line between
TCU and connector J6. 2. Disconnect connector J1 from the
TCU.

transmission.

J1-A3 and J6-18.

P R O O F
MPU sensor ground line between

TCU and connector J6. 2. Disconnect connector J1 from the
TCU.

transmission.

J1-C2 and J6-30.

072705
PN=246
P R O O F
Diagnostic Codes
005
,169

MPU sensor signal line between
connector J6 and the sensor. 2. Disconnect the transmission
output speed MPU sensor from the
harness.

transmission.

pin A.

MPU sensor ground line between
connector J6 and the sensor. 2. Disconnect the transmission
output speed MPU sensor from the
harness.

transmission.

P R O O F
pin B.

072705
PN=247
P R O O F
Diagnostic Codes
005
,170
Faulty transmission output speed 1. Measure resistance between the

MPU sensor. pins of the sensor.
3. If open circuit is indicated, replace

sensor.

DPSG,YZ07927,141 1930NOV983/3
Code 160
Cannot get shift constants from Internal TCU diagnostics code. 1. Turn ignition to "OFF" position.
EEPROM.
- in neutral.
P R O O F
The TCU has encountered a 3. If Code 160 persists, replace TCU

software error. or contact Field Service.
IMPORTANT: This diagnostic

code is typically
not field
serviceable.
DPSG,YZ07927,142 1930NOV981/1

072705
PN=248
P R O O F
Diagnostic Codes
005
Code 161 110
,171
Internal group one enable Improper signal state combination. 1. With ignition OFF disconnect
signal is low; should be high. connector J1 from TCU.
- 2. Disconnect connector J2 from

TCU.
The TCU is receiving an
improper combination of states 3. Check for continuity between
of several important input J2-F3 and J1-K2.
signals.
J2-F3 and J2-A3.
5. If no continuity on one of the two

readings, inspect for open in line and
6. If laptop PC with diagnostics

program is present, reconnect J1and
J2 to TCU. Otherwise, leave J1 and
J2 disconnected.
7. Turn ignition ON, but do not start

engine.
8. Using J1-A2 as multimeter GND,

check voltages for top four signals in
P R O O F
table below as handle is in neutral,

then forward, then reverse position.
9. If laptop with diagnostics program

is available, verify that J1-K2 and
J2-A3 are both active. Otherwise,
probe through wire insulation to
verify presence of system battery
voltage on these lines.
10. If any of the signal conditions in

the table below are not met, identify
the problem signal or signals and
troubleshoot as needed to determine
why signals are in wrong states.
DPSG,YZ07927,143 1930NOV981/1

072705
PN=249
P R O O F
Diagnostic Codes
005
110 Legal Conditions For Code 161
,172
NOTE: Neutral, Forward and Reverse are gear selector

positions. 0 and 1 are binary inputs.
Pins Description Neutral Forward Reverse

J1-J1 FORWARD 0 1 0
J1-J2 REVERSE 0 0 1
J2-A1 NEUTRAL 1 0 0
J2-B2 START 0 0 0
J1-K2 BOTTOM OF CLUTCH 1 1 1
J2-A3 SHIFT CODE (C) 1 1 1
SHIFT CODE (C) and BOTTOM OF CLUTCH should both

be wired to system battery voltage at pin J2-F3.
IMPORTANT: The last row of the table applies only if

the TCU hardware is Funk P/N
YZ103418.
DPSG,YZ07927,176 1905FEB991/1
P R O O F

072705
PN=250
P R O O F
Diagnostic Codes
005
Code 162 110
,173
Internal group two enable Improper signal state combination. 1. With ignition OFF disconnect

TCU.
signals.
J2-F3 and J2-A3.


J2 disconnected.

engine.

P R O O F



DPSG,YZ07927,143CONV1 1930NOV981/1

072705
PN=251
P R O O F
Diagnostic Codes
005
,174


J1-J1 FORWARD 0 1 0
J1-J2 REVERSE 0 0 1
J2-A1 NEUTRAL 1 0 0
J2-B2 START 0 0 0


YZ103418.
DPSG,YZ07927,176CONV1 1905FEB991/1
P R O O F

072705
PN=252
P R O O F
Diagnostic Codes
005
Code 163 110
,175
Internal group three enable Improper signal state combination. 1. With ignition OFF disconnect

TCU.
signals.
J2-F3 and J2-A3.


J2 disconnected.

engine.

P R O O F



DPSG,YZ07927,143CONV2 1930NOV981/1

072705
PN=253
P R O O F
Diagnostic Codes
005
,176


J1-J1 FORWARD 0 1 0
J1-J2 REVERSE 0 0 1
J2-A1 NEUTRAL 1 0 0
J2-B2 START 0 0 0


YZ103418.
DPSG,YZ07927,176CONV2 1905FEB991/1
P R O O F

072705
PN=254
P R O O F
Diagnostic Codes
005
Code 171 110
,177
Internal group one enable Improper signal state combination. 1. With ignition OFF disconnect
signal is high; should be low. connector J1 from TCU.

TCU.
signals.
J2-F3 and J2-A3.


J2 disconnected.

engine.

P R O O F



DPSG,YZ07927,143CONV3 1930NOV981/1

072705
PN=255
P R O O F
Diagnostic Codes
005
,178


J1-J1 FORWARD 0 1 0
J1-J2 REVERSE 0 0 1
J2-A1 NEUTRAL 1 0 0
J2-B2 START 0 0 0


YZ103418.
DPSG,YZ07927,176CONV3 1905FEB991/1
P R O O F

072705
PN=256
P R O O F
Diagnostic Codes
005
Code 172 110
,179
Internal group two enable Improper signal state combination. 1. With ignition OFF disconnect

TCU.
signals.
J2-F3 and J2-A3.


J2 disconnected.

engine.

P R O O F



DPSG,YZ07927,143CONV4 1930NOV981/1

072705
PN=257
P R O O F
Diagnostic Codes
005
,180


J1-J1 FORWARD 0 1 0
J1-J2 REVERSE 0 0 1
J2-A1 NEUTRAL 1 0 0
J2-B2 START 0 0 0


YZ103418.
DPSG,YZ07927,176CONV4 1905FEB991/1
P R O O F

072705
PN=258
P R O O F
Diagnostic Codes
005
Code 173 110
,181
Internal group three enable Improper signal state combination. 1. With ignition OFF disconnect

TCU.
signals.
J2-F3 and J2-A3.


program is present, reconnect J1
and J2 to TCU. Otherwise, leave J1
and J2 disconnected.

engine.

P R O O F



DPSG,YZ07927,143CONV5 1930NOV981/1

072705
PN=259
P R O O F
Diagnostic Codes
005
,182


J1-J1 FORWARD 0 1 0
J1-J2 REVERSE 0 0 1
J2-A1 NEUTRAL 1 0 0
J2-B2 START 0 0 0


YZ103418.
DPSG,YZ07927,176CONV5 1905FEB991/1
P R O O F

072705
PN=260
P R O O F
Diagnostic Codes
005
Code 175 (12 Volt System) 110
,183
This code pertains to the TCU output that controls the transmission front axle output disconnect.
If transmission does not have the front axle output disconnect option refer to vehicle manual for vehicle option device that this TCU
output controls
Solenoid / relay driver 11 cannot Relay disconnected. Verify harness is connected to relay.
get up to requested current.
Due to a problem in the pin

J3-H2 (output) to pin J3-H3
NOTE: Due to the current

requirements of the 12 volt
output disconnect solenoid,
all 12 volt systems requires
the output disconnect
solenoid to be driven by
vehicle electrical power
through an external relay
controlled by this TCU
output. Refer to the
vehicle manual.
Open circuit in wiring to relay. 1. Inspect wiring in relay circuit

between relay and TCU for cuts,
frayed areas, or pinched spots.
P R O O F

necessary.
Relay return line shorted to GND or 1. Disconnect connector J3 from

vehicle frame. TCU.
2. On the wire harness side, check

continuity between return pin J3-H3
and common GND pin J3-A2.


Continued on next page DPSG,YZ07927,157 1915JUL051/2

072705
PN=261
P R O O F
Diagnostic Codes
005
,184
Relay output line shorted to GND or 1. Disconnect connector J3 from

vehicle frame. TCU.

continuity between output pin J3-H2


Open circuit in relay. 1. Disconnect solenoid from harness.
2. Check continuity of relay coil.

more than what is listed in vehicle
manual, replace relay.
Relay is incorrect voltage type. (12V 1. Disconnect relay from harness.

vs. 24V)
2. Measure relay resistance.
3. Check resistance. Refer to the

P R O O F
vehicle manual for resistance value

for a 12 volt relay.

relay.

DPSG,YZ07927,157 1915JUL052/2

072705
PN=262
P R O O F
Diagnostic Codes
005
Code 175 (24 Volt System) 110
,185
output controls.
Solenoid driver 11 cannot get up Solenoid disconnected. Verify harness is connected to

to requested current. solenoid.

J3-H2 (output) to pin J3-H3

frayed areas, or pinched spots.

necessary.


continuity between return pin J3-H3

P R O O F

Continued on next page YZ03225,00001C5 1915JUL051/3

072705
PN=263
P R O O F
Diagnostic Codes
005
,186


continuity between output pin J3-H2



solenoid.
4. Check resistance of the 24 volt

solenoid, which should be
from 16 to 40 ohms with solenoid at
room temperature (resistance will
P R O O F
increase as temperature increases).
5. If a direct short or low resistance

is indicated, replace solenoid. See
Continuity Measurement Note below.
Continued on next page YZ03225,00001C5 1915JUL052/3

072705
PN=264
P R O O F
Diagnostic Codes
005
,187

Some multi-meters have an
feature. Getting the Beep
actual resistance values
Beep. (For example: the
when performing a
good solenoid).

YZ03225,00001C5 1915JUL053/3
P R O O F

072705
PN=265
P R O O F
Diagnostic Codes
005
110 Code 176
,188
This code pertains to TCU output that is used to operate available vehicle option device per customers request. Refer to vehicle manual
for available vehicle options that use this TCU output.
Vehicle option device driver 12 Vehicle option device disconnected. Verify harness is connected to
cannot get up to requested vehicle option device.
current.
Due to a problem in the pin J3-J1

(output) to pin J3-J2 (return)
circuit path.
Open circuit in wiring to vehicle 1. Inspect wiring in vehicle option

option device. device circuit between vehicle option
device and TCU for cuts, frayed
areas, or pinched spots.

necessary.
Vehicle option device return line 1. Disconnect connector J3 from

shorted to GND or vehicle frame. TCU.

continuity between return pin J3-J2

P R O O F


072705
PN=266
P R O O F
Diagnostic Codes
005
,189
Vehicle option device output line 1. Disconnect connector J3 from


continuity between output pin J3-J1


Open circuit in vehicle option device. 1. Disconnect vehicle option device

from harness.
2. Check continuity of vehicle option

device.

resistance measurement does not
meets requirements stated in vehicle
manual for vehicle option device,
replace vehicle option device.
Vehicle option device is incorrect 1. Disconnect vehicle option device

voltage type. (12V vs. 24V) from harness.
P R O O F
2. Measure vehicle option device

resistance.
3. Check resistance of vehicle option

device. Refer to vehicle manual for
specifications.

vehicle option device.

DPSG,YZ07927,158 1915JUL052/2

072705
PN=267
P R O O F
Diagnostic Codes
005
110 Code 177
,190
The code pertains to the TCU output that is used to operate available vehicle option device per customer request.
Refer to vehicle manual for available options that uses this TCU output.
Vehicle option device driver 13 Vehicle option device disconnected. Verify harness is connected to
cannot get up to requested vehicle option device.
current.

(output) to pin J3-K1 (return)
circuit path.
Open circuit in wiring to vehicle 1. Inspect wiring in vehicle option

option device. device circuit between vehicle option
device and TCU for cuts, frayed
areas, or pinched spots.

necessary.
Vehicle option device return line 1. Disconnect connector J3 from


continuity between return pin J3-K1

P R O O F


072705
PN=268
P R O O F
Diagnostic Codes
005
,191
Vehicle option device output line 1. Disconnect connector J3 from


continuity between output pin J3-J3


Open circuit in vehicle option device. 1. Disconnect vehicle option device

from harness.
2. Check continuity of vehicle option

device.

resistance measurement does not
meet requirements stated in the
vehicle manual for the vehicle option
device, replace vehicle option
device.
Vehicle option device is incorrect 1. Disconnect vehicle option device

P R O O F
voltage type. (12V vs. 24V) from harness.
2. Measure vehicle option device

resistance.
3. Check resistance of vehicle option

device. Refer to vehicle manual for
specifications.

vehicle option device.

DPSG,YZ07927,160 1915JUL052/2

072705
PN=269
P R O O F
Diagnostic Codes
005
110 Code 178 (12 Volt System)
,192
output controls.
Solenoid/relay driver 11 cannot Short circuit in relay, or relay has 1. Disconnect relay from harness.
drop to requested current. low resistance.
2. Measure relay resistance.
J3-H2 (output) to pin J3-H3 3. Check relay resistance. Refer to
(return) circuit path. vehicle manual for relay resistance
specifications.
NOTE: Due to the current
requirements of the 12 volt 4. If a direct short or low resistance
output disconnect solenoid, is indicated, replace relay. See
all 12 volt systems requires Continuity Measurement Note below.
the output disconnect
solenoid to be driven by NOTE: Continuity Measurement:
vehicle electrical power Some multi-meters have an
through an external relay audio continuity indication
controlled by this TCU feature. Getting the "beep"
output. Refer to the during a continuity check
vehicle manual. does not mean a direct short
P R O O F

when performing a
good relay.)
YZ03225,00001CC 1915JUL051/1

072705
PN=270
P R O O F
Diagnostic Codes
005
Code 178 (12 Volt System) - Continued 110
,193
- Short circuit in wiring to relay. 1. Disconnect connector J3 from the

(Output line shorted to return line in TCU.
harness)
2. Disconnect relay from harness.

for continuity between the J3-H2
output pin and the J3-H3 return pin.

5. Inspect wiring in relay circuit

between relay and TCU to locate
short.

necessary.
Output line shorted to supply voltage 1. Disconnect connector J3 from the

TCU.

output pin and all other pins in the
P R O O F
J3 connector, excluding return pin

J3-H3.


necessary.

YZ03225,00001CB 1915JUL051/1

072705
PN=271
P R O O F
Diagnostic Codes
005
110 Code 178 (24 Volt System)
,194
output controls.
Solenoid driver 11 cannot drop Short circuit in solenoid, or solenoid 1. Disconnect relay from harness.
to requested current. has low resistance.
J3-H2 (output) to pin J3-H3 3. Check solenoid resistance, which
(return) circuit path. for a 24 Volt solenoid should be
from 16 to 40 ohms with solenoid at
room temperature. Resistance will
increase as temperature increases.)

is indicated, replace solenoid. See
Continuity Measurement Note below.

P R O O F

when performing a
good solenoid.)
YZ03225,00001C4 1915JUL051/1

072705
PN=272
P R O O F
Diagnostic Codes
005
Code 178 (24 Volt System) - Continued 110
,195
- Short circuit in wiring to solenoid. 1. Disconnect connector J3 from the

(Output line shorted to return line in TCU.
harness)
2. Disconnect solenoid from harness.

output pin and the J3-H3 return pin.


short.

necessary.

TCU.

P R O O F

J3-H3.


necessary.

YZ03225,00001C8 1915JUL051/1

072705
PN=273
P R O O F
Diagnostic Codes
005
110 Code 179
,196
This code pertains to TCU output that is used to operate available vehicle option per customer request. Refer to the vehicle manual for
available vehicle options that use this TCU output.
Vehicle option devise driver 12 Short circuit in vehicle option devise, 1. Disconnect solenoid from harness.
cannot drop to requested or vehicle option devise has low
current. resistance. 2. Measure vehicle option devise
resistance.
(output) to pin J3-J2 (return) 3. Check resistance of vehicle option
circuit path. devise. Refer to Vehicle Manual for
Specifications.

is indicated, replace vehicle option
devise. See Continuity Measurement
Note below.

P R O O F

072705
PN=274
P R O O F
Diagnostic Codes
005
,197

when performing a
good solenoid / vehicle
option devise.)
Short circuit in wiring to vehicle 1. Disconnect connector J3 from the

option devise. (Output line shorted to TCU.
return line in harness)
2. Disconnect vehicle option devise
from harness.

for continuity between the J3-J1
output pin and the J3-J2 return pin.

P R O O F

5. Inspect wiring in vehicle option

devise circuit between vehicle option
devise and TCU to locate short.

necessary.

072705
PN=275
P R O O F
Diagnostic Codes
005
,198

TCU.

J3-J2.


necessary.

DPSG,YZ07927,162 1915JUL053/3
Code 180
P R O O F
This code pertains to TCU output that is used to operate available vehicle option per customer request. Refer to the vehicle manual for
available vehicle options that use this TCU output.
Vehicle option devise driver 13 Short circuit in vehicle option devise, 1. Disconnect vehicle option devise
cannot drop to requested or vehicle option devise has low from harness.
current. resistance.
2. Measure vehicle option devise
Due to a problem in the pin J3-J3 resistance.
(output) to pin J3-K1 (return)
circuit path. 3. Check resistance of vehicle option
devise. Refer to Vehicle Manual for
specifications.

is indicated, replace vehicle option
devise. See Continuity Measurement
Note below.

072705
PN=276
P R O O F
Diagnostic Codes
005
,199

when performing a
good solenoid / vehicle
option devise.)
Short circuit in wiring to vehicle 1. Disconnect connector J3 from the

option devise. (Output line shorted to TCU.
return line in harness)
2. Disconnect vehicle option devise
from harness.

output pin and the J3-K1 return pin.

P R O O F

5. Inspect wiring in vehicle option

devise circuit between vehicle option
devise and TCU to locate short.

necessary.

072705
PN=277
P R O O F
Diagnostic Codes
005
,200

TCU.

J3-K1.


necessary.

DPSG,YZ07927,163 1915JUL053/3
P R O O F

072705
PN=278
P R O O F
Diagnostic Codes
005
Code 198 110
,201
CCD communications link failure Open in CCD BUS- signal line 1. Turn ignition to "OFF" position.
between master and slave TCUs. between master and slave TCUs.
- both TCUs.
There is a problem in the CCD 3. Check continuity between pin

BUS+ (pin J2-E2) to CCD BUS- J2-E3 at the master TCU and pin
(pin J2-E3) circuit path. J2-E3 at the slave TCU.
and replace or repair wire as
necessary.
Open in CCD BUS+ signal line 1. Turn ignition to "OFF" position.

between master and slave TCUs.
both TCUs.
3. Check continuity between pin

J2-E2 at the master TCU and pin
J2-E2 at the slave TCU.
and replace or repair wire as
P R O O F
necessary
CCD BUS- signal line shorted to 1. Turn ignition to "OFF" position.

GND or vehicle frame.
master TCU.

J2-F1 (GND) and J2-E3.

J2-E3 line for a short to ground or
vehicle frame, and replace or repair
wire as necessary.

072705
PN=279
P R O O F
Diagnostic Codes
005
,202
CCD BUS+ signal line shorted to 1. Turn ignition to "OFF" position.

GND or vehicle frame.
master TCU.

J2-F1 (GND) and J2-E2.

J2-E2 line for a short to ground or
vehicle frame, and replace or repair
wire as necessary.
Faulty TCU 1. If a spare TCU (must have same

application software installed) is
available, try substituting it for first
the slave, then the master TCU.
2. If code 198 is eliminated, the TCU

substituted for may be faulty.
3. After all other possible causes

have been eliminated, replace TCU.
P R O O F
DPSG,YZ07927,164 1901DEC982/2
Code 199
Non-functional base TCU. The TCU is missing Contact field service for information
application-specific programming. regarding return of TCU for
- programming.
The TCU does not have any

application-specific
programming.
DPSG,YZ07927,165 1901DEC981/1

072705
PN=280
P R O O F
Diagnostic Codes
005
Flashing ECU Message 110
,203
Gear/Diagnostic indicator display No application software in TCU. 1. If a known good spare TCU is
is flashing or displaying "ECU". available, substitute it. If ECU
message is eliminated, original TCU
- likely has no program or is otherwise
faulty.
The display itself has power, but
the TCU is not communicating 2. If laptop PC diagnostics is
with the display. available, verify that communications
with TCU can be established. If not,
TCU likely has no program or is
otherwise faulty.
Open in CCD BUS- signal line 1. Turn ignition to "OFF" position.

between TCU and display.

TCU.
4. Check continuity between pins

S5-D and J2-E3.
and replace or repair wires as
necessary.
P R O O F

072705
PN=281
P R O O F
Diagnostic Codes
005
,204
Open in CCD BUS+ signal line 1. Turn ignition to "OFF" position.

between TCU and display.

TCU.
4. Check continuity between harness

pins S5-C and J2-E2.
and replace or repair wires as
necessary.

DPSG,YZ07927,166 1901DEC982/2
P R O O F

072705
PN=282
P R O O F
Index
Page Page
A J1 and mating connector. . . . . . . . . . . . .005-105-6

J2 and mating connector. . . . . . . . . . . . .005-105-8
Abbreviations and Acronyms J3 and mating connector. . . . . . . . . . . .005-105-10
BOC . . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-2 J4 gear selector . . . . . . . . . 005-100-4, 005-105-15 Indx
CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-2 J6 connector . . . . . . . . . . . . . . . . . . . . .005-105-34 1
CCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-2 Output speed MPU . . . . . . . . . . . . . . . .005-105-20
CYL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-2 Park brake pressure switch . . . . . . . . . .005-105-21
DC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-2 Proportional valve . . . . . . . . . . . . . . . . .005-105-24
ENG . . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-2 Solenoids . . . . . . . . . . . . . . . . . . . . . . .005-105-24
GND . . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-2 Temperature sensor . . . . . . . . . . . . . . .005-105-22
MPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-2 Transient voltage protection module . . .005-105-28
ms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-2 Current Gear
P. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-2 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-3
POT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-2 Cylinder Speed
PWM. . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-2 MPU . . . . . . . . . . . . . . . . . . . . . . . . . . .005-105-19
RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-2 Cylinder speed MPU
SOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-2 Connector pinout. . . . . . . . . . . . . . . . . .005-105-19
TCLU . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-2 TCU pin . . . . . . . . . . . . . . . . . . . . . . . .005-105-19
TCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-2
TEMP . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-2
TOC . . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-2
TVP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-2 D
V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-2
Active Diagnostic Code
Glosary . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-3 Code 100 . . . . . . . . . . . . . . . . . . . . . . 005-110-141
Actual Gear Code 101 . . . . . . . . . . . . . . . . . . . . . . 005-110-143
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-3 Code 102 . . . . . . . . . . . . . . . . . . . . . . 005-110-143
Analog Code 103 . . . . . . . . . . . . . . . . . . . . . . 005-110-144
P R O O F
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-3 Code 104 . . . . . . . . . . . . . . . . . . . . . . 005-110-145

Code 105 . . . . . . . . . . . . . . . . . . . . . . 005-110-147
Code 106 . . . . . . . . . . . . . . . . . . . . . . 005-110-148
Code 107 . . . . . . . . . . . . . . . . . . . . . . 005-110-149
B
Code 108 . . . . . . . . . . . . . . . . . . . . . . 005-110-150
Code 109 . . . . . . . . . . . . . . . . . . . . . . 005-110-150
Bus
Code 110 . . . . . . . . . . . . . . . . . . . . . . 005-110-150
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-3
Code 111 . . . . . . . . . . . . . . . . . . . . . . 005-110-151
Code 112 . . . . . . . . . . . . . . . . . . . . . . 005-110-151
Code 113 . . . . . . . . . . . . . . . . . . . . . . 005-110-151
C Code 114 . . . . . . . . . . . . . . . . . . . . . . 005-110-151
Code 115 . . . . . . . . . . . . . . . . . . . . . . 005-110-152
Calibration Code 116 . . . . . . . . . . . . . . . . . . . . . . 005-110-152
Reasons to calibrate . . . . . . . . . . . . . . .005-100-12 Code 117 . . . . . . . . . . . . . . . . . . . . . . 005-110-152
4 speeds forward, 4 reverse . . . . . . . . .005-100-13 Code 127 disc brake. . . . . . . . . . . . . . 005-110-153
8 speeds forward, 4 reverse . . . . . . . . .005-100-14 Code 127 pressure switch. . . . . . . . . . 005-110-159
Come-Home Code 127 wet brake . . . . . . . . . . . . . . 005-110-156
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-3 Code 145 . . . . . . . . . . . . . . . . . . . . . . 005-110-160
Commanded Gear Code 146 . . . . . . . . . . . . . . . . . . . . . . 005-110-161
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-3 Code 147 . . . . . . . . . . . . . . . . . . . . . . 005-110-163
Connector Pins Code 150 . . . . . . . . . . . . . . . . . . . . . . 005-110-164
Cylinder speed MPU . . . . . . . . . . . . . . .005-105-19 Code 154 . . . . . . . . . . . . . . . . . . . . . . 005-110-166
Engine speed MPU . . . . . . . . . . . . . . . .005-105-18 Code 155 . . . . . . . . . . . . . . . . . . . . . . 005-110-168
Gear diagnostic indicator . . . . . . . . . . .005-105-12 Code 160 . . . . . . . . . . . . . . . . . . . . . . 005-110-170
Inching pedal . . . . . . . . . . . . . . . . . . . .005-105-16 Code 161 . . . . . . . . . . . . . . . . . . . . . . 005-110-171
CTM157 (15JUL05) Index-1 DF Series TCU Analog System

072705
PN=1
P R O O F
Index
Page Page
Code 161 legal conditions. . . . . . . . . . 005-110-172 Code 52 . . . . . . . . . . . . . . . . . . . . . . . .005-110-84

Code 162 . . . . . . . . . . . . . . . . . . . . . . 005-110-173 Code 54 . . . . . . . . . . . . . . . . . . . . . . . .005-110-89
Indx Code 163 . . . . . . . . . . . . . . . . . . . . . . 005-110-175 Code 57 . . . . . . . . . . . . . . . . . . . . . . . .005-110-93
2 Code 163 legal conditions. . . . . . . . . . 005-110-176 Code 58 . . . . . . . . . . . . . . . . . . . . . . . .005-110-96
Code 171 . . . . . . . . . . . . . . . . . . . . . . 005-110-177 Code 59 . . . . . . . . . . . . . . . . . . . . . . . .005-110-97
Code 172 . . . . . . . . . . . . . . . . . . . . . . 005-110-179 Code 80 . . . . . . . . . . . . . . . . . . . . . . . .005-110-99
Code 172 legal conditions. . . . . . . . . . 005-110-180 Code 84 . . . . . . . . . . . . . . . . . . . . . . . 005-110-100
Code 173 . . . . . . . . . . . . . . . . . . . . . . 005-110-181 Code 85 . . . . . . . . . . . . . . . . . . . . . . . 005-110-103
Code 173 legal conditions. . . . . . . . . . 005-110-182 Code 86 . . . . . . . . . . . . . . . . . . . . . . . 005-110-109
Code 175 (12 Volt System) . . . . . . . . . 005-110-183 Code 87 . . . . . . . . . . . . . . . . . . . . . . . 005-110-113
Code 176 . . . . . . . . . . . . . . . . . . . . . . 005-110-188 Code 89 disc brake system. . . . . . . . . 005-110-120
Code 177 . . . . . . . . . . . . . . . . . . . . . . 005-110-190 Code 89 wet brake system . . . . . . . . . 005-110-124
Code 179 . . . . . . . . . . . . . . . . . . . . . . 005-110-196 Code 92 . . . . . . . . . . . . . . . . . . . . . . . 005-110-138
Code 180 . . . . . . . . . . . . . . . . . . . . . . 005-110-198 Code 93 . . . . . . . . . . . . . . . . . . . . . . . 005-110-138
Code 198 . . . . . . . . . . . . . . . . . . . . . . 005-110-201 Code 98 . . . . . . . . . . . . . . . . . . . . . . . 005-110-139
Code 199 . . . . . . . . . . . . . . . . . . . . . . 005-110-202 Code 99 . . . . . . . . . . . . . . . . . . . . . . . 005-110-140
Code 20 . . . . . . . . . . . . . . . . . . . . . . . . .005-110-5 Flashing "ECU" message . . . . . . . . . . 005-110-203
Code 21 . . . . . . . . . . . . . . . . . . . . . . . . .005-110-7 System diagnostics code . . . . . . . . . . . .005-110-1
Code 22 . . . . . . . . . . . . . . . . . . . . . . . . .005-110-9 TCU . . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-203
Code 23 . . . . . . . . . . . . . . . . . . . . . . . .005-110-11 Digital
Code 24 . . . . . . . . . . . . . . . . . . . . . . . .005-110-13 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-3
Code 25 . . . . . . . . . . . . . . . . . . . . . . . .005-110-15 Downshift Inhibit
Code 26 . . . . . . . . . . . . . . . . . . . . . . . .005-110-17 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-3
P R O O F
Code 27 . . . . . . . . . . . . . . . . . . . . . . . .005-110-19
Code 28 . . . . . . . . . . . . . . . . . . . . . . . .005-110-21
Code 29 . . . . . . . . . . . . . . . . . . . . . . . .005-110-23
Code 30 . . . . . . . . . . . . . . . . . . . . . . . .005-110-26 E
Code 31 . . . . . . . . . . . . . . . . . . . . . . . .005-110-28
Code 32 . . . . . . . . . . . . . . . . . . . . . . . .005-110-30 Engine Speed MPU
Code 33 . . . . . . . . . . . . . . . . . . . . . . . .005-110-32 Connector pinout. . . . . . . . . . . . . . . . . .005-105-18
Code 34 . . . . . . . . . . . . . . . . . . . . . . . .005-110-34 TCU pin . . . . . . . . . . . . . . . . . . . . . . . .005-105-18
Code 35 . . . . . . . . . . . . . . . . . . . . . . . .005-110-36
Code 36 . . . . . . . . . . . . . . . . . . . . . . . .005-110-38
Code 37 . . . . . . . . . . . . . . . . . . . . . . . .005-110-40 F
Code 38 . . . . . . . . . . . . . . . . . . . . . . . .005-110-42
Code 39 . . . . . . . . . . . . . . . . . . . . . . . .005-110-44 Fault
Code 40 . . . . . . . . . . . . . . . . . . . . . . . .005-110-46 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-3
Code 41 . . . . . . . . . . . . . . . . . . . . . . . .005-110-47
Code 42 . . . . . . . . . . . . . . . . . . . . . . . .005-110-50
Code 43 disc brake system. . . . . . . . . 005-110-52,
005-110-53 G
Code 43 wet brake system . . . . . . . . . .005-110-55
Code 44 . . . . . . . . . . . . . . . . . . . . . . . .005-110-58 Gear Selector
Code 45 . . . . . . . . . . . . . . . . . . . . . . . .005-110-64 Connector pinout. . . . . . . . . . . . . . . . . . .005-100-4
Code 48 . . . . . . . . . . . . . . . . . . . . . . . .005-110-70 Gear selector
Code 49 . . . . . . . . . . . . . . . . . . . . . . . .005-110-76 PC diagnostics . . . . . . . . . . . . . . . . . . . .005-100-7
Code 50 . . . . . . . . . . . . . . . . . . . . . . . .005-110-78 Gear Selector
Code 51 . . . . . . . . . . . . . . . . . . . . . . . .005-110-81 Shift pattern . . . . . . . . . . . . . . . . . . . . .005-105-13

072705
PN=2
P R O O F
Index
Page Page
TCU pin . . . . . . . . . . . . . . . . . . . . . . . . .005-100-4 J2

Gear/diagnostic Indicator Connector pin . . . . . . . . . . . . . . . . . . . . .005-105-8
Connector pinout. . . . . . . . . . . . . . . . . .005-105-12 J3
TCU Pin . . . . . . . . . . . . . . . . . . . . . . . .005-105-12 Connector pin . . . . . . . . . . . . . . . . . . . .005-105-10 Indx
General Information J4 3
Abbreviations . . . . . . . . . . . . . . . . . . . . . .005-10-2 Connector pin . . . . . . . . . . . . . . . . . . . .005-105-15
Acronyms . . . . . . . . . . . . . . . . . . . . . . . . .005-10-2 J6 Connector
Common circuit . . . . . . . . . . . . . . . . . . . . .005-10-5 Connector . . . . . . . . . . . . . . . . . . . . . . .005-105-34
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-3 TCU pin . . . . . . . . . . . . . . . . . . . . . . . .005-105-34
Grounded circuit . . . . . . . . . . . . . . . . . . .005-10-10
High resistance circuit . . . . . . . . . . . . . . . .005-10-6
Multimeter . . . . . . . . . . . . . . . . . . . . . . . . .005-10-4
Open circuit . . . . . . . . . . . . . . . . . . . . . . .005-10-8 L
Seven step electrical test . . . . . . . . . . . .005-10-14
Shorted circuit. . . . . . . . . . . . . . . . . . . . .005-10-12 Label
TCU label . . . . . . . . . . . . . . . . . . . . . . . . .005-10-2 TCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-2
Theory of TCU . . . . . . . . . . . . . . . . . . . . .005-10-1 Legal Conditions
Glossary Glossary . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-3
Active . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-3
Actual gear . . . . . . . . . . . . . . . . . . . . . . . .005-10-3
Analog . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-3
Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-3 M
Come-home . . . . . . . . . . . . . . . . . . . . . . .005-10-3
Commanded gear . . . . . . . . . . . . . . . . . . .005-10-3 Malfunctions
Current gear . . . . . . . . . . . . . . . . . . . . . . .005-10-3 Common circuit . . . . . . . . . . . . . . . . . . . . .005-10-5
Digital . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-3 Grounded circuit . . . . . . . . . . . . . . . . . . .005-10-10
Downshift inhibit . . . . . . . . . . . . . . . . . . . .005-10-3 High resistance circuit . . . . . . . . . . . . . . . .005-10-6
Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-3 Open circuit . . . . . . . . . . . . . . . . . . . . . . .005-10-8
P R O O F
Intershift pause time . . . . . . . . . . . . . . . . .005-10-3 Seven step test procedure . . . . . . . . . . .005-10-14

Legal conditions . . . . . . . . . . . . . . . . . . . .005-10-3 Shorted circuit. . . . . . . . . . . . . . . . . . . . .005-10-12
Neutral recoverable. . . . . . . . . . . . . . . . . .005-10-3 Multimeter
Next gear . . . . . . . . . . . . . . . . . . . . . . . . .005-10-3 General information. . . . . . . . . . . . . . . . . .005-10-4
Nonvolatile memory . . . . . . . . . . . . . . . . .005-10-3
Passive . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-3
Previous gear . . . . . . . . . . . . . . . . . . . . . .005-10-3
Sequence shift . . . . . . . . . . . . . . . . . . . . .005-10-3 N
Shuttle shift . . . . . . . . . . . . . . . . . . . . . . . .005-10-3
Neutral Recoverable
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-3
I Next Gear
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-3
Inching Pedal Nonvolatile Memory
Connector pinout. . . . . . . . . . . . . . . . . .005-105-16 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-3
Inching pedal connector . . . . . . . . . . . . .005-100-9
TCU pin . . . . . . . . . . . . . . . . . . . . . . . .005-105-16
Intershift Pause Time
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-3 O
Output Speed
J MPU . . . . . . . . . . . . . . . . . . . . . . . . . . .005-105-20
Output speed MPU
J1 Connector pinout. . . . . . . . . . . . . . . . . .005-105-20
Connector pin . . . . . . . . . . . . . . . . . . . . .005-105-6 TCU pin . . . . . . . . . . . . . . . . . . . . . . . .005-105-20

072705
PN=3
P R O O F
Index
Page Page
P J2 and mating connector. . . . . . . . . . . . .005-105-8

J3 and mating connector. . . . . . . . . . . .005-105-10
Park Brake J4 connector . . . . . . . . . . . . . . . . . . . . .005-105-15
Indx Connector pinout. . . . . . . . . . . . . . . . . .005-105-21 J6 connector . . . . . . . . . . . . . . . . . . . . .005-105-34
4 Switch . . . . . . . . . . . . . . . . . . . . . . . . . .005-105-21 Mounting . . . . . . . . . . . . . . . . . . . . . . . . .005-105-2
TCU pin . . . . . . . . . . . . . . . . . . . . . . . .005-105-21 Output Speed MPU. . . . . . . . . . . . . . . .005-105-20
Passive Park brake switch . . . . . . . . . . . . . . . . .005-105-21
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-3 Proportional valves . . . . . . . . . . . . . . . .005-105-24
Previous Direction Solenoid combinations . . . . . . . . . . . . .005-105-25
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-3 System components . . . . . . . . . . . . . . . .005-105-1
Proportional Valves TCU function. . . . . . . . . . . . . . . . . . . . . .005-105-2
Connector pinouts . . . . . . . . . . . . . . . . .005-105-24 Temperature sensor . . . . . . . . . . . . . . .005-105-22
TCU pin . . . . . . . . . . . . . . . . . . . . . . . .005-105-24 Transient voltage protection . . . . . . . . .005-105-28
Transmission wiring diagram. . . . . . . . 005-105-30,
005-105-31, 005-105-32, 005-105-33
Warranty . . . . . . . . . . . . . . . . . . . . . . . . .005-105-2
S
TCU Pins
Cylinder speed MPU . . . . . . . . . . . . . . .005-105-19
Sequence Shift
Engine speed MPU . . . . . . . . . . . . . . . .005-105-18
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-3
Gear diagnostic indicator . . . . . . . . . . .005-105-12
Shuttle Shift
Gear selector . . . . . . . . . . . . . . . . . . . . .005-100-4
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-3
Gear selector w/ PC Diagnostics. . . . . . .005-100-7
Solenoid/Gear Combinations
Inching pedal . . . . . . . . . . . . . . . . . . . .005-105-16
Active solenoids . . . . . . . . . . . . . . . . . .005-105-25
J4 gear selector . . . . . . . . . . . . . . . . . .005-105-15
Gear engaged. . . . . . . . . . . . . . . . . . . .005-105-25
J6 Connector . . . . . . . . . . . . . . . . . . . .005-105-34
System Components
Output speed MPU . . . . . . . . . . . . . . . .005-105-20
Cylinder speed MPU sensor . . . . . . . . .005-105-19
Park brake pressure switch . . . . . . . . . .005-105-21
Electronic gear selector. . . . . . . . . . . . .005-105-13
Proportional valve
Engine MPU sensor . . . . . . . . . . . . . . .005-105-18
P R O O F
Solenoid . . . . . . . . . . . . . . . . . . . . . .005-105-24
Gear indicator . . . . . . . . . . . . . . . . . . . .005-105-12
Temperature sensor . . . . . . . . . . . . . . .005-105-22
Inching pedal . . . . . . . . . . . . . . . . . . . .005-105-16
Temperature Sensor
Output speed MPU sensor . . . . . . . . . .005-105-20
Connector pinout. . . . . . . . . . . . . . . . . .005-105-22
Park brake switch . . . . . . . . . . . . . . . . .005-105-21
TCU pin . . . . . . . . . . . . . . . . . . . . . . . .005-105-22
Proportional valve . . . . . . . . . . . . . . . . .005-105-24
TCU . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-105-2
Calibrate 4 speeds forward . . . . . . . . . .005-100-13
Temperature sensor . . . . . . . . . . . . . . .005-105-22
Calibrate 8 speeds forward . . . . . . . . . .005-100-14
Transient voltage protection module . . .005-105-28
Calibration. . . . . . . . . . . . . . . . . . . . . . .005-100-12
Transmission wiring harness . . . . . . . . .005-105-30
Electrical system . . . . . . . . . . . . . . . . . . .005-100-2
Electronic gear selector. . . . . . . . . . . . . .005-100-4
Gear selector with PC diagnostics . . . . .005-100-7
T General troubleshooting tips . . . . . . . . . .005-100-3
Inching pedal system . . . . . . . . . . . . . . .005-100-9
TCU and Accessories Troubleshooting introduction . . . . . . . . . .005-100-1
Cylinder speed MPU . . . . . . . . . . . . . . .005-105-19 Visually inspect electrical system . . . . . .005-100-2
Electronic gear selector. . . . . . . . . . . . .005-105-13 Transient Voltage Protection Module
Engine speed magnetic pickup sensor (input Connector pinout. . . . . . . . . . . . . . . . . .005-105-28
speed) . . . . . . . . . . . . . . . . . . . . . . . .005-105-18 Transmission Control Unit
Function of proportional valves . . . . . . .005-105-23 Abbreviations . . . . . . . . . . . . . . . . . . . . . .005-10-2
Gear combinations . . . . . . . . . . . . . . . .005-105-25 Acronyms . . . . . . . . . . . . . . . . . . . . . . . . .005-10-2
Gear selector . . . . . . . . . . . . . . . . . . . .005-105-13 Calibrate 4 speed . . . . . . . . . . . . . . . . .005-100-13
Gear/diagnostic indicator. . . . . . . . . . . .005-105-12 Calibration. . . . . . . . . . . . . . . . . . . . . . .005-100-12
Inching pedal . . . . . . . . . . . . . . . . . . . .005-105-16 Calibration 8 speed . . . . . . . . . . . . . . . .005-100-14
J1 and mating connector. . . . . . . . . . . . .005-105-6 High-pressure washers . . . . . . . . . . . . . . .005-05-2

072705
PN=4
P R O O F
Index
Page
Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-10-2
Theory of operation. . . . . . . . . . . . . . . . . .005-10-1
Transmission Wiring Harness
1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . .005-105-30 Indx
2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . .005-105-31 5
3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . .005-105-32
4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . .005-105-33
Troubleshooting
Calibration. . . . . . . . . . . . . . . . . . . . . . .005-100-12
Calibration 4 forward 4 reverse . . . . . . .005-100-13
Calibration 8 forward 4 reverse . . . . . . .005-100-14
Gear selector . . . . . . . . . . . . . . . . . . . . .005-100-4
Gear selector w/ PC diagnostics . . . . . . .005-100-7
Inching pedal . . . . . . . . . . . . . . . . . . . . .005-100-9
Introduction . . . . . . . . . . . . . . . . . . . . . . .005-100-1
Warranty
TCU and welding . . . . . . . . . . . . . . . . . .005-105-2
Wiring Harness
1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . .005-105-30
2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . .005-105-31
3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . .005-105-32
4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . .005-105-33
P R O O F

072705
PN=5
P R O O F
Index
Indx
6
P R O O F

072705
PN=6

DF 150 and 250 Transmission DIAGNOSTIC

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DF 150 and 250 Transmission DIAGNOSTIC

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For complete service information also see:

DF150/250 Series Transmission Manual . . . CTM147

Funk Manufacturing Company

CTM157 (15JUL05) DF Series TCU Analog System

All information, illustrations and specifications in this manual are based on

CTM157 (15JUL05) i DF Series TCU Analog System

CTM157 (15JUL05) ii DF Series TCU Analog System

Group 05Safety . . . . . . . . . . . . . . . . . . . . .005-05-1 Engine Speed Magnetic Pickup Sensor. . . .005-105-18

Troubleshooting The Gear Selector. . . . . . . .005-100-4 Code 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-5

CTM157 (15JUL05) 005-1 DF Series TCU Analog System

Code 36 (Continued) . . . . . . . . . . . . . . . . . .005-110-39 Code 108 . . . . . . . . . . . . . . . . . . . . . . . . . 005-110-150

Code 60 . . . . . . . . . . . . . . . . . . . . . . . . . . .005-110-98 Legal Conditions For Code 163. . . . . . . . . 005-110-176

CTM157 (15JUL05) 005-2 DF Series TCU Analog System

This is a safety-alert symbol. When you see this symbol

Prepare for Emergencies

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service,

Wear Protective Clothing

Wear close fitting clothing and safety equipment

Prolonged exposure to loud noise can cause impairment

CTM157 (15JUL05) 005-05-1 DF Series TCU Analog System

Engine exhaust fumes can cause sickness or death. If it is

Work in Clean Area

Before starting a job:

Clean work area and machine.

Illuminate Work Area Safely

Illuminate your work area adequately but safely. Use a

Using High-Pressure Washers

IMPORTANT: Directing pressurized water at

sensitive parts and components may

CTM157 (15JUL05) 005-05-2 DF Series TCU Analog System

Lifting heavy components incorrectly can cause severe

Follow recommended procedure for removal and

Use Proper Tools

Use tools appropriate to the work. Makeshift tools and

Use power tools only to loosen threaded parts and

Use only service parts meeting John Deere specifications.

Support Machine Properly

Always lower the attachment or implement to the ground

Do not support the machine on cinder blocks, hollow tiles,

Follow recommended procedures in this manual.

When implements or attachments are used with a

CTM157 (15JUL05) 005-05-3 DF Series TCU Analog System

When you work around fuel, do not smoke or work near

Store flammable fluids away from fire hazards. Do not

Do not store oily rags; they can ignite and burn

Prevent Battery Explosions

Keep sparks, lighted matches, and open flame away from

Never check battery charge by placing a metal object

battery to 16C (60F).

CTM157 (15JUL05) 005-05-4 DF Series TCU Analog System

Sulfuric acid in battery electrolyte is poisonous. It is strong

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.

If you spill acid on yourself:

1. Flush your skin with water.

1. Do not induce vomiting.

Avoid Heating Near Pressurized Fluid Lines

Flammable spray can be generated by heating near

accidentally burst when heat goes beyond the immediate

CTM157 (15JUL05) 005-05-5 DF Series TCU Analog System

Escaping fluid under pressure can penetrate the skin