Silvercrest | SKAS 1000 A16 | Specifications | Silvercrest SKAS 1000 A16 Specifications

Maintenance and Diagnostics Manual MM-0150
ZF-FreedomLine Transmission
Revised 06-09
Service Notes
ZF-FreedomLine Transmission
Maintenance and Diagnostics Manual MM-0150
USING THIS MAINTENANCE MANUAL
This maintenance manual addresses maintenance, diagnostics and use issues that owners and users of
ZF-FreedomLine transmissions may encounter. It is not intended as a discussion of every issue that may
arise in those contexts but is illustrative of certain information that might be considered in conjunction
with installation, maintenance, repair and use of the subject transmissions.
Owners and users of ZF-FreedomLine transmissions are responsible for familiarizing themselves with the
content of this maintenance manual and using the information (and following the warnings) contained
herein for any function or condition covered. They are also responsible for communicating the information
contained in this maintenance manual to any persons performing installation, maintenance or repair
services with respect to the subject transmissions. Correct maintenance, diagnostics and use of the
subject transmissions, and observance of the suggestions and directives contained in this maintenance
manual, are integral requirements of continued warranty coverage for the subject transmissions.
This maintenance manual is provided under the following limitations, restrictions and disclaimers, which
are applicable to any person or entity using or relying on the same, as a condition to such usage or
reliance:
THESE MATERIALS PROVIDE SUGGESTIONS, AS WELL AS CERTAIN REQUIREMENTS, WITH RESPECT TO
THE INSTALLATION, MAINTENANCE, REPAIR AND USAGE OF ZF-FREEDOMLINE TRANSMISSIONS.
INSTALLATION, MAINTENANCE, REPAIR AND USAGE OF THE SUBJECT TRANSMISSIONS IS SOLELY THE
RESPONSIBILITY OF THE OWNERS AND USERS OF THE SUBJECT TRANSMISSIONS, AND IMPROPER OR
INCORRECT ACTIONS OR OMISSIONS IN THAT REGARD ARE NOT THE RESPONSIBILITY OF
ZF FRIEDRICHSHAFEN AG.
WARRANTY OBLIGATIONS WITH RESPECT TO THE SUBJECT TRANSMISSIONS ARE CONTAINED IN THE
WARRANTY INFORMATION MATERIAL ACCOMPANYING THAT PRODUCT. THE INFORMATION IN THESE
MATERIALS IS PROVIDED ON AN ‘AS IS’ BASIS, AND ALL WARRANTIES OF ANY KIND, EXPRESS OR
IMPLIED, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR
A PARTICULAR PURPOSE AND NONINFRINGEMENT OF PROPRIETARY RIGHTS ARE EXPRESSLY
DISCLAIMED. CHANGES MAY BE MADE PERIODICALLY TO THE INFORMATION CONTAINED HEREIN.
THOSE CHANGES MAY OR MAY NOT BE INCORPORATED IN ANY NEW VERSION OF THESE MATERIALS,
AND THESE MATERIALS CAN QUICKLY BECOME OUT-OF-DATE.
TO THE EXTENT THAT ANY OPERATION OR FUNCTION DESCRIBED IN THIS MAINTENANCE MANUAL
REQUIRES INTERFACE WITH PRODUCTS, EQUIPMENT OR MATERIALS OF MANUFACTURERS OTHER THAN
ZF FRIEDRICHSHAFEN AG, THE PRODUCTS MANUFACTURED BY ZF FRIEDRICHSHAFEN AG ARE
WARRANTED ONLY AS SEPARATELY SPECIFIED BY ZF FRIEDRICHSHAFEN AG. REFERENCE SHOULD BE
MADE TO THE WARRANTY INFORMATION DOCUMENT ACCOMPANYING THE SUBJECT TRANSMISSION
FOR WARRANTY COVERAGE PROVIDED BY ZF FRIEDRICHSHAFEN AG. ZF FRIEDRICHSHAFEN AG MAKES NO
WARRANTY WITH RESPECT TO PRODUCTS, EQUIPMENT AND MATERIALS MANUFACTURED OR
SUPPLIED BY OTHER ENTITIES OR THE INTERFACE OF THE SUBJECT TRANSMISSIONS WITH OTHER
PRODUCTS, EQUIPMENT OR MATERIALS.
IN NO EVENT SHALL ZF FRIEDRICHSHAFEN AG BE LIABLE FOR ANY DIRECT, INDIRECT, INCIDENTAL,
SPECIAL, EXEMPLARY OR CONSEQUENTIAL DAMAGES (INCLUDING, BUT NOT LIMITED TO,
PROCUREMENT OF SUBSTITUTE GOODS OR SERVICES; TOWING; CARGO DAMAGE; LOSS OF USE, DATA
OR PROFITS; OR BUSINESS INTERRUPTION) HOWEVER CAUSED, AND ON ANY THEORY OF LIABILITY,
WHETHER IN CONTRACT, STRICT LIABILITY OR TORT (INCLUDING NEGLIGENCE OR OTHERWISE)
ARISING IN ANY WAY OUT OF THE USE OF THE INFORMATION CONTAINED HEREIN, EVEN IF
ZF FRIEDRICHSHAFEN AG IS ADVISED OF THE POSSIBILITY OF SUCH DAMAGE.
WHILE ZF FRIEDRICHSHAFEN AG HAS MADE EVERY ATTEMPT TO ENSURE THAT THE INFORMATION
CONTAINED IN THESE MATERIALS HAS BEEN OBTAINED FROM RELIABLE SOURCES,
ZF FRIEDRICHSHAFEN AG IS NOT RESPONSIBLE FOR ANY ERRORS OR OMISSIONS OR FOR THE
RESULTS OBTAINED FROM THE USE OF THESE MATERIALS. IN NO EVENT WILL ZF FRIEDRICHSHAFEN
AG BE LIABLE TO ANYONE FOR ANY DECISION MADE OR ACTION TAKEN IN RELIANCE ON THE
INFORMATION IN THESE MATERIALS.
*
*
*
*
Affiliates of ArvinMeritor, Inc., act as the sales and service representatives for various products of ZF Friedrichshafen AG,
under contractual arrangements with ZF Friedrichshafen AG. For answers to product and service questions, and to order
literature, call ArvinMeritor’s Customer Service Center at 866-668-7221 Monday through Friday from 8 a.m. to 8 p.m. EST,
with a 24-hour on-call answer service. You can also visit Literature on Demand at arvinmeritor.com to access and order
product and service literature.
Service Notes
Before You Begin
To Order Information
This manual provides maintenance and diagnostic
instructions for ZF-FreedomLine transmissions.
Before you begin procedures:
Call OnTrac at 866-668-7221 to order the following
publications or visit ArvinMeritor’s commercial
vehicle website at www.meritorhvs.com for free
downloads. (Keyword Transmissions).
1.
Read and understand all instructions and
procedures before you begin to service
components.
앫 ZF-FreedomLine Transmission
(Operator Manual TP-20170) (French and
Spanish versions available)
2. Read and observe all Caution and Warning
safety alerts that precede instructions or
procedures you will perform. These alerts help
to avoid damage to components, serious
personal injury, or both.
앫 ZF-FreedomLine Transmission
(Parts Book PB-0127)
앫 ZF-FreedomLine Transmission Maintenance and
Diagnostic Manual (MM-0150)
3. Follow your company’s maintenance and
service, installation, and diagnostics
guidelines.
앫 ZF-FreedomLine Transmission Fault Code
Diagnostics and Wiring Diagram (TP-01110)
–
9
Y
0
R
8
A
1
T
E
6
I
0
R
D
P
E
O
S
R
A
P
E
–
L
E
R
T
NO
How to Order Tools Specified in This
Manual
4. Use special tools when required to help avoid
serious personal injury and damage to
components.
Call ArvinMeritor’s Commercial Vehicle
Aftermarket at 888-725-9355 to order Meritor tools.
Safety Alerts, Torque Symbol and Notes
SPX Kent-Moore, 28635 Mound Road, Warren,
Michigan, 48092. Call the company’s customer
service center at 800-345-2233, or visit their
website at spxkentmoore.com.
A Warning alerts you to an
WARNING instruction or procedure
that you must follow
exactly to avoid serious
personal injury and
damage to components.
FreedomLine is a product of ZF Friedrichshafen AG.
ArvinMeritor is the sole authorized sales and
service representative in North America for
class 6-8 trucks for the ZF-FreedomLine
Transmissions.
A torque symbol alerts you
to tighten fasteners to a
specified torque value.
NOTE
Information contained in this publication was in
effect at the time the publication was approved for
printing and is subject to change without notice or
liability. ZF Friedrichshafen AG reserves the right to
revise the information presented or to discontinue
the production of parts described at any time.
A Note provides
information or suggestions
that help you correctly
service a component.
Access Product and Service Information
on Our Website
Visit Literature on Demand at www.meritorhvs.com
to access product, service, aftermarket, and
warranty literature for ArvinMeritor’s truck, trailer
and specialty vehicle components.
-v
Table of Contents
Regulatory Guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Model Numbers and Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
12-Speed ZF-FreedomLine
16-Speed ZF-FreedomLine
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
ZF-FreedomLine Fasteners Tightening Torque
Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Acronyms Referenced in Manual
Section 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
ZF-FreedomLine Automated Two-Pedal Transmission
Features
ZF-FreedomLine Transmissions Use a Self-Adjusting Integral Clutch
Clutch Features
How the Clutch Operates
Tools Used in This Manual
Approved Oil Lubricant Specifications for ZF-FreedomLine Transmissions . . . . . . . . . . . . . . . . . . . . . .2
Recommended Preventive Maintenance
ZF-FreedomLine Transmissions Fluid Capacities
How to Identify a ZF-FreedomLine Transmission
Shift Module and Joystick
NEUTRAL Button
FUNCTION Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Shift-n-CruiseTM Speed Control
Instrument Panel and Shift Module Displays
Instrument Panel Display
System Malfunction Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
What to do if a System Malfunction Occurs
System Self-Check Status
System Air is Low
Clutch Overload Status
Clutch Wear Warning
How to Shift the Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Automatic Mode
Manual Mode
Parking a Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Shift Labels
Section 2: Fault Code Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Before You Make a Warranty Repair on a ZF-FreedomLine Transmission
Fault Codes and Volt-Ohm Meter (VOM) Diagnostics
Fault Codes
How to Retrieve Active and Inactive SAE and ISO Fault Codes from the Instrument Panel Display
Using the ZF-FreedomLine Shifter
Active SAE and ISO Fault Codes
Inactive Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
To View Active or Inactive Fault Codes Again
How to Clear Inactive Fault Codes from TCU Memory
How to Retrieve Active and Inactive SAE and ISO Fault Codes from the Instrument Panel Display
Using a Steering Column-Mount Shift Lever
Active Fault Codes
Inactive Fault Codes
Table of Contents
How to Clear Inactive Fault Codes from the Instrument Panel Display Using a Steering
Column-Mount Shift Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
How to Retrieve Active and Inactive ISO Fault Codes from the Instrument Panel Display
Using an SAE J1939 Push-Button Shift Lever
Active ISO Fault Codes
Inactive ISO Fault Codes
How to Clear Inactive Fault Codes from the Instrument Panel Display Using an SAE J1939
Push-Button Shift Lever
SAE Fault Code Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ISO Fault Code Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Section 3: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Release Fork Greasing Procedure (Standard and Roller Fork Applications)
SAE J1939 Requirements Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Requirements Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pneumatic Requirements Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No-Start Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PTO Requirements Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60
62
74
80
91
Section 4: Wiring/Pneumatic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Resistance Specifications
Diagnostic Connector
Connector Pin Assignments
Section 5: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Transmission
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Voltage Doubler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
ZF-FreedomLine Transmission Electronic Controller (ZMTEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Transmission Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Output Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Input Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Output Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Air Filter Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
TCU Top Half/Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Transmission Control Unit (TCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Shift Rail/TCU Cylinder Adjustments for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Adjust the Cylinder Pistons
Selector Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Travel Sensors Engage, Splitter, Range and Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Air Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Transmission Wiring Harness Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Cooler By-Pass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Neutral Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Output Shaft Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Clutch Actuator Housing and Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Release Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Regulatory Guidance
Regulatory Guidance
Regulatory Guidance
All persons working with, handling or exposed to
the area where work on the transmission occurs,
are warned to consult and comply with all
applicable health, safety, medical or environmental
standards and regulations governing non-asbestos
fibers.
References to OSHA, NIOSH, MSHA, and EPA,
which are regulatory agencies in the United States,
are made to provide further guidance to employers
and workers employed within the United States.
Employers and workers employed outside of the
United States should consult the regulations that
apply to them for further guidance.
i
Model Numbers and Ratios
Model Numbers and Ratios
O
M
–
Z
16
12
A
–
A
Highest Torque
in Top Two Gears
13 = 1350 lb-ft
14 = 1450 lb-ft
15 = 1550 lb-ft
16 = 1650 lb-ft
ZF-FreedomLine
Ratio
A
O = Overdrive
No Letter = Direct Drive
Torque Rating
13 = 1350 lb-ft
14 = 1450 lb-ft
15 = 1550 lb-ft
16 = 1650 lb-ft
16
12 = 12-Speed
16 = 16-Speed
A = Fully Automated
Platform
Z = ZF-FreedomLine
4002082b
12-Speed ZF-FreedomLine
Transmission
Description
Torque
Rating
lb-ft
Model
Number
Overall
Ratio
Rev. Rev.
L
H
FWD. REV.
12-Speed
Direct Drive
M-13Z12A-A13
1,350
M-14Z12A-A14
1,450
12-Speed
Overdrive
MO-13Z12A-A13
1,350
MO-14Z12A-A14
1,450
MO-15Z12A-A15
1,550
MO-16Z12A-A16
1,650
Ratio and Percent Step
1
% 2
% 3 % 4 % 5 % 6 % 7 % 8
% 9 % 10 % 11 % 12
15.86 14.68 14.68 11.41 15.86 29 12.33 29 9.57 29 7.44 27 5.87 28 4.57 32 3.47 28 2.70 29 2.10 29 1.63 26 1.29 29 1.00
15.81 14.62 11.41 8.88 12.33 29 9.59 29 7.44 29 5.78 26 4.57 29 3.55 31 2.70 29 2.10 29 1.63 28 1.27 27 1.00 28 .78
16-Speed ZF-FreedomLine
Transmission
Model
Description Number
Torque
Rating
lb-ft
Overall
Ratio
FWD. REV.
16-Speed
Overdrive
MO-13Z16A-A13
1,350
MO-14Z16A-A14
1,450
MO-15Z16A-A15
1,550
MO-16Z16A-A16
1,650
Rev. Rev.
L
H
Ratio and Percent Step
1 % 2 % 3 % 4 % 5 % 6 % 7 % 8 % 9 % 10 % 11 % 12 % 13 % 14 % 15 % 16
17.01 15.75 13.07 10.81 14.12 21 11.68 22 9.54 21 7.89 21 6.52 21 5.39 18 4.57 21 3.78 22 3.09 21 2.56 22 2.09 21 1.73 21 1.43 21 1.18 18 1.00 20 0.83
ii
Torque Specifications
ZF-FreedomLine Fasteners Tightening Torque
Torque Specification
Description
Size
(lb-ft)
(N•m)
Drain plug
M24 x 1.5
44
60
Fill/Spill plug
M24 x 1.5
44
60
Fill plug (optional, located on the PTO cover)
M24 x 1.5
44
60
Neutral switch
M20 x 1.5
33
45
Output shaft speed sensor
M20 x 1.5
15
21
Air line fittings
M16 x 1.5
15
21
Cooler by-pass tubes
M30 x 1.5
36
50
Oil line fittings
M22 x 1.5
66
90
Bolt, clutch cover to flywheel (Cummins, Caterpillar and Mercedes
engines)
7/16-14
Consult the OEM. Consult the OEM.
Bolt, clutch cover to flywheel (Detroit Diesel, Volvo and Mack engines)
M10
Consult the OEM. Consult the OEM.
Bolt, transmission case to flywheel housing
7/16-14
Consult the OEM. Consult the OEM.
Bolt, fork to front cover
M12
85
115
Bolt, quill tube to front cover
M8
17
23
Bolt, clutch inspection cover to transmission case
M8
17
23
Nut, clutch actuator to transmission case
M8
17
23
Stud, clutch actuator to transmission case
M8
7
10
Vent plug, clutch actuator
M12 x 1.5
16
22
Bolt, TCU to transmission case
M8
17
23
Vent, TCU
M8
7
10
Bolt, bottom accessory bracket to case
M10
36
50
Bolt, bottom accessory bracket to case (rear-most position of configuration
2 only)
M12
58
79
Bolt, top accessory bracket to bottom accessory bracket
5/16-18
11
15
Stud, top accessory bracket to bottom accessory bracket
5/16-18 to M8
11
15
Bolt, ZMTEC to top accessory bracket
1/4-20
12
16
Bolt, voltage doubler to top accessory bracket
1/4-20
12
16
Bolt, lifting hook to housing
M12
58
79
Bolt, PTO cover to housing (International vehicles only)
M12
58
79
Bolt, output shaft seal retainer to transmission case
M10
34
46
Bolt, yoke retaining plate to output shaft
M12
89
120
Stud, transmission case (Volvo only)
M10 to M10
36
50
Bolt, oil cooler hose L bracket to housing (3 of 4)
M10
36
50
Bolt, oil cooler hose L bracket to housing (1 of 4)
M12
58
79
Bolt, oil cooler clip to L bracket
1/4-20
10
14
Bolt, oil cooler bottom mounting bracket to transmission case
M12
34
46
Bolt, oil cooler top mounting bracket to bottom mounting bracket
1/4-20
12
16
Bolt, transmission wiring harness to ZMTEC
1/4-20
7
9.5
iii
Acronyms
Acronyms Referenced in Manual
ABS — Anti-Lock Braking System
ACC — Accessory
ASR — Anti-Slip Regulation
CAN — Controller Area Network
CCVS — Cruise Control/Vehicle Speed
EBC1 — Electronic Brake Controller #1
ECM — Engine Control Module
ECU — Electronic Control Unit
EEC1 — Electronic Engine Controller #1
EEC2 — Electronic Engine Controller #2
EEPROM — Electronically Erasable Programmable Read Only Memory
ERC1 — Electronic Retarder Controller #1
ETC1 — Electronic Transmission Controller #1
ETC2 — Electronic Transmission Controller #2
ISO — International Standards Organization
OEM — Original Equipment Manufacturer
PSI — Pounds Per Square Inch
PTO — Power Take-Off
SAE — Society of Automotive Engineers
TC1 — Transmission Controller #1
TCU — Transmission Control Unit
WSI — Wheel Speed Information
ZMTEC — ZF Meritor Electronic Transmission Controller
iv
Section 1
Introduction
ZF-FreedomLine Automated
Two-Pedal Transmission
Section 1
Introduction
This manual provides maintenance and service
information for the ZF-FreedomLine automated
two-pedal transmission. To order information on
other Meritor transmission models, refer to the
Service Notes page at the front of this publication.
Features
ZF-FreedomLine transmission models are
available in 12-speed direct and overdrive, and
16-speed overdrive to meet a variety of application
requirements.
ZF-FreedomLine transmissions are automated
with integrated electronics for worry-free shifting.
An operator can easily switch to manual control at
any time.
The exclusive “no clutch pedal” design completely
eliminates clutch pedal actuation for starts and
stops, freeing operators from potential distractions
and extending clutch life. The ZF-FreedomLine shift
module enables less-experienced operators to shift
as well as seasoned veterans.
The clutch has a stamped housing and snap-in
connection between the release bearing and
diaphragm spring. The housing contains the
shipment cups, diaphragm spring, pressure plate,
spring straps, and snap-in bearing connection.
The single-plate clutch disc assembly has a
cushioned, riveted organic facing material for
smooth clutch engagement.
The clutch disc is designed with two torsional
dampeners: A six-spring main dampener, which
helps to reduce drivetrain wear that results from
engine torsion; and a six-spring pre-dampener,
which helps to reduce engine gear noise.
How the Clutch Operates
The ZF-FreedomLine transmission control unit
(TCU) controls the clutch actuator cylinder, which
engages the clutch. The actuator checks clutch
travel and adjusts clearances as required.
Figure 1.1
CLUTCH DISC
CLUTCH HOUSING
Torque ratings range from 1,350 lb-ft to 1,650 lb-ft
for today’s high torque, low rpm engines.
RELEASE
BEARING
A twin countershaft with full helical gearing sets
industry standards for quiet, long-life operation.
An aluminum case yields a weight savings of up
to 132 pounds.
ZF-FreedomLine Transmissions Use
a Self-Adjusting Integral Clutch
Clutch Features
The integral clutch is self-adjusting. The release
bearing is permanently-lubricated and sealed for
maintenance-free operation.
The clutch is air-operated and electronicallycontrolled.
Clutch adjustment and wear are continually
monitored, so no clutch adjustment is necessary.
Tools Used in This Manual
SPX Kent-Moore specifies the following tools in
this manual. Refer to the Service Notes page on
the inside front cover for instructions to order
these tools.
앫
앫
앫
앫
Seal Remover (part number J-24171-A)
Yoke Puller (part number J-7804-01)
Input Shaft Turning Tool (part number J-45556)
Output Shaft Seal Installer (part number J-45247)
An in-cab display indicates when to replace the
clutch.
1
Section 1
Introduction
Approved Oil Lubricant
Specifications for ZF-FreedomLine
Transmissions
WARNING
Use of inappropriate oil may damage the
transmission.
Do not use multi-viscosity or EP (extreme pressure
additive) oils.
NOTE: The ZF-FreedomLine transmission is
designed to be used only with 50 weight synthetic
oil.
NOTE: The following partial listing shows
lubricants that have been approved for use with
ZF-FreedomLine transmissions. If your intended
lubricant is not listed, prease contact OnTrac at
866-668-7221.
Specification
Cognis Emgard SAE 50 Synthetic Transmission Lube
BP Syn-Gear CD-50
Chevron Delo Synthetic Transmission Fluid SAE 50
ZF-FreedomLine Transmissions Fluid
Capacities
Transmission
Oil Capacity (Quarts)
12 sp Direct Drive
12.7
12 sp Overdrive
12.7
16 sp Overdrive
13.5
How to Identify a ZF-FreedomLine
Transmission
You can identify a ZF-FreedomLine transmission
from the identification plate located on the left side
of the transmission. Refer to Model Numbers and
Ratios at the beginning of this manual.
Shift Module and Joystick
The ZF-FreedomLine transmission’s shift module,
designed with a joystick, is located next to the
driver’s seat. The shift module replaces the
standard shift lever, shift tower and shift knob.
Move the joystick FORWARD to upshift and
BACKWARD to downshift (manual mode only).
Figure 1.2.
Texaco Syn-Star TL SAE 50
Conoco Phillips Family Synthetic Transoil 50
Mobil Delvac Synthetic Transmission Fluid 50
Fleetrite Synthetic SAE 50 Transmission Oil
Kenworth SAE 50 Original Factory Fill Fluid
Shell Spirax® GSX SAE 50
Pennzoil® Long-Life™ Transmission Fluid EW-50
Valvoline HD Synthetic Trans Oil SAE 50
Recommended Preventive
Maintenance
Figure 1.2
�
� Joystick
�
� NEUTRAL Button
� Shift Module Display
� Shift-n-Cruise
�
TM
Speed Control
Buttons
� FUNCTION Button
�
�
WARNING
When you install a fill plug and a drain plug into a
transmission, first manually position the plug, and
then install and tighten it by hand. When you’ve
hand tightened the plug, use a torque wrench to
tighten it to 44 lb-ft (60 N•m). Do not overtighten
the plug. Damage to the aluminum housing can
result. T
Item
Interval (Miles)
Lubricant level inspection
10,000
Visual leak inspection
10,000
Visual release bearing inspection
10,000
Clear the inactive codes
10,000
2
NEUTRAL Button
Press and release the NEUTRAL button at any time
to shift into Neutral.
Press and hold the NEUTRAL and FUNCTION
buttons at the same time to list active fault codes
on the instrument panel display.
Press and hold the NEUTRAL button, FUNCTION
button and service brake at the same time to list
inactive fault codes on the instrument panel
display.
Section 1
Introduction
FUNCTION Button
Press and release the FUNCTION button to switch
between automatic and manual mode, move into
Reverse from a stop, and skip shift (manual mode
only).
앫 Moving into reverse is FUNCTION button
+ DOWNSHIFT (pull back lever) at standstill.
앫 FUNCTION + UP/DOWNSHIFT results in a skip
shift in manual mode at standstill and when
driving.
Instrument Panel and Shift Module
Displays
Both the instrument panel display and the shift
module display illuminate to provide operating
information, as well as alert you that a system
malfunction has occurred.
Instrument Panel Display
Status
Display
The system is performing a self-check.
Press and hold the FUNCTION button and
NEUTRAL button at the same time to list active
fault codes on the instrument panel display.
CH
The transmission is in Neutral.
N
Press and hold the FUNCTION button, NEUTRAL
button and service brake at the same time to list
inactive fault codes on the instrument panel
display.
No ▼ = Manual mode
(example shows 12th gear engaged)
12
Reverse Low is engaged.
RL
Reverse High is engaged.
RH
System Malfunction
SM
System air is low.
AL
A clutch overload occurred.
CL
Clutch wear indicator (the clutch requires
replacement)
CW
NO DATA (the SAE J1587 info is absent or
possible loss of power to the transmission)
––
The display line between the main
transmission control unit (main TCU) and the
ZF-FreedomLine transmission electronic
controller (ZMTEC) is faulty.
EE
Shift-n-CruiseTM Speed Control
WARNING
Only use the Shift-n-Cruise speed control feature
when you operate a vehicle under normal
operating conditions. Do not use this feature in
heavy traffic or on winding, wet or slippery roads.
These conditions can affect cruise control
performance, which can result in loss of vehicle
control, serious personal injury and damage to
components.
TM
Only use your finger to press the Shift-n-CruiseTM
speed control PAUSE, RESUME or SET buttons
located on the shift knob. If you use a screwdriver,
ballpoint pen or any sharp item, a button can stick
in the switch assembly and affect speed control
operation. Damage to components can result.
Shift-n-Cruise buttons located on the shift module
enable you to easily select speed control
functions.
1.
Press the SET button to select cruise speed.
2. Press the PAUSE button to temporarily
deactivate speed control.
3. Press the RESUME button to return to the
speed you selected at SET.
▲
▼
No
= Automated mode
(example shows 12th gear engaged)
▲
PTO 1 is activated. The transmission is in
Neutral.
PTO 1 and 2 are activated. Third gear is
engaged as a starting gear.
▲
▼
12
▲
▲
▼
PN
P3
High Temperature: TCU temperature is above
threshold or transmission oil temperature is
above threshold.
HT
Neutral Shift Timeout
NS
All truck OEMs except Freightliner LLC:
The system was designed to react as follows
when the vehicle idles for extended periods
while in-gear:
앫 Between 0 and 14 minutes: no outward
changes
앫 Between 14 and 15 minutes: “NS” on the
display, and you may have an audible
alarm depending on vehicle configuration.
앫 15th minute: Transmission attempts an
automated shift to neutral
Any changes to service brake, accelerator
pedal, gearshift position, etc., reset the timer.
Timer was designed to not run during
PTO operation or in the event of certain
critical faults.
3
Section 1
Introduction
System Malfunction Warning
WARNING
If a system malfunction occurs, the instrument
panel display illuminates “SM” for system
malfunction and you may have an audible alarm
depending on vehicle configuration. When this
warning occurs, you may be unable to shift the
transmission. Do not continue to operate the
vehicle. Serious personal injury and damage to
components can result. Safely move the vehicle to
the side of the road and call for assistance.
The instrument panel display illuminates SM for
system malfunction. The shift module emits a
single beep.
“SM” indicates that an active fault has occurred in
the transmission.
What to do if a System Malfunction
Occurs
Follow these procedures to move the vehicle to
the side of the road and come to a safe stop.
1.
Apply the brakes to slow the vehicle. Safely
move the vehicle to the side of the road.
NOTE: In most cases the vehicle can still be
driven in a Manual mode (No Auto shifts) or may
only be driven in a starting gear.
ATTENTION: As some fault conditions lead to the
transmission remaining in Neutral after coming to
a Stop, be sure you are stopped in a safe place
before determining if you can continue.
2. Stop the vehicle. Apply the parking brake.
3. Call OnTrac at 866-668-7221 for assistance.
System Self-Check Status
“CH” will display on the instrument panel
while the TCU performs a system self-check.
A self-check is performed when the ignition is
turned ON. Typically, the self-check continues until
the engine is started, but can last longer if the TCU
is being powered-up for the first time or there is
not enough air pressure for the transmission to
finish self check.
앫 If the system self-check continues after the
engine is started: Contact OnTrac at
866-668-7221 and request a transmission
specialist.
4
System Air is Low
WARNING
If “AL” displays on the instrument panel, the
transmission control unit (TCU) has determined
that system air pressure is low. Apply the brakes
and safely move to the shoulder of the road. Shift
into neutral and idle to allow air pressure to
build-up. Do not drive the vehicle with “AL” on the
display. Serious personal injury and damage to
components can result.
“AL” will display on the instrument panel if the
TCU determines that system air pressure is low.
Apply the brakes and safely move to the shoulder
of the road. Shift into neutral and idle to allow air
pressure to build-up. Do not drive the vehicle with
“AL” on the display. Do not turn the ignition OFF
with “AL” on the display. The vehicle may shut
down in gear and not start until air pressure is
built-up again.
Clutch Overload Status
WARNING
If “CL” displays on the instrument panel, the
transmission control unit (TCU) has determined
that the clutch is hot. Apply the brakes and safely
move to the shoulder of the road. Shift into
neutral and idle to allow the clutch to cool. Do not
drive the vehicle with “CL” on the display. Serious
personal injury and damage to components can
result.
“CL” will display on the instrument panel if the
TCU determines that the clutch is hot. Apply the
brakes and safely move to the shoulder of the
road. Shift into neutral and idle to allow the clutch
to cool. Do not drive the vehicle with “CL” on
the display.
Clutch Wear Warning
WARNING
If “CW” displays on the instrument panel, the
transmission control unit (TCU) has determined
that the clutch is worn. Replace the clutch. Do not
drive the vehicle more than 1,000 miles (1610 km)
with a worn clutch. Serious personal injury and
damage to components can result.
“CW” will display on the instrument panel if the
TCU determines that the clutch is worn. Replace
the clutch. Do not drive the vehicle more than
1,000 miles (1610 km) with a worn clutch.
Section 1
Introduction
Adjust the Starting Gear
WARNING
This vehicle is equipped with ZF-FreedomLine
automated manual transmission. The vehicle can
roll backward when stopped on a hill or grade, or
when the vehicle is starting from a stop on a hill
or grade. Serious personal injury and damage to
components can result.
1.
Press and release the FUNCTION button as
necessary to switch to manual mode.
2. Move the joystick FORWARD or BACKWARD.
3. Press and release the FUNCTION button to
switch back to automatic mode.
Shift Into Low Reverse from Neutral at a Stop
WHEN STOPPED ON A HILL OR GRADE: Press the
brake pedal to keep the vehicle stationary.
WHEN STARTING FROM A STOP ON A HILL OR GRADE:
Quickly move your foot from the brake pedal and
firmly press the accelerator pedal.
How to Shift the Transmission
1.
Start the engine.
2. Allow air pressure in the system to reach the
specified range on the gauge.
NOTE: When you shift from a forward gear to a
reverse gear, or from a reverse gear to a forward
gear, you must first shift into Neutral with the
vehicle stationary. Depending on vehicle OEM
(see your vehicle operator manual), you may be
required to press the vehicle service brake before
the system will allow a shift from neutral into gear.
It is recommended to press the system brake
whenever shifting from neutral into gear!
1.
Press and hold the brake pedal.
2. Press and hold the FUNCTION button. Move
the joystick BACKWARD.
3. Release the FUNCTION button and joystick.
Shift Between Reverse Low and Reverse High
While the Vehicle is Moving as Well as at
Standstill
1.
Move the joystick FORWARD to shift from
Reverse Low to Reverse High.
2. Move the joystick BACKWARD to shift from
Reverse High to Reverse Low.
Upshift and Downshift
The transmission automatically shifts when in
forward gears.
Manual Mode
Switch Between Manual and Automatic Modes
Automatic Mode
Press and release the FUNCTION button without
moving the joystick.
Switch Between Automatic and Manual Modes
Shift Into Neutral at any Time
Press and release the FUNCTION button without
moving the joystick.
Press and release the NEUTRAL button.
Shift Into Neutral at any Time
To Prevent the Vehicle from Rolling Backward
When Stopped on a Hill or Grade
Press and release the NEUTRAL button.
To Prevent the Vehicle from Rolling Backward
When Stopped on a Hill or Grade
Press the brake pedal to keep the vehicle
stationary.
To Prevent the Vehicle from Rolling Backward
When Starting from a Stop on a Hill or Grade
Quickly move your foot from the brake pedal and
firmly press the accelerator pedal.
Press the brake pedal to keep the vehicle
stationary.
To Prevent the Vehicle from Rolling Backward
When Starting from a Stop on a Hill or Grade
Quickly move your foot from the brake pedal and
firmly press the accelerator pedal.
Shift Into a Forward Gear from Neutral at a Stop
Move the joystick FORWARD.
Shift Into a Forward Gear from Neutral at a Stop
Move the joystick FORWARD.
5
Section 1
Introduction
Adjust the Starting Gear
1.
2. Move the joystick FORWARD or BACKWARD.
3. Press and release the FUNCTION button to
switch back to automatic mode.
Shift Into Low Reverse from Neutral at a Stop
1.
Press and hold the brake pedal.
2. Press and hold the FUNCTION button. Move
the joystick BACKWARD.
3. Release the FUNCTION button.
Shift Between Reverse Low and Reverse High
While the Vehicle is Moving as Well as at
Standstill
Move the joystick FORWARD to shift from Reverse
Low to Reverse High.
Move the joystick BACKWARD to shift from
Reverse High to Reverse Low.
Shift Between Forward Gears
Upshift One Gear
Move the joystick FORWARD.
Upshift Two Gears
1.
Parking a Vehicle
Press and release the FUNCTION button as
necessary to switch to manual mode.
Press and hold the FUNCTION button while
you move the joystick FORWARD.
2. Release the FUNCTION button.
Downshift One Gear
Move the joystick BACKWARD.
Downshift Two Gears
WARNING
You must put the transmission into Neutral and
follow the vehicle manufacturer’s procedures
when you park a vehicle. If the transmission is in
gear when you start the vehicle, the vehicle can
suddenly move forward. Serious personal injury
and damage to components can result.
1.
Bring the vehicle to a stop.
2. Apply the parking brake. Refer to the vehicle
manufacturer’s instructions for the correct
procedures.
Shift Labels
1.
Refer to the shift label affixed to the sun visor
or instrument panel for instructions on how to
shift the transmission.
2. If the label is missing or unreadable, call
ArvinMeritor’s Commercial Aftermarket at
888-725-9355 to order a new label. Install the
new label in the vehicle.
Operating ZF-FreedomLine Automated Transmission
To Prevent the Vehicle from Rolling BACKWARDS on a Hill or Grade at a Stop: Press the
brake pedal.
When starting from a Stop: Quickly move your foot from the brake pedal and firmly
press the accelerator pedal.
SHIFTING IN AUTOMATIC MODE
Shift Into Neutral at any Time: Press
and release the NEUTRAL button.
Shift Into a Forward Gear from
Neutral at a Stop: Press and hold
the brake pedal. Move the joystick
FORWARD.
Shift Into Reverse from Neutral at a
Stop: Press and hold the brake
pedal. Move the joystick
BACKWARDS. Release the
FUNCTION button.
SHIFTING IN MANUAL MODE
Shift Into Neutral at any Time: Press and release
the NEUTRAL button.
Shift Into a Forward Gear from Neutral at a Stop:
Press and hold the brake pedal.
Move the joystick FORWARD.
Shift Into Reverse from Neutral at a Stop: Same
as automatic mode.
Upshift One Gear: Move the joystick FORWARD.
Downshift One Gear: Move the joystick
BACKWARDS.
Skip Shift: Press the FUNCTION button while
moving the joystick.
Also refer to ZF-FreedomLine Operator Manual Tp-20170.
1.
Press and hold the FUNCTION button while
you move the joystick BACKWARD.
2. Release the FUNCTION button.
2297-N-8463
4007247a
WARNING
This vehicle is equipped with a ZF-FreedomLine fully-automated manual
transmission. The vehicle can roll BACKWARDS when stopped on a hill or
grade, or when starting from a stop on a hill or grade. Serious personal
injury and damage to components can result.
WHEN STOPPED ON A HILL OR GRADE: Press the brake pedal.
WHEN STARTING FROM A STOP ON A HILL OR GRADE: Quickly move your
foot from the brake pedal and firmly press the accelerator pedal.
For more information, or to order ZF-FreedomLine Operator Manual
TP-20170, call ArvinMeritor’s Customer Service Center at 800-535-5560.
2297-Z-8346 (03-01)
4007259a
6
Section 2
Fault Code Diagnostics
Section
Fault
Code
2 Diagnostics
WARNING
To prevent serious eye injury, always wear safe
eye protection when you perform vehicle
maintenance or service.
Test and Repair Faults
1.
Retrieve the fault codes.
2. Use a Volt-Ohm meter to test the areas where
the fault codes indicate that malfunctions have
occurred in the system.
When you work on an electrical system, the
possibility of electrical shock exists, and sparks
can ignite flammable substances. You must
always disconnect the battery ground cable before
you work on an electrical system to prevent
serious personal injury and damage to
components.
앫 Active Faults: Have a ZF-FreedomLineauthorized technician repair the fault.
앫 Inactive Faults: Have a ZF-FreedomLineauthorized technician verify that the fault was
previously repaired. Repair faults, if
necessary.
3. Clear all fault codes from TCU memory.
Before You Make a Warranty Repair
on a ZF-FreedomLine Transmission
Call OnTrac at 866-668-7221 for approval. You’ll be
asked to provide the transmission’s model
number, mileage, in-service date, serial number,
VIN number and the reason for the repair.
Fault Codes and Volt-Ohm Meter
(VOM) Diagnostics
How to Retrieve Active and Inactive
SAE and ISO Fault Codes from the
Instrument Panel Display Using the
ZF-FreedomLine Transmission Shifter
NOTE: The vehicle must be stationary to retrieve
active fault codes.
1.
ZF-FreedomLine transmission control unit (TCU)
uses a series of fault codes to identify system
malfunctions that the TCU detects and stores into
memory.
After you retrieve a fault code from the instrument
panel display and identify the fault, use a volt-ohm
meter (VOM) to test the area where the fault code
indicates that the malfunction has occurred. An
authorized distributor/dealer should repair the
fault.
Fault Codes
Fault Code Diagnostics
ZF-FreedomLine transmission control unit (TCU)
uses a series of fault codes to identify system
malfunctions that the TCU detects and stores into
memory.
After you retrieve a fault code from the instrument
panel display and identify the fault, use a volt-ohm
meter to test the area where the fault code
indicates that the malfunction has occurred. An
authorized ZF-FreedomLine distributor or dealer
should repair the fault.
Park the vehicle and set the parking brake.
Turn the engine OFF, but leave the ignition ON.
Prepare to record the fault codes before you
begin to retrieve them from the instrument
panel display.
2. Use the following procedures to retrieve active
and inactive SAE and ISO fault codes.
Active SAE and ISO Fault Codes
NOTE: All active fault codes will steadily display
for approximately 1-1/2 seconds each. Ignore fault
codes that flash. When the TCU has listed all
active fault codes, the list will repeat.
Shifter
FreedomLine
Transmission
Shifter
1.
Active SAE
Display Codes
Active ISO Display
Codes
Neutral +
Function
Neutral + Function +
Downshift
The TCU will begin to list the active fault codes
on the instrument panel display.
2. Record the fault codes.
NOTE: ISO display codes may not be available on
vehicles built prior to January 2006.
3. When you’re finished retrieving fault codes,
release the NEUTRAL and FUNCTION buttons.
Turn the ignition OFF.
7
Section 2
Fault Code Diagnostics
Inactive Fault Codes
NOTE: All inactive fault codes will steadily display
for approximately 1-1/2 seconds each. Ignore fault
codes that flash. When the TCU has listed all
inactive fault codes, the list will repeat.
Shifter
FreedomLine
Transmission
Shifter
1.
Inactive SAE
Display Codes
Inactive ISO Display
Codes
“With brake
pedal
depressed”
Neutral +
Function
“With brake pedal
depressed”
Neutral + Function +
Downshift
The TCU will begin to list the inactive fault
codes on the instrument panel display.
2. Record the fault codes.
NOTE: ISO display codes may not be available on
vehicles built prior to January 2006.
3. When you’re finished retrieving fault codes,
release the NEUTRAL and FUNCTION buttons,
and the service brake. Turn the ignition OFF.
To View Active or Inactive Fault Codes
Again
Repeat the previous steps.
How to Clear Inactive Fault Codes
from TCU Memory
NOTE: Inactive faults are repaired active faults
that have not been cleared from TCU memory.
1.
The vehicle must be stationary to clear
inactive fault codes. Park the vehicle and set
the parking brake. Turn the engine OFF. Turn
the ignition OFF.
2. Press and hold the NEUTRAL button and the
FUNCTION button at the same time.
3. Turn the ignition ON. Do not start the engine.
Count to three and release both buttons.
4. Count to three and press and hold the
NEUTRAL button and the FUNCTION button at
the same time.
5. Turn the ignition OFF. Count to three and
release both buttons. The fault codes will be
cleared from TCU memory.
8
How to Retrieve Active and Inactive
SAE and ISO Fault Codes from the
Instrument Panel Display Using a
Steering Column-Mount Shift Lever
NOTE: The vehicle must be stationary.
1.
Park the vehicle and set the parking brake.
Turn the engine OFF, but leave the ignition ON.
Prepare to record the fault codes before you
begin to retrieve them from the instrument
panel display.
2. Use the following procedures to retrieve active
and inactive SAE and ISO fault codes.
Active Fault Codes
NOTE: All active fault codes will steadily display
for approximately 1-1/2 seconds each. Ignore fault
codes that flash. When the TCU has listed all
active fault codes, the list will repeat.
Shifter
Analog Shifter
(Freightliner and
Sterling Vehicles
Only)
1.
Active SAE
Display Codes
Active ISO Display
Codes
Neutral +
Manual + Up
Neutral + Manual +
Down
The TCU will begin to list the active fault codes
on the instrument panel display.
2. Record the fault codes. When you’re finished,
turn the ignition OFF.
NOTE: ISO display codes may not be available on
vehicles built prior to January 2006.
앫 To view the fault codes again: Repeat
Step 1.
Inactive Fault Codes
NOTE: All inactive fault codes will steadily display
for approximately 1-1/2 seconds each. Ignore fault
codes that flash. When the TCU has listed all
active fault codes, the list will repeat.
Shifter
Analog Shifter
(Freightliner and
Sterling Vehicles
Only)
Inactive SAE
Display Codes
Inactive ISO Display
Codes
“With brake
pedal
depressed”
Neutral +
Manual + Up
“With brake pedal
depressed”
Neutral + Manual +
Down
Section 2
Fault Code Diagnostics
3. The TCU will begin to list the inactive fault
codes on the instrument panel display.
Active ISO Fault Codes
4. Record the fault codes. When you’re finished,
turn the ignition OFF.
NOTE: All active fault codes will steadily display
for approximately 1-1/2 seconds each. Ignore fault
codes that flash. When the TCU has listed all
active fault codes, the list will repeat.
앫 To view the fault codes again: Repeat
Step 1.
NOTE: ISO display codes may not be available on
vehicles built prior to January 2006.
How to Clear Inactive Fault Codes
from the Instrument Panel Display
Using a Steering Column-Mount
Shift Lever
1.
Turn the ignition OFF.
2. Select Neutral and manual mode on the shift
lever. Pull and hold the shift lever in the
UPSHIFT position.
3. Turn the ignition ON. Wait three seconds.
Release the shift lever. Wait three seconds.
4. Pull and hold the lever in the UPSHIFT
position.
Shift Lever Type
SAE J1939 Push-Button
(ITE Vehicles)
1.
앫 If the fault codes have not cleared: Repeat
this procedure.
How to Retrieve Active and Inactive
ISO Fault Codes from the
Instrument Panel Display Using
SAE J1939 Push-Button Shift Lever
Press and hold up-shift
button while lever is in
Neutral
The TCU will begin to list the active fault codes
on the instrument panel display.
2. Record the fault codes. When you’re finished,
turn the ignition OFF.
앫 To view the fault codes again: Repeat Step 1.
Inactive ISO Fault Codes
All active fault codes will steadily display for
approximately 1-1/2 seconds each. Ignore fault
codes that flash. When the TCU has listed all
active fault codes, the list will repeat.
5. Turn the ignition OFF. Wait three seconds.
Release the shift lever.
6. Check that the inactive fault codes have been
cleared from the instrument panel display.
Active ISO Display
Codes
Shift Lever Type
SAE J1939 Push-Button
(ITE Vehicles)
1.
Inactive ISO Display
Codes
With brake pedal depressed:
Press and hold up-shift
button while lever is in
Neutral
The TCU will begin to list the active fault codes
on the instrument panel display.
2. Record the fault codes. When you’re finished,
turn the ignition OFF.
앫 To view the fault codes again: Repeat Step 1.
NOTE: The vehicle must be stationary.
1.
Park the vehicle and set the parking brake.
Turn the engine OFF, but leave the ignition ON.
Prepare to record the fault codes before you
begin to retrieve them from the instrument
panel display.
2. Use the following procedures to retrieve active
and inactive ISO fault codes.
NOTE: This shift lever does not retrieve SAE fault
codes. ISO fault codes only.
How to Clear Inactive Fault Codes
from the Instrument Panel Display
Using SAE J1939 Push-Button Shift
Lever
1.
Turn the ignition “OFF”.
2. Wait until all shift lever LEDs are off.
3. Turn ignition “ON” (do not start engine).
4. Wait until only Neutral LED is lit.
5. Immediately press up-shift button.
6. Wait 3 seconds.
9
Section 2
Fault Code Diagnostics
7.
Release up-shift button.
8. Wait 3 seconds.
9. Press up-shift button.
10. Turn ignition “OFF”.
11. Wait until all shift lever LEDs are off.
12. Release up-shift button.
13. Check that the inactive fault codes have been
cleared from the instrument panel display.
앫 If the fault codes have not cleared: Repeat
this procedure.
10
Section 2
Fault Code Diagnostics
SAE Fault Code Repair Instructions
Repair Instructions
SAE J1587 Fault
Code
Fault FMI
PID/
SID
Instrument
Panel
Display
Fault Code
20
SID
14
3
Fault Description
Short circuit to positive of the
output ACC (power conversion
enable signal for ZMTEC and
continuation signal for voltage
doubler and voltage supply to
output speed sensor #2)
NOTE: The following repair instructions pertain
to active faults only. For information and
instructions about inactive faults, please
contact OnTrac at 866-668-7221 and request a
transmission specialist.
Complete the electrical requirements flowchart.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
20
5
SID
14
Open circuit of the output ACC
Complete the electrical requirements flowchart.
(power conversion enable signal for
Contact OnTrac at 866-668-7221 and request a
ZMTEC and continuation signal for
ZF-FreedomLine transmission specialist.
voltage doubler and voltage supply
to output speed sensor #2)
20
6
SID
14
Short circuit to ground of the output Complete the electrical requirements flowchart.
ACC (power conversion enable
Contact OnTrac at 866-668-7221 and request a
signal for ZMTEC and continuation
ZF-FreedomLine transmission specialist.
signal for voltage doubler and
voltage supply to output speed
sensor #2)
21
0
PID
15
ECU temperature too high
If an ISO fault code 128 exists, address it first.
Check for obstructions within the transmission cooler,
cooler lines and by-pass valve. Check the oil level.
Both low and high oil levels can lead to overheating.
21
2
PID
15
Error on ECU temperature sensor
signal
The upper part of the transmission TCU requires
replacement.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
31
3
PID
1F
Short circuit to positive of the range When submitting a warranty claim under standard
position sensor
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim. Out-of-warranty only and/or no warranty claim
submitted, replace the sensor or replace the lower part
of the TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
31
5
PID
1F
Open circuit of the range position
sensor
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim. Out-of-warranty only and/or no warranty claim
submitted, replace the sensor or replace the lower part
of the TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
31
6
PID
1F
Short circuit to ground of the range
position sensor
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim. Out-of-warranty only and/or no warranty claim
submitted, replace the sensor or replace the lower part
of the TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
11
Section 2
Fault Code Diagnostics
SAE Fault Code Repair Instructions
Repair Instructions
SAE J1587 Fault
Code
NOTE: The following repair instructions pertain
to active faults only. For information and
instructions about inactive faults, please
contact OnTrac at 866-668-7221 and request a
transmission specialist.
Fault FMI
PID/
SID
Instrument
Panel
Display
Fault Code
31
7
PID
1F
Range position sensor signal
disengages during driving
Using TransSoft, verify that the engagement position
sensor counts are outside of the nominal range: 80 to
120 or 530 to 580. The measured values should not drift
or show signal disturbances after engagement shifting.
Values outside range, exchange main transmission. If
error occurs sporadically: When submitting a warranty
claim under standard warranty conditions, the
complete TCU should be replaced and the entire unit
submitted with warranty claim. Out-of warranty,
replace the lower part of TCU. For assistance, contact
OnTrac at 866-668-7221 and ask for a transmission
specialist.
31
13
PID
1F
Self-adjustment fault of range
position sensor
If the TCU has not just been installed, complete the
pneumatic requirements flowchart.
Fault Description
If the TCU has just been installed, the range actuator
did not correctly engage into the rail. Using TransSoft,
verify that the range position sensor counts are outside
of the nominal range: 80 to 130 or 490 to 590. If so,
remove the TCU and reinstall it.
32
3
PID
20
Short circuit to positive of the
splitter position sensor signal
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim. Out-of-warranty only and/or no warranty claim
submitted, replace the sensor or replace the lower part
of the TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
32
5
PID
20
Open circuit of the splitter position
sensor signal
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim. Out-of-warranty only and/or no warranty claim
submitted, replace the sensor or replace the lower part
of the TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
32
6
PID
20
Short circuit to ground of the splitter When submitting a warranty claim under standard
position sensor signal
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim. Out-of-warranty only and/or no warranty claim
submitted, replace the sensor or replace the lower part
of the TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
32
7
PID
20
Splitter position sensor signal
leaves engaged position during
driving
Using TransSoft, verify that the splitter position sensor
counts are outside of the nominal range: 70 to 140 or
500 to 620. The measured values should not drift or
show signal disturbances after splitter shifting. Values
outside range, exchange main transmission. If error
occurs sporadically: When submitting a warranty claim
under standard warranty conditions, the complete TCU
should be replaced and the entire unit submitted with
warranty claim. Out-of-warranty only and/or no
warranty claim submitted, replace the lower part of
TCU.
For assistance, contact OnTrac at 866-668-7221 and ask
for a transmission specialist.
12
Section 2
Fault Code Diagnostics
SAE Fault Code Repair Instructions
Repair Instructions
SAE J1587 Fault
Code
Fault FMI
PID/
SID
Instrument
Panel
Display
Fault Code
32
PID
20
33
13
2
PID
21
Fault Description
NOTE: The following repair instructions pertain
to active faults only. For information and
instructions about inactive faults, please
contact OnTrac at 866-668-7221 and request a
transmission specialist.
Splitter position sensor
self-adjustment fault
If the TCU has not just been installed, complete the
pneumatic requirements flowchart.
NOTE: The gear engage position
sensor is unable to cycle.
If the TCU has just been installed, the splitter actuator
did not correctly engage into the rail. Using TransSoft,
verify that the splitter position sensor counts are
outside of the nominal range: 70 to 140 or 500 to 650.
If so, remove the TCU and reinstall it.
Error on clutch cylinder position
Verify that the release bearing is correctly engaged to
the clutch.
Complete the pneumatic requirements flowchart: Verify
air supply/air quality.
Using TransSoft, under the clutch info tab, verify clutch
absolute stroke: Engine must be running and
transmission in neutral: Absolute clutch stroke > 58-60
mm, replace clutch assembly: If absolute clutch stroke
is not between 27-60 mm, replace the clutch actuator: If
issue still not resolved, contact OnTrac at 866-668-7221
and request a ZF-FreedomLine transmission specialist.
33
13
PID
21
Error in clutch self-adjustment
process
33
14
PID
21
Clutch actuator position sensor
voltage supply too high or too low
If error occurs immediately after engine startup, then
check the clutch engagement hardware for issues such
as a broken fork, jammed release bearing, failed
NOTE: The clutch is unable to cycle.
release bearing, broken clutch retaining clip, possible
glazed clutch disc, jammed clutch actuator rod, etc.).
Address any issues as necessary. If nothing is found,
grease the interface between the fork and the release
bearing (this includes the tips of the forks as well as the
side walls of the release bearing). If clutch actuator
does not move when engine is started, replace clutch
actuator.
Unplug the clutch actuator connector at the TCU. Check
for 4.6 to 5.8 VDC between pins 15 and 16 of the TCU.
If the voltage level is within this range, replace the
clutch actuator; if the voltage level is outside of this
range, replace the upper part of the TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
34
3
PID
22
Short circuit to positive at output
stage to the clutch actuator
assembly solenoids
If possible, retrieve ISO fault code using TransSoft or if
applicable, perform procedure for retrieving fault codes
using the transmission shift lever. Follow the ISO fault
code repair instructions. Contact OnTrac at
866-668-7221 and request a ZF-FreedomLine
transmission specialist.
34
5
PID
22
Open circuit at output stage to the
clutch actuator assembly solenoids
If possible, retrieve ISO fault code using TransSoft or if
applicable, perform procedure for retrieving fault codes
using the transmission shift lever. Follow the ISO fault
code repair instructions. Contact OnTrac at 866-6687221 and request a ZF-FreedomLine transmission
specialist.
34
6
PID
22
Short circuit to ground at output
stage to the clutch actuator
assembly solenoids
If possible, retrieve ISO fault code using TransSoft or if
applicable, perform procedure for retrieving fault codes
using the transmission shift lever. Follow the ISO fault
code repair instructions. Contact OnTrac at
866-668-7221 and request a ZF-FreedomLine
transmission specialist.
13
Section 2
Fault Code Diagnostics
SAE Fault Code Repair Instructions
Repair Instructions
SAE J1587 Fault
Code
NOTE: The following repair instructions pertain
to active faults only. For information and
instructions about inactive faults, please
contact OnTrac at 866-668-7221 and request a
transmission specialist.
Fault FMI
PID/
SID
Instrument
Panel
Display
Fault Code
34
7
PID
22
Mechanical failure of the clutch
actuator assembly solenoids
35
3
SID
23
Short circuit to positive at the output When submitting a warranty claim under standard
stage to the high range solenoid
warranty conditions, the complete TCU should be
(Y9)
replaced and the entire unit submitted with warranty
claim. Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU. Contact OnTrac
at 866-668-7221 and request a ZF-FreedomLine
transmission specialist.
35
5
SID
23
Open circuit at the output stage to
the high range solenoid (Y9)
35
6
SID
23
Short circuit to ground at the output When submitting a warranty claim under
stage to the high range solenoid
standard warranty conditions, the complete TCU
(Y9)
should be replaced and the entire unit submitted
with warranty claim. Out-of-warranty only
and/or no warranty claim submitted, replace
lower part of TCU. Contact OnTrac at
866-668-7221 and request a ZF-FreedomLine
transmission specialist.
36
3
SID
24
Short circuit to positive at the output When submitting a warranty claim under
stage to the low range solenoid (Y8) standard warranty conditions, the complete TCU
should be replaced and the entire unit submitted
with warranty claim. Out-of-warranty only
and/or no warranty claim submitted, replace
lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
36
5
SID
24
Open circuit at the output stage to
the low range solenoid (Y8)
36
6
SID
24
Short circuit to ground at the output When submitting a warranty claim under
stage to the low range solenoid
standard warranty conditions, the complete TCU
(Y8)
should be replaced and the entire unit submitted
with warranty claim. Out-of-warranty only
and/or no warranty claim submitted, replace
lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
14
Fault Description
If possible, retrieve ISO fault code using TransSoft or if
applicable, perform procedure for retrieving fault codes
using the transmission shift lever. Follow the ISO fault
code repair instructions. Contact OnTrac at
866-668-7221 and request a ZF-FreedomLine
transmission specialist.
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim. Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU. Contact OnTrac
at 866-668-7221 and request a ZF-FreedomLine
transmission specialist.
When submitting a warranty claim under
standard warranty conditions, the complete TCU
should be replaced and the entire unit submitted
with warranty claim. Out-of-warranty only
and/or no warranty claim submitted, replace
lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
Section 2
Fault Code Diagnostics
SAE Fault Code Repair Instructions
Repair Instructions
SAE J1587 Fault
Code
NOTE: The following repair instructions pertain
to active faults only. For information and
instructions about inactive faults, please
contact OnTrac at 866-668-7221 and request a
transmission specialist.
Fault FMI
PID/
SID
Instrument
Panel
Display
Fault Code
37
3
SID
25
Short circuit to positive at the output When submitting a warranty claim under
stage to the splitter direct solenoid
standard warranty conditions, the complete TCU
(Y2)
should be replaced and the entire unit submitted
with warranty claim. Out-of-warranty only
and/or no warranty claim submitted, replace
lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
37
5
SID
25
Open circuit at the output stage to
the splitter direct solenoid (Y2)
37
6
SID
25
Short circuit to ground at the output When submitting a warranty claim under
stage to the splitter direct solenoid
standard warranty conditions, the complete TCU
(Y2)
should be replaced and the entire unit submitted
with warranty claim. Out-of-warranty only
and/or no warranty claim submitted, replace
lower part of TCU.
Fault Description
When submitting a warranty claim under
standard warranty conditions, the complete TCU
should be replaced and the entire unit submitted
with warranty claim. Out-of-warranty only
and/or no warranty claim submitted, replace
lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
38
3
SID
26
Short circuit to positive at the output When submitting a warranty claim under
stage to the splitter indirect solenoid standard warranty conditions, the complete TCU
(Y3)
should be replaced and the entire unit submitted
with warranty claim. Out-of-warranty only
and/or no warranty claim submitted, replace
lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
38
5
SID
26
Open circuit at the output stage to
the splitter indirect solenoid (Y3)
38
6
SID
26
Short circuit to ground at the output When submitting a warranty claim under
stage to the splitter indirect solenoid standard warranty conditions, the complete TCU
(Y3)
should be replaced and the entire unit submitted
with warranty claim. Out-of-warranty only
and/or no warranty claim submitted, replace
lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
39
3
SID
27
Short circuit to positive at the output When submitting a warranty claim under
stage to the rail select #1 solenoid
standard warranty conditions, the complete TCU
(Y4)
should be replaced and the entire unit submitted
with warranty claim. Out-of-warranty only
and/or no warranty claim submitted, replace
lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
When submitting a warranty claim under
standard warranty conditions, the complete TCU
should be replaced and the entire unit submitted
with warranty claim. Out-of-warranty only
and/or no warranty claim submitted, replace
lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
15
Section 2
Fault Code Diagnostics
SAE Fault Code Repair Instructions
Repair Instructions
SAE J1587 Fault
Code
NOTE: The following repair instructions pertain
to active faults only. For information and
instructions about inactive faults, please
contact OnTrac at 866-668-7221 and request a
transmission specialist.
Fault FMI
PID/
SID
Instrument
Panel
Display
Fault Code
39
5
SID
27
Open circuit at the output stage to
the rail select #1 solenoid (Y4)
39
6
SID
27
Short circuit to ground at the output When submitting a warranty claim under
stage to the rail select #1 solenoid
standard warranty conditions, the complete TCU
(Y4)
should be replaced and the entire unit submitted
with warranty claim. Out-of-warranty only
and/or no warranty claim submitted, replace
lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
40
3
SID
28
Short circuit to positive at the output When submitting a warranty claim under
stage to the gear engage #1
standard warranty conditions, the complete TCU
solenoid (Y6)
should be replaced and the entire unit submitted
with warranty claim. Out-of-warranty only
and/or no warranty claim submitted, replace
lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
40
5
SID
28
Open circuit at the output stage to
the gear engage #1 solenoid (Y6)
40
6
SID
28
Short circuit to ground at the output When submitting a warranty claim under
stage to the gear engage #1
standard warranty conditions, the complete TCU
solenoid (Y6)
should be replaced and the entire unit submitted
with warranty claim. Out-of-warranty only
and/or no warranty claim submitted, replace
lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
43
2
PID
2B
Error on “Ignition lock” signal
(terminal 15)
Fault Description
When submitting a warranty claim under
standard warranty conditions, the complete TCU
should be replaced and the entire unit submitted
with warranty claim. Out-of-warranty only
and/or no warranty claim submitted, replace
lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
When submitting a warranty claim under
standard warranty conditions, the complete TCU
should be replaced and the entire unit submitted
with warranty claim. Out-of-warranty only
and/or no warranty claim submitted, replace
lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
Verify voltage at pin 6/7 of the doubler.
Key on voltage should be 24 volts nominal. If
< 18 volts, replace the transmission voltage
doubler.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
48
16
3
SID
30
Short circuit to positive of the gear
engage position sensor signal
When submitting a warranty claim under
standard warranty conditions, the complete TCU
should be replaced and the entire unit submitted
with warranty claim. Out-of-warranty only
and/or no warranty claim submitted, replace the
sensor or replace the lower part of the TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
Section 2
Fault Code Diagnostics
SAE Fault Code Repair Instructions
Repair Instructions
SAE J1587 Fault
Code
NOTE: The following repair instructions pertain
to active faults only. For information and
instructions about inactive faults, please
contact OnTrac at 866-668-7221 and request a
transmission specialist.
Fault FMI
PID/
SID
Instrument
Panel
Display
Fault Code
48
5
SID
30
Open circuit of the gear engage
position sensor signal
When submitting a warranty claim under
standard warranty conditions, the complete TCU
should be replaced and the entire unit submitted
with warranty claim. Out-of-warranty only
and/or no warranty claim submitted, replace the
sensor or replace the lower part of the TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
48
6
SID
30
Short circuit to ground of the gear
engage position sensor signal
When submitting a warranty claim under
standard warranty conditions, the complete TCU
should be replaced and the entire unit submitted
with warranty claim. Out-of-warranty only
and/or no warranty claim submitted, replace the
sensor or replace the lower part of the TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
48
7
SID
30
Gear engage position sensor signal
leaves engaged position during
driving
Using TransSoft, verify that the engagement
position sensor counts are outside of the
nominal range: 80 to 120 or 530 to 580. The
measured values should not drift or show signal
disturbances after engagement shifting. Values
outside range, exchange main transmission. If
error occurs sporadically: When submitting a
warranty claim under standard warranty
conditions, the complete TCU should be
replaced and the entire unit submitted with
warranty claim. Out-of-warranty only and/or no
warranty claim submitted, replace the lower part
of TCU. For assistance, contact OnTrac at
866-668-7221 and ask for a transmission
specialist.
48
13
SID
30
Self adjustment error of gear
engage position sensor
If the TCU has not just been installed, complete
the pneumatic requirements flowchart. When
submitting a warranty claim under standard
warranty conditions, the complete TCU should
be replaced and the entire unit submitted with
warranty claim.
Fault Description
NOTE: The gear engage position
sensor is unable to cycle.
Out-of-warranty only and/or no warranty claim
submitted, replace the sensor or replace the
lower part of the TCU.
If the TCU has just been installed, the
engagement actuator did not correctly engage
into the rail. Using TransSoft, verify that the
engagement position sensor counts are outside
of the nominal range: 300 to 350.
If so, remove the TCU and reinstall it.
50
3
SID
32
Short circuit to positive at the output When submitting a warranty claim under
stage to the rail select #2 solenoid
standard warranty conditions, the complete TCU
(Y5)
should be replaced and the entire unit submitted
with warranty claim. Out-of-warranty only
and/or no warranty claim submitted, replace
lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
17
Section 2
Fault Code Diagnostics
SAE Fault Code Repair Instructions
Repair Instructions
SAE J1587 Fault
Code
NOTE: The following repair instructions pertain
to active faults only. For information and
instructions about inactive faults, please
contact OnTrac at 866-668-7221 and request a
transmission specialist.
Fault FMI
PID/
SID
Instrument
Panel
Display
Fault Code
50
5
SID
32
Open circuit at the output stage to
the rail select #2 solenoid (Y5)
50
6
SID
32
Short circuit to ground at the output When submitting a warranty claim under
stage to the rail select #2 solenoid
standard warranty conditions, the complete TCU
(Y5)
should be replaced and the entire unit submitted
with warranty claim. Out-of-warranty only
and/or no warranty claim submitted, replace
lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
51
3
SID
33
Short circuit to positive at the output When submitting a warranty claim under
stage to the gear engage #2
standard warranty conditions, the complete TCU
solenoid (Y7)
should be replaced and the entire unit submitted
with warranty claim. Out-of-warranty only
and/or no warranty claim submitted, replace
lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
51
5
SID
33
Open circuit at the output stage to
the gear engage #2 solenoid (Y7)
51
6
SID
33
Short circuit to ground at the output When submitting a warranty claim under standard
stage to the gear engage #2
warranty conditions, the complete TCU should be
solenoid (Y7)
replaced and the entire unit submitted with warranty
claim. Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
54
3
SID
36
Short circuit to positive at the output When submitting a warranty claim under standard
stage to the inertia brake solenoid
warranty conditions, the complete TCU should be
(Y1)
replaced and the entire unit submitted with warranty
claim. Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
54
5
SID
36
Open circuit at the output stage to
the inertia brake solenoid (Y1)
18
Fault Description
When submitting a warranty claim under
standard warranty conditions, the complete TCU
should be replaced and the entire unit submitted
with warranty claim. Out-of-warranty only
and/or no warranty claim submitted, replace
lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
When submitting a warranty claim under
standard warranty conditions, the complete TCU
should be replaced and the entire unit submitted
with warranty claim. Out-of-warranty only
and/or no warranty claim submitted, replace
lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim. Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
Section 2
Fault Code Diagnostics
SAE Fault Code Repair Instructions
Repair Instructions
SAE J1587 Fault
Code
NOTE: The following repair instructions pertain
to active faults only. For information and
instructions about inactive faults, please
contact OnTrac at 866-668-7221 and request a
transmission specialist.
Fault FMI
PID/
SID
Instrument
Panel
Display
Fault Code
54
6
SID
36
Short circuit to ground at the output When submitting a warranty claim under standard
stage to the inertia brake solenoid
warranty conditions, the complete TCU should be
(Y1)
replaced and the entire unit submitted with warranty
claim. Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
55
7
SID
37
Clutch engagement/disengagement
fault
Fault Description
Complete the pneumatic requirements flowchart.
Verify air supply/air quality.
Remove and inspect clutch actuator filter screen for
contamination.
If the root cause of the issue is not found, then check
the clutch engagement hardware for issues such as a
broken fork, jammed release bearing, failed release
bearing, broken clutch retaining clip, possible glazed
clutch disc, jammed clutch actuator rod, etc. Address
any issues as necessary. If the root cause is not
identified, then obtain the ISO fault codes and address
the appropriate repair instructions. If clutch actuator
does not move when engine is started, replace clutch
actuator.
56
57
7
2
SID
SID
38
39
Range shift engagement/
disengagement fault
Complete the pneumatic requirements flowchart.
Shift lever error
First check all wiring harness connections between the
shift lever and the ZMTEC and the ZMTEC and the GS3.
If they look good (no damaged pins, correctly set
home, etc.), then do the following.
ZF-FreedomLine shifter
Analog shift lever (Freightliner and
Sterling vehicles only)
SAE J1939 push-button shift lever
(ITE vehicles) fault description for
SAE J1939 shift lever
Error on “CAN TC1” message
“Requested Gear”
The range actuator did not correctly engage into the
rail. Using TransSoft, verify that the range position
sensor counts are outside of the normal range: 80 to
130 or 490 to 590. The measured values should not drift
or show signal disturbances after range shifting. Values
outside range, exchange main transmission. If error
occurs sporadically: When submitting a warranty claim
under standard warranty conditions, the complete TCU
should be replaced and the entire unit submitted with
warranty claim. Out-of-warranty only and/or no
warranty claim submitted, replace the lower part of
TCU. For assistance, contact OnTrac at 866-668-7221
and ask for a transmission specialist.
Check for continuity (0.0 to 0.5 ohms) between pins 1
and 8 of the shift lever harness connector (J10) and
pin G3 of the ZMTEC connector (J3). Check for
continuity between pin 3 of the shift lever harness
connector (J10) and ground. Check for continuity
between pin 7 of the shift lever harness connector (J10)
and pin F1 of the ZMTEC connector (J3). Check for
continuity between pin 9 of the shift lever harness
connector (J10) and pin E3 of the ZMTEC connector
(J3). Also check for shorts between these circuits and
all other pins in the wiring harness. If these resistances
check out okay and no short circuits exist, replace the
shift lever assembly. For diagnostic procedures
concerning the Freightliner SmartShift lever and the
push-button shift lever for International trucks, contact
the applicable OEM. For assistance, contact OnTrac at
866-668-7221 and request a ZF-FreedomLine
transmission specialist.
19
Section 2
Fault Code Diagnostics
SAE Fault Code Repair Instructions
Repair Instructions
SAE J1587 Fault
Code
Fault FMI
PID/
SID
Instrument
Panel
Display
Fault Code
57
SID
39
14
Fault Description
ZF CAN timeout
NOTE: The following repair instructions pertain
to active faults only. For information and
instructions about inactive faults, please
contact OnTrac at 866-668-7221 and request a
transmission specialist.
Unplug the ZMTEC only and check for 58.0 to
62.0 ohms resistance across pins D1 and D2 of the
ZMTEC connector (J3). Now remove the transmission
wiring harness and check for continuity (0.0 to 0.5
ohms) between pin 3 of the TCU connector (J1), pin D1
of the ZMTEC connector (J3), and pin A of the CAN
terminator connector (J8). Check for continuity
between pin 6 of the TCU connector (J1), pin D2 of the
ZMTEC connector (J3), and pin B of the CAN
terminator connector (J8).
If any of these tests reveal issues with the wiring
harness, replace the wiring harness. If these
resistances check out okay and no short circuits exist,
contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
58
7
SID
3A
Main transmission engagement/
disengagement fault
Complete the pneumatic requirements flowchart:
The engagement actuator did not correctly disengage
from the rail. Using TransSoft, verify that the
engagement position sensor counts are outside of the
nominal range: 80 to 120 or 530 to 580.
The measured values should not drift or show signal
disturbances after engagement shifting. Values outside
range, exchange main transmission. If error occurs
sporadically: When submitting a warranty claim under
standard warranty conditions, the complete TCU should
be replaced and the entire unit submitted with warranty
claim. Out-of-warranty only and/or no warranty claim
submitted, replace the lower part of TCU.
For assistance, contact OnTrac at 866-668-7221 and ask
for a transmission specialist.
59
7
SID
3B
Rail select cylinder engagement/
disengagement fault
Complete the pneumatic requirements flowchart:
The select cylinder does not change over to new gatel.
Using TransSoft, verify that the select position sensor
counts are outside of the nominal range: 70 to 120 or
500 to 580. The measured values should not drift or
show signal disturbances after rail select shifting.
Values outside range, exchange main transmission. If
error occurs sporadically: When submitting a warranty
claim under standard warranty conditions, the
complete TCU should be replaced and the entire unit
submitted with warranty claim. Out-of-warranty only
and/or no warranty claim submitted, replace the lower
part of TCU.
For assistance, contact OnTrac at 866-668-7221 and ask
for a transmission specialist.
60
3
PID
3C
Short circuit to positive of the rail
select position sensor
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace the sensor or replace the lower part
of the TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
20
Section 2
Fault Code Diagnostics
SAE Fault Code Repair Instructions
Repair Instructions
SAE J1587 Fault
Code
Fault FMI
PID/
SID
Instrument
Panel
Display
Fault Code
60
PID
3C
5
Fault Description
Open circuit of the rail select
position sensor
NOTE: The following repair instructions pertain
to active faults only. For information and
instructions about inactive faults, please
contact OnTrac at 866-668-7221 and request a
transmission specialist.
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace the sensor or replace the lower part
of the TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
60
6
PID
3C
Short circuit to ground of the rail
select position sensor
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace the sensor or replace the lower part
of the TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
60
13
PID
3C
Gate select sensor self-adjustment
error
If the TCU has not just been installed, complete the
pneumatic requirements flowchart.
If the TCU has just been installed, the gate selector
actuator did not correctly engage into the rail. Using
TransSoft, verify that the gate selector position sensor
counts are outside of the nominal range: 70 to 120 to
120 or 500 to 580. If so, remove the TCU and reinstall it.
61
7
SID
3D
Splitter cylinder engagement/
disengagement fault
Complete the pneumatic requirements flowchart:
The splitter group does not changeover to new position
in defined time. Using TransSoft, verify that the splitter
position sensor counts are outside of the nominal
range: 70 to 140 or 500 to 620.
The measured values should not drift or show signal
disturbances after splitter shifting. Values outside
range, exchange main transmission. If error occurs
sporadically: When submitting a warranty claim under
standard warranty conditions, the complete TCU
should be replaced and the entire unit submitted with
warranty claim. Out-of-warranty only and/or no
warranty claim submitted, replace the lower part of
TCU.
For assistance, contact OnTrac at 866-668-7221 and ask
for a transmission specialist.
21
Section 2
Fault Code Diagnostics
SAE Fault Code Repair Instructions
Repair Instructions
SAE J1587 Fault
Code
Fault FMI
PID/
SID
Instrument
Panel
Display
Fault Code
63
SID
3F
14
Fault Description
NOTE: The following repair instructions pertain
to active faults only. For information and
instructions about inactive faults, please
contact OnTrac at 866-668-7221 and request a
transmission specialist.
Error on output shaft speed
sensor #2 (the lower one)
Clear the faults first and switch the OSS #1 and OSS #2
connectors. Test drive the vehicle so that an OSS code
NOTE: Output shaft speed sensor #2 is set. If the code stays with the same speed sensor
(#1 or #2), then replace the appropriate wiring harness
is a four wiring harness that plugs
into the transmission wiring harness (either the transmission wiring harness or the clutch
actuator wiring harness which is integrated into the
(the same one that is connected
to the voltage doubler and ZMTEC). clutch actuator). If the code switches to the other speed
sensor (from #1 to #2 or from #2 to #1), replace the
It is protected with convoluted
appropriate speed sensor. If these steps don’t identify
tubing. Automatic mode is
the inoperative component, move onto the next set of
available, there are no system
instructions.
restrictions.
Remove and troubleshoot the transmission wiring
harness. Pin 7 of the TCU connector (J1) and pin 3 of
the output shaft speed sensor #2 connector (J5) should
have continuity (resistance of 0.0 to 0.5 ohms) and not
be shorted to any other circuit. If a short or open circuit
is found, replace the wiring harness. If not, replace the
output shaft speed sensor.
106
106
0
14
PID
PID
6A
6A
Faulty transmission air pressure
regulator valve
Complete the pneumatic requirements flowchart.
Error on pressure sensor signal
(TCU internal)
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
If the root cause is not found, use TransSoft to verify
that the transmission’s pressure reduction valve is
regulating the air pressure to 102.5 ± 4 psi. Replace the
air pressure regulator as necessary.
Out-of-warranty only and/or no warranty claim
submitted, replace the pressure sensor.
150
7
SID
96
Engagement/disengagement fault
Complete the PTO requirements flowchart.
of PTO 1 and/or PTO 2 (The
If necessary, contact OnTrac at 866-668-7221 and
transmission TCU has requested
request a ZF-FreedomLine transmission specialist.
that the PTO turn on or off and it has
not)
150
14
SID
96
PTO 1 and/or PTO 2 fault
acknowledgement (The PTO is
active but the transmission hasn’t
requested it)
Complete the PTO requirements flowchart.
Using TransSoft, check the main TCU for programming
mistakes (the programming is gear-dependent and
must reflect the actual transmission model). For
assistance, contact OnTrac at 866-668-7221 and request
a ZF-FreedomLine transmission specialist. If the
programming is incorrect, an OnTrac representative
will assist you.
If necessary, contact OnTrac at 866-668-7221 and
request a ZF-FreedomLine transmission specialist.
151
14
SID
97
Plausibility error between
transmission input speed and
output speed (The actual speeds
registered by the input shaft and
output shaft speed sensors do not
match the expected ratios)
152
3
SID
98
Short circuit to positive at the output When submitting a warranty claim under standard
stage to the main solenoid (Y1)
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
22
Section 2
Fault Code Diagnostics
SAE Fault Code Repair Instructions
Repair Instructions
SAE J1587 Fault
Code
Fault FMI
PID/
SID
Instrument
Panel
Display
Fault Code
152
SID
98
5
Fault Description
Open circuit at the output stage to
the main solenoid (Y1)
NOTE: The following repair instructions pertain
to active faults only. For information and
instructions about inactive faults, please
contact OnTrac at 866-668-7221 and request a
transmission specialist.
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
152
6
SID
98
Short circuit to ground at the output When submitting a warranty claim under standard
stage to the main solenoid (Y1)
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
153
14
SID
99
Error on ISO 14230 communications Remove and troubleshoot the transmission wiring
line
harness. Pin 2 of the TCU connector (J1) and pin F3
of the ZMTEC connector (J3) should have continuity
(resistance of 0.0 to 0.5 ohms) and not be shorted to
any other circuit. If a short or open circuit is found,
replace the wiring harness; if not, replace the ZMTEC.
154
14
SID
9A
Error on both output speed signals
Inspect the output shaft speed sensors and
corresponding wiring harnesses for obvious signs of
damage including corrosion within the connectors.
If nothing is found, contact OnTrac at 866-668-7221 and
request a ZF-FreedomLine transmission specialist.
161
14
PID
A1
Input shaft speed sensor fault
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
177
2
PID
B1
Oil temperature sensor fault
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
23
Section 2
Fault Code Diagnostics
SAE Fault Code Repair Instructions
Repair Instructions
SAE J1587 Fault
Code
Fault FMI
PID/
SID
Instrument
Panel
Display
Fault Code
191
PID
BF
14
Fault Description
NOTE: The following repair instructions pertain
to active faults only. For information and
instructions about inactive faults, please
contact OnTrac at 866-668-7221 and request a
transmission specialist.
Output shaft speed sensor #1 faulty It is highly recommended that the ISO fault codes be
or both sources of vehicle speed are retrieved and used for troubleshooting instead of SAE
inoperative.
code PID 191 FMI 14. If the ISO fault codes are not
NOTE: Output shaft speed sensor #1 available, then proceed as follows.
is a three wire sensor that plugs into Check the ABS, engine and VECU (if applicable) for
the clutch actuator wiring harness.
fault codes that pertain to the SAE J1939 data bus.
It does not have convoluted tubing. If none are found, then proceed to the next step.
Clear the faults first and switch the OSS #1 and OSS #2
connectors. Test drive the vehicle such that an OSS
code is set. If the code stays with the same speed
sensor (#1 or #2) then replace the appropriate wiring
harness (either the transmission wiring harness or the
clutch actuator). If the code switches to the other speed
sensor (from #1 to #2 or from #2 to #1), replace the
appropriate speed sensor. If these steps don’t identify
the faulty component, then do the following.
Remove and troubleshoot the clutch actuator wiring
harness. Pin 11 of the driver side TCU connector and pin
4 of the lower output shaft speed sensor connector
(sensor #1) should have continuity (resistance of 0.0 to
0.5 ohms) and not be shorted to any other circuit. If a
short or open circuit is found, replace the clutch
actuator, if not, replace the output shaft speed sensor #1.
230
14
SID
E6
Permanent idle signal
NOTE: The idle switch is built into
the accelerator pedal and is
d into the engine controller, not the
transmission controller, or main
TCU. The main TCU receives the
status of the idle switch over the
SAE J1939 bus. The transmission is
receiving contradictory messages
indicating that the idle switch is
open (truck is idling) and the
accelerator pedal is pressed (truck is
not idling).
231
7
SID
E7
Engine does not react to torque
intervention
Using TransSoft, troubleshoot the idle switch and the
status of the pedal. Refer to the OEM for details should
repair work be necessary.
The ECM did not react correctly to an SAE J1939
message. Follow your OEM’s SAE J1939 diagnostic
procedures to correct for a fault SAE J1939 data link.
Check for engine codes that would cause the engine to
go into derate mode.
(Fuel restriction, air restriction, high temp, low coolant
etc.)
231
11
SID
E7
The SAE J1939 bus is not
functioning correctly.
Can error frames or can queue
overrun.
NOTE: The backbone of the SAE
J1939 bus is terminated at each end
with a 120 ohm resistor. Each
component communicating over the
bus must connect into the
backbone.
24
Due to an issue with the vehicle’s SAE J1939 data link,
the TCU did not receive an expected SAE J1939
message. Follow your OEM’s SAE J1939 diagnostic
procedures to correct the issue.
NOTE: The resistance across pins C and D of the
9 pin diagnostic connector will be about 60 ohms if
both terminating resistors are in place (120 ohms if
only one is installed).
Section 2
Fault Code Diagnostics
SAE Fault Code Repair Instructions
Repair Instructions
SAE J1587 Fault
Code
Fault FMI
PID/
SID
Instrument
Panel
Display
Fault Code
231
SID
E7
14
Fault Description
The main TCU has not received
expected SAE J1939
communications
From the engine ECM, body
controller, or ABS ECU. This fault
can occur when the message is
faulty or missing.
NOTE: The following repair instructions pertain
to active faults only. For information and
instructions about inactive faults, please
contact OnTrac at 866-668-7221 and request a
transmission specialist.
Either there is an issue with the vehicle’s SAE J1939
data link causing the TCU not to receive an expected
SAE J1939 message or the TCU has received an SAE
J1939 message with information that is not within
specifications. Verify that the engine and ABS systems
are approved with the ZF-FreedomLine transmission
and that all settings are correct. If so, follow your
OEM’s SAE J1939 diagnostic procedures to correct
the issue.
248
3
SID
F8
Short circuit to positive at output SD Troubleshoot the ZF-FreedomLine transmission wiring
to display (The display will read
harness. Pin 9 of the TCU connector (J1) and pin F2 of
“EE”)
the ZMTEC connector (J3) should all have continuity
(resistance of 0.0 to 0.5 ohms) and not be shorted to
any other circuit. If a short or open circuit is found,
replace the wiring harness. If not, replace the ZMTEC.
248
6
SID
F8
Short circuit to ground at output SD Troubleshoot the ZF-FreedomLine transmission wiring
to display (The display will read
harness. Pin 9 of the TCU connector (J1) and pin F2 of
“EE”)
the ZMTEC connector (J3) should all have continuity
(resistance of 0.0 to 0.5 ohms) and not be shorted to
any other circuit. If a short or open circuit is found,
replace the wiring harness. If not replace the ZMTEC.
Should the ZMTEC not, resolve the issue, then replace
the TCU top half.
251
0
SID
FB
High voltage (voltage doubler 24
volt output too high)
The transmission voltage doubler requires
replacement.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
251
1
SID
FB
Low voltage (vehicle electrical
system or voltage doubler output
too low).
If no issues are found with the
vehicle electrical system, verify all
inputs and outputs at the
transmission voltage doubler.
253
14
SID
FD
EOL EEPROM fault
Complete the electrical requirements flowchart.
If no issues are found with the vehicle electrical
system, verify all inputs and outputs at the
transmission voltage doubler.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
If the transmission has just been programmed, cycle
the key (remain in the off position for 10 seconds)
If the transmission has not just been programmed,
then the EOL parameters need to be updated. This
can be accomplished with TransSoft. Contact OnTrac at
866-668-7221 and request a ZF-FreedomLine
transmission specialist.
Should the EOL parameter values check out, and the
code not clear, replace the upper part of the
transmission TCU.
254
12
SID
FE
Cut-off relay in ECU does not switch The transmission TCU top half requires replacement.
off
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
254
13
SID
FE
No voltage supply at pin 30 or
cut-off relay in ECU does not
switch on
The transmission TCU top half requires replacement.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
25
Section 2
Fault Code Diagnostics
SAE Fault Code Repair Instructions
Repair Instructions
SAE J1587 Fault
Code
Fault FMI
PID/
SID
Instrument
Panel
Display
Fault Code
254
SID
FE
14
Fault Description
Main TCU fault
NOTE: The following repair instructions pertain
to active faults only. For information and
instructions about inactive faults, please
contact OnTrac at 866-668-7221 and request a
transmission specialist.
If issue occurs during transmission software upgrade,
the TCU is incompatible with the level of software.
Replace the upper part of the transmission TCU.
Cycling the key off and then back on too quickly can
cause this fault to log active
Ensure that the key is left in the off position at least
5 seconds before turning it back on. If this does not
resolve the issue, complete the electrical requirements
flowchart
If no issues are found, replace the upper part of the
transmission TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
255
11
SID
FF
ZMTEC does not recognize the ISO
Troubleshoot the ZF Freedomline transmission
harness.
Check for open circuit between pin-2 of the TCU
connector (J1) vehicle side and pin F3 of the ZMTEC
connector (J3).
Replace ZMTEC if no open circuit detected.
26
Section 2
Fault Code Diagnostics
ISO Fault Code Diagnostics
NOTE: ISO display codes may not be available on vehicles built prior to January 2006.
Repair Instructions
ISO Display
ISO Fault Fault Codes
Identifier (J587 Display)
2
2
Fault Description
Short circuit to ground at the output
stage to the splitter direct solenoid (Y2)
NOTE: The following repair instructions pertain to
active faults only. For information and instructions
about inactive faults, please contact OnTrac at
866-668-7221 and request a transmission
specialist.
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
3
3
Short circuit to ground at the output
When submitting a warranty claim under standard
stage to the splitter indirect solenoid (Y3) warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
4
4
Short circuit to ground at the output
stage to the rail select #1 solenoid (Y4)
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
5
5
Short circuit to ground at the output
stage to the rail select #2 solenoid (Y5)
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
6
6
Short circuit to ground at the output
stage to the gear engage #1 solenoid
(Y6)
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
7
7
Short circuit to ground at the output
stage to the gear engage #2 solenoid
(Y7)
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
27
Section 2
Fault Code Diagnostics
ISO Fault Code Diagnostics
NOTE: ISO display codes may not be available on vehicles built prior to January 2006.
Repair Instructions
ISO Display
ISO Fault Fault Codes
Identifier (J587 Display)
8
8
Fault Description
Short circuit to ground at the output
stage to the low range solenoid (Y8)
NOTE: The following repair instructions pertain to
active faults only. For information and instructions
about inactive faults, please contact OnTrac at
866-668-7221 and request a transmission
specialist.
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
9
9
Short circuit to ground at the output
stage to the high range solenoid (Y9)
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
10
A
Short circuit to ground at the output
stage to the main solenoid (Y1)
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
17
11
Short circuit to ground at the output
stage to the inertia brake solenoid (Y1)
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
18
12
Short circuit to ground at the output
stage to slow disengagement clutch
valve
Measure the resistance between pin 9 and pin 16 of
clutch actuator connector.
Nominal value should be 14-16 ohms.
If resistance is < 14 ohms, exchange clutch actuator.
If resistance is within correct range, exchange TCU top
assembly.
19
13
Short circuit to ground at the output
stage to slow engagement clutch valve
Measure the resistance between pin 7 and pin 16 of
clutch actuator connector.
Nominal value should be 14-16 ohms.
If resistance is < 14 ohms, exchange clutch actuator.
If resistance is within correct range, exchange TCU top
assembly.
20
14
Short circuit to ground at the output
Measure the resistance between pin 12 and pin 17 of
stage to fast disengagement clutch valve clutch actuator connector.
Nominal value should be 14-16 ohms.
If resistance is < 14 ohms, exchange clutch actuator.
If resistance is within correct range, exchange TCU top
assembly.
28
Section 2
Fault Code Diagnostics
ISO Fault Code Diagnostics
NOTE: ISO display codes may not be available on vehicles built prior to January 2006.
Repair Instructions
ISO Display
ISO Fault Fault Codes
Identifier (J587 Display)
21
15
Fault Description
NOTE: The following repair instructions pertain to
active faults only. For information and instructions
about inactive faults, please contact OnTrac at
866-668-7221 and request a transmission
specialist.
Short circuit to ground at the output
stage to fast engagement clutch valve
Measure the resistance between pin 8 and pin 17 of
clutch actuator connector.
Nominal value should be 14-16 ohms.
If resistance is < 14 ohms, exchange clutch actuator.
If resistance is within correct range, exchange TCU top
assembly.
22
25
16
19
Short circuit to ground at the output ACC
(power conversion enable signal for
ZMTEC and continuation signal voltage
doubler and voltage supply to output
speed sensor #2)
Complete the electrical requirements flowchart.
Short circuit to ground at output SD to
display
Troubleshoot the ZF-FreedomLine transmission wiring
harness. Pin 9 of the TCU connector (J1) and pin F2 of
the ZMTEC connector (J3) should all have continuity
(resistance of 0.0 to 0.5 ohms) and not be shorted to any
other circuit. If a short or open circuit is found, replace
the wiring harness. If not, replace the ZMTEC. Should
the ZMTEC not resolve the issue, then replace the TCU
top half.
NOTE: The display will read “EE.”
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
26
1A
The main TCU has not received expected
communications from the engine (CAN
engine configuration timeout)
Due to an issue with the vehicle’s SAE J1939 data link,
the TCU did not receive an expected SAE J1939
message. Follow your OEM’s SAE J1939 diagnostic
procedures to correct the issue.
27
1B
The main TCU has not received expected
communications from the engine (error
on engine configuration message
(engine configuration))
The TCU received the SAE J1939 message from the
ECM, but the information within the message was not
within specifications. Verify that the ECM software level
is approved with the ZF-FreedomLine transmission and
that all settings are correct.
If necessary, contact OnTrac at 866-668-7221 and request
a ZF-FreedomLine transmission specialist.
31
1F
The main TCU has not received expected
communications from the engine (error
on actual engine retarder-percent torque
message ERC1_ER)
The TCU received the SAE J1939 message from the
engine retarder, but the information within the message
was not within specifications. Verify that the ECM
software level is approved with the ZF-FreedomLine
transmission and that all settings are correct.
If necessary, contact OnTrac at 866-668-7221 and request
a ZF-FreedomLine transmission specialist.
32
20
The main TCU has not received expected
communications from the engine (error
on engine retarder configuration
message (engine retarder configuration))
The TCU received the SAE J1939 message from the
engine retarder, but the information within the message
was not within specifications. Verify that the ECM
software level is approved with the ZF-FreedomLine
transmission and that all settings are correct.
If necessary, contact OnTrac at 866-668-7221 and request
a ZF-FreedomLine transmission specialist.
33
21
The main TCU has not received expected
communications from the engine (CAN
engine retarder configuration timeout)
Due to an issue with the vehicle’s SAE J1939 data link,
the TCU did not receive an expected SAE J1939
message. Follow your OEM’s SAE J1939 diagnostic
procedures to correct the issue.
29
Section 2
Fault Code Diagnostics
ISO Fault Code Diagnostics
NOTE: ISO display codes may not be available on vehicles built prior to January 2006.
Repair Instructions
ISO Display
ISO Fault Fault Codes
Identifier (J587 Display)
34
22
Fault Description
Open circuit at the output stage to the
splitter direct solenoid (Y2)
NOTE: The following repair instructions pertain to
active faults only. For information and instructions
about inactive faults, please contact OnTrac at
866-668-7221 and request a transmission
specialist.
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
35
23
Open circuit at the output stage to the
splitter indirect solenoid (Y3)
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
36
24
Open circuit at the output stage to the
rail select #1 solenoid (Y4)
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
37
25
Open circuit at the output stage to the
rail select #2 solenoid (Y5)
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
38
26
Open circuit at the output stage to the
gear engage #1 solenoid (Y6)
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
39
27
Open circuit at the output stage to the
gear engage #2 solenoid (Y7)
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
30
Section 2
Fault Code Diagnostics
ISO Fault Code Diagnostics
NOTE: ISO display codes may not be available on vehicles built prior to January 2006.
Repair Instructions
ISO Display
ISO Fault Fault Codes
Identifier (J587 Display)
40
28
Fault Description
Open circuit at the output stage to the
low range solenoid (Y8)
NOTE: The following repair instructions pertain to
active faults only. For information and instructions
about inactive faults, please contact OnTrac at
866-668-7221 and request a transmission
specialist.
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
41
29
Open circuit at the output stage to the
high range solenoid (Y9)
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
42
2A
Open circuit at the output stage to the
main solenoid (Y1)
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
49
31
Open circuit at the output stage to the
inertia brake solenoid (Y1)
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
50
32
Open circuit at output stage to small
disengagement clutch valve
Additional fault codes 51/52/53 also active, verify
connection of clutch actuator connector to TCU. Measure
the resistance between pin 9 and pin 16 of clutch
actuator connector.
Nominal value should be 14-16 ohms.
If resistance is < 14 ohms, exchange clutch actuator.
If resistance is within correct range, exchange upper part
of TCU.
51
33
Open circuit at output stage to small
engagement clutch valve
Additional fault codes 51/52/53 also active, verify
connection of clutch actuator connector to TCU. Measure
the resistance between pin 7 and pin 16 of clutch
actuator connector.
Nominal value should be 14-16 ohms.
If resistance is < 14 ohms, exchange clutch actuator.
If resistance is within correct range, exchange upper part
of TCU.
31
Section 2
Fault Code Diagnostics
ISO Fault Code Diagnostics
NOTE: ISO display codes may not be available on vehicles built prior to January 2006.
Repair Instructions
ISO Display
ISO Fault Fault Codes
Identifier (J587 Display)
52
34
Fault Description
Open circuit at output stage to large
disengagement clutch valve
NOTE: The following repair instructions pertain to
active faults only. For information and instructions
about inactive faults, please contact OnTrac at
866-668-7221 and request a transmission
specialist.
Additional fault codes 51/52/53 also active, verify
connection of clutch actuator connector to TCU. Measure
the resistance between pin 12 and pin 17 of clutch
actuator connector.
Nominal value should be 14-16 ohms.
If resistance is < 14 ohms, exchange clutch actuator.
If resistance is within correct range, exchange upper part
of TCU.
53
35
Open circuit at output stage to large
engagement clutch valve
Additional fault codes 51/52/53 also active, verify
connection of clutch actuator connector to TCU. Measure
the resistance between pin 8 and pin 17 of clutch
actuator connector.
Nominal value should be 14-16 ohms.
If resistance is < 14 ohms, exchange clutch actuator.
If resistance is within correct range, exchange upper part
of TCU.
54
59
60
61
62
63
64
32
36
3B
3C
3D
3E
3F
40
Open circuit of the output ACC (power
conversion signal for ZMTEC and
continuation signal for voltage doubler
voltage doubler and voltage supply to
output speed sensor #2)
Complete the electrical requirements flowchart.
Acknowledge fault of PTO 1
Complete the PTO requirements flowchart.
NOTE: The PTO is active but the
ZF-FreedomLine hasn’t requested it.
If necessary, contact OnTrac at 866-668-7221 and request
a ZF-FreedomLine transmission specialist.
Acknowledge fault of PTO 2
Complete the PTO requirements flowchart.
NOTE: The PTO is active but the
ZF-FreedomLine hasn’t requested it.
If necessary, contact OnTrac at 866-668-7221 and request
a ZF-FreedomLine transmission specialist.
PTO 1 disengagement fault
Complete the PTO requirements flowchart.
NOTE: The ZF-FreedomLine TCU has
requested that the PTO turn OFF and it
has not.
If necessary, contact OnTrac at 866-668-7221 and request
a ZF-FreedomLine transmission specialist.
PTO 2 disengagement fault
Complete the PTO requirements flowchart.
NOTE: The ZF-FreedomLine TCU has
requested that the PTO turn OFF and it
has not.
If necessary, contact OnTrac at 866-668-7221 and request
a ZF-FreedomLine transmission specialist.
PTO 1 engagement fault
Complete the PTO requirements flowchart.
NOTE: The ZF-FreedomLine TCU has
requested that the PTO turn ON and it
has not.
If necessary, contact OnTrac at 866-668-7221 and request
a ZF-FreedomLine transmission specialist.
PTO 2 engagement fault
Complete the PTO requirements flowchart.
NOTE: The ZF-FreedomLine TCU has
requested that the PTO turn ON and it
has not.
If necessary, contact OnTrac at 866-668-7221 and request
a ZF-FreedomLine transmission specialist.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
Section 2
Fault Code Diagnostics
ISO Fault Code Diagnostics
NOTE: ISO display codes may not be available on vehicles built prior to January 2006.
Repair Instructions
ISO Display
ISO Fault Fault Codes
Identifier (J587 Display)
66
42
Fault Description
Short circuit to positive at the output
stage to the splitter direct solenoid (Y2)
NOTE: The following repair instructions pertain to
active faults only. For information and instructions
about inactive faults, please contact OnTrac at
866-668-7221 and request a transmission
specialist.
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
67
43
Short circuit to positive at the output
When submitting a warranty claim under standard
stage to the splitter indirect solenoid (Y3) warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
68
44
Short circuit to positive at the output
stage to the rail select #1 solenoid (Y4)
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
69
45
Short circuit to positive at the output
stage to the rail select #2 solenoid (Y5)
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
70
46
Short circuit to positive at the output
stage to the gear engage #1 solenoid
(Y6)
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
71
47
Short circuit to positive at the output
stage to the gear engage #2 solenoid
(Y7)
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
33
Section 2
Fault Code Diagnostics
ISO Fault Code Diagnostics
NOTE: ISO display codes may not be available on vehicles built prior to January 2006.
Repair Instructions
ISO Display
ISO Fault Fault Codes
Identifier (J587 Display)
72
48
Fault Description
Short circuit to positive at the output
stage to the low range solenoid (Y8)
NOTE: The following repair instructions pertain to
active faults only. For information and instructions
about inactive faults, please contact OnTrac at
866-668-7221 and request a transmission
specialist.
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
73
49
Short circuit to positive at the output
stage to the high range solenoid (Y9)
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
74
4A
Short circuit to positive at the output
stage to the main solenoid (Y1)
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
81
51
Short circuit to positive at the output
stage to the inertia brake solenoid (Y1)
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
82
52
Short circuit to positive at output stage
to small disengagement clutch valve
Measure the resistance between pin 9 and pin 16 of
clutch actuator connector
Nominal value should be 14-16 ohms
If resistance is < 14 ohms, exchange clutch actuator
If resistance is within spec, exchange upper part of TCU.
83
53
Short circuit to positive at output stage
to small engagement clutch valve
Measure the resistance between pin 7 and pin 16 of
clutch actuator connector
Nominal value should be 14-16 ohms
If resistance is < 14 ohms, exchange clutch actuator
If resistance is within spec, exchange upper part of TCU.
84
54
Short circuit to positive at output stage
to large disengagement clutch valve
Measure the resistance between pin 12 and pin 17 of
clutch actuator connector.
Nominal value should be 14-16 ohms.
If resistance is < 14 ohms, exchange clutch actuator.
If resistance is within spec, exchange upper part of TCU.
34
Section 2
Fault Code Diagnostics
ISO Fault Code Diagnostics
NOTE: ISO display codes may not be available on vehicles built prior to January 2006.
Repair Instructions
ISO Display
ISO Fault Fault Codes
Identifier (J587 Display)
85
55
Fault Description
NOTE: The following repair instructions pertain to
active faults only. For information and instructions
about inactive faults, please contact OnTrac at
866-668-7221 and request a transmission
specialist.
Short circuit to positive at output stage
to large engagement clutch valve
Measure the resistance between pin 8 and pin 17 of
clutch actuator connector.
Nominal value should be 14-16 ohms.
If resistance is < 14 ohms, exchange clutch actuator.
If resistance is within correct range, exchange upper part
of TCU.
86
89
56
59
Short circuit to positive of the output
ACC (power conversion enable signal for
ZMTEC and continuation signal for
voltage doubler voltage doubler and
voltage supply to output speed
sensor #2)
Complete the electrical requirements flowchart.
Short circuit to positive at output SD to
display
Troubleshoot the ZF-FreedomLine vehicle wiring
harness. Pin 9 of the TCU connector (J1) and pin F2 of
the ZMTEC connector (J3) should all have continuity
(resistance of 0.0 to 0.5 ohms) and not be shorted to any
other circuit. If a short or open circuit is found, replace
the wiring harness. If not, replace the ZMTEC.
NOTE: The display will read “EE.”
90
91
5A
5B
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
Communication error between TCU 1
and TCU 2: ECU failure
The transmission TCU top half requires replacement.
The main TCU has not received
communication from the ABS. Timeout
error: CAN EBC1
Due to an issue with the vehicle’s SAE J1939 data link,
the TCU did not receive an expected SAE J1939
message. Follow your OEM’s SAE J1939 diagnostic
procedures to correct the issue.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
In conjunction with an active or logged ISO 199 fault
code, verify that the ABS controller is connected
properly to the SAE J939
Verify power and ground circuits to the ABS controller.
92
5C
The main TCU has not received
communication from the ABS. ABS
active message error: EBC1
The TCU received the SAE J1939 message from the ABS
controller, but the information within the message was
not within specifications. Verify that the ABS system is
approved with the ZF-FreedomLine transmission, that all
settings are correct, and wheel-end speed sensors are
correctly installed.
If necessary, contact OnTrac at 866-668-7221 and request
a ZF-FreedomLine transmission specialist.
93
5D
The main TCU has not received
communication from the ABS. ASR
engine control active message error:
EBC1
The TCU received the SAE J1939 message from the ABS
controller, but the information within the message was
not within specifications. Verify that the ABS system is
approved with the ZF-FreedomLine transmission, that all
settings are correct, and wheel-end speed sensors are
correctly installed.
If necessary, contact OnTrac at 866-668-7221 and request
a ZF-FreedomLine transmission specialist.
35
Section 2
Fault Code Diagnostics
ISO Fault Code Diagnostics
NOTE: ISO display codes may not be available on vehicles built prior to January 2006.
Repair Instructions
ISO Display
ISO Fault Fault Codes
Identifier (J587 Display)
94
5E
Fault Description
NOTE: The following repair instructions pertain to
active faults only. For information and instructions
about inactive faults, please contact OnTrac at
866-668-7221 and request a transmission
specialist.
The main TCU has not received
The TCU received the SAE J1939 message from the ABS
communication from the ABS. ASR
controller, but the information within the message was
brake control active message error: EBC1 not within specifications. Verify that the ABS system is
approved with the ZF-FreedomLine transmission, that all
settings are correct, and wheel-end speed sensors are
correctly installed.
If necessary, contact OnTrac at 866-668-7221 and request
a ZF-FreedomLine transmission specialist.
95
5F
The main TCU has not received
communication from the engine. Cruise
control active message error: CCVS
The TCU received the SAE J1939 message from the ECM
but the information within the message was not within
specifications. Verify that the ECM software level is
approved with the ZF-FreedomLine transmission and
that all settings are correct.
If necessary, contact OnTrac at 866-668-7221 and request
a ZF-FreedomLine transmission specialist.
96
60
The main TCU has not received
communication from the engine. Cruise
control set speed message error: CCVS
The TCU received the SAE J1939 message from the ECM
but the information within the message was not within
specifications. Verify that the ECM software level is
approved with the ZF-FreedomLine transmission and
that all settings are correct.
If necessary, contact OnTrac at 866-668-7221 and request
a ZF-FreedomLine transmission specialist.
97
61
The main TCU has not received
communication from the engine. Engine
speed message error: EEC1
The TCU received the SAE J1939 message from the ECM
but the information within the message was not within
specifications. Verify that the ECM software level is
approved with the ZF-FreedomLine transmission and
that all settings are correct.
If necessary, contact OnTrac at 866-668-7221 and request
a ZF-FreedomLine transmission specialist.
98
62
Input shaft speed sensor fault
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
99
63
Output shaft speed sensor #1 (the upper
one) fault
NOTE: Output shaft speed sensor #1
plugs into the ZF-FreedomLine
transmission wiring harness (the same
one that is connected to the clutch
actuator).
Clear the faults first and switch the OSS #1 and OSS #2
connectors. Test drive the vehicle such that an OSS code
is set. If the code stays with the same speed sensor (#1
or #2), then replace the appropriate wiring harness
(either the transmission wiring harness or the clutch
actuator). If the code switches to the other speed sensor
(from #1 to #2 or from #2 to #1), replace the appropriate
speed sensor. If these steps don’t identify the faulty
component, then do the following.
Remove and troubleshoot the clutch actuator wiring
harness. Pin 11 of the driver side TCU connector and pin
4 of the lower output shaft speed sensor connector
(sensor #1) should have continuity (resistance of 0.0 to
0.5 ohms) and not be shorted to any other circuit. If a
short or open circuit is found, replace the clutch actuator;
if not, replace the output shaft speed sensor #1.
36
Section 2
Fault Code Diagnostics
ISO Fault Code Diagnostics
NOTE: ISO display codes may not be available on vehicles built prior to January 2006.
Repair Instructions
ISO Display
ISO Fault Fault Codes
Identifier (J587 Display)
100
64
Fault Description
Error on output speed signal 2 (the lower
one)
NOTE: Output shaft speed sensor #2
plugs into the ZF-FreedomLine vehicle
wiring harness (the same one that is
connected to the voltage doubler and
ZMTEC).
NOTE: The following repair instructions pertain to
active faults only. For information and instructions
about inactive faults, please contact OnTrac at
866-668-7221 and request a transmission
specialist.
Clear the faults first and switch the OSS #1 and OSS #2
connectors. Test drive the vehicle such that an OSS code
is set. If the code stays with the same speed sensor (#1
or #2), then replace the appropriate wiring harness
(either the transmission wiring harness or the clutch
actuator). If the code switches to the other speed sensor
(from #1 to #2 or from #2 to #1), replace the appropriate
speed sensor. If these steps don’t identify the faulty
component, then do the following.
Remove and troubleshoot the transmission wiring
harness. Pin 7 of the TCU connector (J1) and pin 3 of the
output shaft speed sensor #2 connector (J5) should have
continuity (resistance of 0.0 to 0.5 ohms) and not be
shorted to any other circuit. If a short or open circuit is
found, replace the transmission wiring harness, if not,
replace the output shaft speed sensor #2.
101
65
Error on both output speed signals
Inspect the output shaft speed sensors and
corresponding wiring harnesses for obvious signs of
damage including corrosion within the connectors.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
102
66
Plausibility error between transmission
input speed and output speed
103
67
The main TCU has not received
communication from the engine.
Wheel-based vehicle speed message
error: CCVS
Using TransSoft, check the main TCU for programming
mistakes (the programming is gear-dependent and must
reflect the actual transmission model). For assistance,
NOTE: The actual speeds registered by
contact OnTrac at 866-668-7221 and request a
the input shaft and output shaft speed
sensors do not match the expected ratios. ZF-FreedomLine transmission specialist. If the
programming is incorrect, an OnTrac representative will
assist you.
The TCU received the SAE J1939 message from the ECM
but the information within the message was not within
specifications. Verify that the ECM software level is
approved with the ZF-FreedomLine transmission and
that all settings are correct.
If necessary, contact OnTrac at 866-668-7221 and request
a ZF-FreedomLine transmission specialist.
104
105
68
69
High voltage (voltage doubler 24 volt
output too high)
The transmission voltage doubler requires replacement.
Low voltage (vehicle electrical system or
transmission voltage doubler output too
low)
Complete the electrical requirements flowchart.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
If not issues are found with the vehicle electrical system,
verify all inputs and outputs at the transmission voltage
doubler.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
107
6B
Clutch actuator position sensor voltage
supply too low
Unplug the clutch actuator connector at the TCU. Check
for 4.6 to 5.8 VDC between pins 15 and 16 of the TCU. If
the voltage level is within this range, replace the clutch
actuator; if the voltage level is outside of this range,
replace the upper part of the TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
37
Section 2
Fault Code Diagnostics
ISO Fault Code Diagnostics
NOTE: ISO display codes may not be available on vehicles built prior to January 2006.
Repair Instructions
ISO Display
ISO Fault Fault Codes
Identifier (J587 Display)
Fault Description
108
Shift lever error
6C
ZF-FreedomLine shifter analog shift lever
(Freightliner and Sterling vehicles only)
NOTE: The following repair instructions pertain to
active faults only. For information and instructions
about inactive faults, please contact OnTrac at
866-668-7221 and request a transmission
specialist.
First check all wiring harness connections between the
shift lever and the ZMTEC and the ZMTEC and the GS3.
If they look good (no damaged pins, correctly set home,
etc.), then do the following.
Check for continuity (0.0 to 0.5 ohms) between pins 1
and 8 of the shift lever harness connector (J10) and pin
G3 of the ZMTEC connector (J3). Check for continuity
between pin 3 of the shift lever harness connector (J10)
and ground. Check for continuity between pin 7 of the
shift lever harness connector (J10) and pin F1 of the
ZMTEC connector (J3). Check for continuity between pin
9 of the shift lever harness connector (J10) and pin E3 of
the ZMTEC connector (J3). Also check for shorts between
these circuits and all other pins in the wiring harness. If
these resistances check out okay and no short circuits
exist, replace the shift lever assembly. For diagnostic
procedures concerning the Freightliner SmartShift lever
and the push-button shift lever for International trucks,
contact the applicable OEM. For assistance, contact
OnTrac at 866-668-7221 and request a ZF-FreedomLine
transmission specialist.
110
6E
ZF CAN timeout
Unplug the ZMTEC only and check for 58.0 to 62.0 ohms
resistance across pins D1 and D2 of the ZMTEC
connector (J3). Now remove the transmission wiring
harness and check for continuity (0.0 to 0.5 ohms)
between pin 3 of the TCU connector (J1), pin D1 of the
ZMTEC connector (J3), and pin A of the CAN terminator
connector (J8). Check for continuity between pin 6 of the
TCU connector (J1), pin D2 of the ZMTEC connector (J3),
and pin B of the CAN terminator connector (J8).
If any of these tests reveal issues with the wiring
harness, replace the wiring harness.
For assistance, contact OnTrac at 866-668-7221 and
request a ZF-FreedomLine transmission specialist.
114
72
Clutch engagement error
NOTE: The clutch engaged
unintentionally at a standstill with the
gear engaged.
117
75
Error in clutch self-adjustment process
NOTE: The clutch is unable to cycle.
Verify air supply into clutch actuator (system pressure
should be 110-130 psi) air supply within spec, replace
clutch actuator.
If error occurs immediately after engine startup, then
check the clutch engagement hardware for issues such
as a broken fork, jammed release bearing, failed release
bearing, broken clutch retaining clip, possible glazed
clutch disc, jammed clutch actuator rod, etc.). Address
any issues as necessary. If nothing is found, grease the
interface between the fork and the release bearing (this
includes the tips of the forks as well as the side walls of
the release bearing).
If clutch actuator does not move when engine is started,
replace clutch actuator.
38
Section 2
Fault Code Diagnostics
ISO Fault Code Diagnostics
NOTE: ISO display codes may not be available on vehicles built prior to January 2006.
Repair Instructions
ISO Display
ISO Fault Fault Codes
Identifier (J587 Display)
Fault Description
NOTE: The following repair instructions pertain to
active faults only. For information and instructions
about inactive faults, please contact OnTrac at
866-668-7221 and request a transmission
specialist.
118
Clutch does not disengage
Complete the pneumatic requirements flowchart.
76
Verify air supply/air quality.
Remove and inspect clutch actuator filter screen for
contamination.
If the root cause of the issue is not found, then check the
clutch engagement hardware for issues such as a broken
fork, jammed bearing, failed release bearing, broken
clutch retaining clip, possible glazed clutch disc, jammed
clutch actuator rod, etc. Address any issues as
necessary.
If clutch actuator does not move when engine is started,
replace clutch actuator.
119
77
Clutch does not engage/does not
transmit engine torque
Complete the pneumatic requirements flowchart.
Verify air supply/air quality.
Remove and inspect clutch actuator filter screen for
contamination.
If the root cause of the issue is not found, then check the
clutch engagement hardware for issues such as a broken
fork, jammed release bearing, failed release bearing,
broken clutch retaining clip, possible glazed clutch disc,
jammed clutch actuator rod, etc. Address any issues as
necessary.
If clutch actuator does not move when engine is started,
replace clutch actuator.
120
78
Mechanical failure of small clutch
disengagement solenoid
Complete the pneumatic requirements flowchart.
Verify air supply/air quality.
Remove and inspect clutch actuator filter screen for
contamination.
If root cause of the issue is not found, check the clutch
engagement hardware for issues such as a broken fork,
jammed release bearing, failed release bearing, broken
clutch retaining clip, jammed clutch actuator rod, etc.
Address any issues as necessary.
If clutch actuator does not move when engine is started,
replace clutch actuator.
121
79
Mechanical failure of large clutch
disengagement solenoid
Complete the pneumatic requirements flowchart.
Verify air supply/air quality.
Remove and inspect clutch actuator filter screen for
contamination.
If root cause of the issue is not found, check the clutch
engagement hardware for issues such as a broken fork,
jammed release bearing, failed release bearing, broken
clutch retaining clip, jammed clutch actuator rod, etc.
Address any issues as necessary.
If clutch actuator does not move when engine is started,
replace clutch actuator.
39
Section 2
Fault Code Diagnostics
ISO Fault Code Diagnostics
NOTE: ISO display codes may not be available on vehicles built prior to January 2006.
Repair Instructions
ISO Display
ISO Fault Fault Codes
Identifier (J587 Display)
122
7A
Fault Description
Mechanical failure of small clutch
engagement solenoid
NOTE: The following repair instructions pertain to
active faults only. For information and instructions
about inactive faults, please contact OnTrac at
866-668-7221 and request a transmission
specialist.
Complete the pneumatic requirements flowchart.
Verify air supply/air quality.
Remove and inspect clutch actuator filter screen for
contamination.
If root cause of the issue is not found, check the clutch
engagement hardware for issues such as a broken fork,
jammed release bearing, failed release bearing, broken
clutch retaining clip, jammed clutch actuator rod, etc.
Address any issues as necessary.
If clutch actuator does not move when engine is started,
replace clutch actuator.
123
7B
Mechanical failure of large clutch
engagement solenoid
Complete the pneumatic requirements flowchart.
Verify air supply/air quality.
Remove and inspect clutch actuator filter screen for
contamination.
If root cause of the issue is not found, check the clutch
engagement hardware for issues such as a broken fork,
jammed release bearing, failed release bearing, broken
clutch retaining clip, jammed clutch actuator rod, etc.
Address any issues as necessary.
If clutch actuator does not move when engine is started,
replace clutch actuator.
124
7C
Error on clutch actuator position sensor
signal
Complete the pneumatic requirements flowchart.
Verify air supply/air quality.
Using transsoft, under the clutch info tab, verify clutch
absolute stroke.
Engine must be running and transmission in neutral.
Absolute clutch stroke > 65 mm, replace the clutch
assembly.
If issue still not resolved, contact OnTrac at 866-668-7221
and request a ZF-FreedomLine transmission specialist.
125
126
7D
7E
Pressure reduction valve (TCU air filter
regulator)
Complete the pneumatic requirements flowchart.
Pressure sensor signal fault
The transmission TCU top half requires replacement.
If the root cause is not found, use TransSoft to verify that
the transmission’s pressure reduction valve is regulating
the air pressure to 102.5 ± 4 psi. Replace the air pressure
regulator as necessary.
Out-of-warranty only and/or no warranty claim
submitted, replace the pressure sensor.
127
7F
TCU temperature sensor signal fault
The transmission TCU top half requires replacement.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
40
Section 2
Fault Code Diagnostics
ISO Fault Code Diagnostics
NOTE: ISO display codes may not be available on vehicles built prior to January 2006.
Repair Instructions
ISO Display
ISO Fault Fault Codes
Identifier (J587 Display)
Fault Description
128
Oil temperature sensor fault
80
NOTE: The following repair instructions pertain to
active faults only. For information and instructions
about inactive faults, please contact OnTrac at
866-668-7221 and request a transmission
specialist.
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace lower part of TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
129
81
Short circuit to positive of the gear
engage position sensor signal
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace the sensor or replace the lower part
of the TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
130
82
Short circuit to ground of the gear
engage position sensor signal
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace the sensor or replace the lower part
of the TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
131
83
Open circuit of the gear engage position
sensor signal
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace the sensor or replace the lower part
of the TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
132
84
Self adjustment error of gear engage
position sensor
If the TCU has not just been installed, complete the
pneumatic requirements flowchart.
NOTE: The gear engage position sensor
is unable to cycle.
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, purchase kit and rebuild the main
engagement piston on the lower part of TCU or replace
the lower part of TCU.
If the TCU has just been installed, the engagement
actuator did not correctly engage into the rail. Using
TransSoft, verify that the engagement position sensor
counts are outside of the nominal range: 300 to 350. If
so, remove the TCU and reinstall it.
41
Section 2
Fault Code Diagnostics
ISO Fault Code Diagnostics
NOTE: ISO display codes may not be available on vehicles built prior to January 2006.
Repair Instructions
ISO Display
ISO Fault Fault Codes
Identifier (J587 Display)
133
85
Fault Description
Short circuit to positive of the rail select
position sensor
NOTE: The following repair instructions pertain to
active faults only. For information and instructions
about inactive faults, please contact OnTrac at
866-668-7221 and request a transmission
specialist.
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace the sensor or replace the lower part
of the TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
134
86
Short circuit to ground of the rail select
position sensor
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace the sensor or replace the lower part
of the TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
135
87
Open circuit of the rail select position
sensor
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace the sensor or replace the lower part
of the TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
136
88
Gate select sensor self-adjustment error
If the TCU has not just been installed, complete the
pneumatic requirements flowchart.
If the TCU has just been installed, the gate selector
actuator did not correctly engage into the rail. Using
TransSoft, verify that the gate selector position sensor
counts are outside of the nominal range: 70 to 120 or
500 to 580. If so, remove the TCU and reinstall it.
137
89
No range change group sensor signal
(short circuit to positive)
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace the sensor or replace the lower part
of the TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
138
8A
No range change group sensor signal
(short circuit to ground)
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace the sensor or replace the lower part
of the TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
42
Section 2
Fault Code Diagnostics
ISO Fault Code Diagnostics
NOTE: ISO display codes may not be available on vehicles built prior to January 2006.
Repair Instructions
ISO Display
ISO Fault Fault Codes
Identifier (J587 Display)
139
8B
Fault Description
No range change group sensor signal
(open circuit)
NOTE: The following repair instructions pertain to
active faults only. For information and instructions
about inactive faults, please contact OnTrac at
866-668-7221 and request a transmission
specialist.
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace the sensor or replace the lower part
of the TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
140
8C
Self-adjustment fault of range position
sensor
If the TCU has not just been installed, complete the
pneumatic requirements flowchart.
If the TCU has just been installed, the range actuator did
not correctly engage into the rail. Using TransSoft, verify
that the range position sensor counts are outside of the
nominal range: 80 to 130 or 490 to 590. If so, remove the
TCU and reinstall it.
141
8D
Short circuit to positive of the splitter
position sensor signal
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace the sensor or replace the lower part
of the TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
142
8E
Short circuit to ground of the splitter
position sensor signal
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace the sensor or replace the lower part
of the TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
143
8F
Open circuit of the splitter position
sensor signal
When submitting a warranty claim under standard
warranty conditions, the complete TCU should be
replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace the sensor or replace the lower part
of the TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
144
90
Splitter position sensor self-adjustment
fault
If the TCU has not just been installed, complete the
pneumatic requirements flowchart.
NOTE: The gear engage position sensor
is unable to cycle.
If the TCU has just been installed, the splitter actuator
did not correctly engage into the rail. Using TransSoft,
verify that the splitter position sensor counts are outside
of the nominal range: 70 to 140 or 500 to 650. If so,
remove the TCU and reinstall it.
43
Section 2
Fault Code Diagnostics
ISO Fault Code Diagnostics
NOTE: ISO display codes may not be available on vehicles built prior to January 2006.
Repair Instructions
ISO Display
ISO Fault Fault Codes
Identifier (J587 Display)
Fault Description
NOTE: The following repair instructions pertain to
active faults only. For information and instructions
about inactive faults, please contact OnTrac at
866-668-7221 and request a transmission
specialist.
145
Range shift disengagement error
Complete the pneumatic requirements flowchart.
91
If no issues are found with the air system, contact
OnTrac at 866-668-7221 and request a ZF-FreedomLine
transmission specialist.
146
92
Range shift changeover error
Complete the pneumatic requirements flowchart.
The range actuator did not correctly engage into the rail.
Using TransSoft, verify that the range position sensor
counts are outside of the nominal range: 80 to 130 or 490
to 590. The measured values should not drift or show
signal disturbances after range shifting. Values outside
range, exchange main transmission. If error occurs
sporadically: When submitting a warranty claim under
standard warranty conditions, the complete TCU should
be replaced and the entire unit submitted with warranty
claim. Out-of-warranty only and/or no warranty claim
submitted, replace the lower part of TCU.
For assistance contact OnTrac at 866-668-7221 and ask
for a transmission specialist.
147
93
Range shift engagement error
Complete the pneumatic requirements flowchart.
The range actuator did not correctly engage into the rail.
Using TransSoft, verify that the range position sensor
counts are outside of the nominal range: 80 to 130 or
490 to 590. The measured values should not drift or
show signal disturbances after range shifting. Values
outside range, exchange main transmission. If error
occurs sporadically: When submitting a warranty claim
under standard warranty conditions, the complete TCU
should be replaced and the entire unit submitted with
warranty claim. Out-of-warranty only and/or no
warranty claim submitted, replace the lower part of
TCU.
For assistance contact OnTrac at 866-668-7221 and ask
for a transmission specialist.
148
94
Splitter selection fault; splitter cylinder
does not disengage
Complete the pneumatic requirements flowchart.
The splitter group does not leave the previous position
within defined time. Using TransSoft, verify that the
splitter position sensor counts are outside of the nominal
range: 70 to 140 or 500 to 620.
The measured values should not drift or show signal
disturbances after splitter shifting. Values outside range,
exchange main transmission. If error occurs
sporadically: When submitting a warranty claim under
standard warranty conditions, the complete TCU should
be replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace the lower part of TCU.
For assistance, contact OnTrac at 866-668-7221 and ask
for a transmission specialist.
44
Section 2
Fault Code Diagnostics
ISO Fault Code Diagnostics
NOTE: ISO display codes may not be available on vehicles built prior to January 2006.
Repair Instructions
ISO Display
ISO Fault Fault Codes
Identifier (J587 Display)
149
95
Fault Description
Splitter selection fault during the splitter
selection procedure
NOTE: The following repair instructions pertain to
active faults only. For information and instructions
about inactive faults, please contact OnTrac at
866-668-7221 and request a transmission
specialist.
Complete the pneumatic requirements flowchart.
The splitter group does not changeover to new position
in defined time. Using TransSoft, verify that the splitter
position sensor counts are outside of the nominal range:
70 to 140 or 500 to 620.
The measured values should not drift or show signal
disturbances after splitter shifting. Values outside range,
exchange main transmission. If error occurs
sporadically: When submitting a warranty claim under
standard warranty conditions, the complete TCU should
be replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace the lower part of TCU.
For assistance, contact OnTrac at 866-668-7221 and ask
for a transmission specialist.
150
96
Splitter selection fault; splitter cylinder
does not engage
Complete the pneumatic requirements flowchart.
The splitter actuator did not correctly engage into the
rail. Using TransSoft, verify that the splitter position
sensor counts are outside of the nominal range: 70 to
140 or 500 to 620.
The measured values should not drift or show signal
disturbances after splitter shifting. Values outside range,
exchange main transmission. If error occurs
sporadically: When submitting a warranty claim under
standard warranty conditions, the complete TCU should
be replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace the lower part of TCU.
For assistance, contact OnTrac at 866-668-7221 and ask
for a transmission specialist.
151
97
Rail select cylinder does not disengage
Complete the pneumatic requirements flowchart.
The select actuator did not correctly disengage. Using
TransSoft, verify that the splitter position sensor counts
are outside of the nominal range: 70 to 120 or 500
to 580.
The measured values should not drift or show signal
disturbances after rail select shifting. Values outside
range, exchange main transmission. If error occurs
sporadically: When submitting a warranty claim under
standard warranty conditions, the complete TCU should
be replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace the lower part of TCU.
For assistance, contact OnTrac at 866-668-7221 and ask
for a transmission specialist.
45
Section 2
Fault Code Diagnostics
ISO Fault Code Diagnostics
NOTE: ISO display codes may not be available on vehicles built prior to January 2006.
Repair Instructions
ISO Display
ISO Fault Fault Codes
Identifier (J587 Display)
152
98
Fault Description
Rail selection fault during the rail
selection procedure
NOTE: The following repair instructions pertain to
active faults only. For information and instructions
about inactive faults, please contact OnTrac at
866-668-7221 and request a transmission
specialist.
Complete the pneumatic requirements flowchart.
The select cylinder does not change over to new gatel.
Using TransSoft, verify that the select position sensor
counts are outside of the nominal range: 70 to 120 or
500 to 580.
The measured values should not drift or show signal
disturbances after rail select shifting. Values outside
range, exchange main transmission. If error occurs
sporadically: When submitting a warranty claim under
standard warranty conditions, the complete TCU should
be replaced and the entire unit submitted with warranty
claim. Out-of-warranty only and/or no warranty claim
submitted, replace the lower part of TCU.
For assistance, contact OnTrac at 866-668-7221 and ask
for a transmission specialist.
153
99
Rail selection fault; rail select cylinder
does not engage
Complete the pneumatic requirements flowchart.
The select actuator did not correctly engage into the rail.
Using TransSoft, verify that the range position sensor
counts are outside of the nominal range: 70 to 120 or
500 to 580.
The measured values should not drift or show signal
disturbances after rail select shifting. Values outside
range, exchange main transmission. If error occurs
sporadically: When submitting a warranty claim under
standard warranty conditions, the complete TCU should
be replaced and the entire unit submitted with warranty
claim. Out-of-warranty only and/or no warranty claim
submitted, replace the lower part of TCU.
For assistance contact OnTrac at 866-668-7221 and ask
for a transmission specialist.
154
9A
Main transmission gear does not
disengage
Complete the pneumatic requirements flowchart.
The engagement actuator did not correctly disengage
from the rail. Using TransSoft, verify that the
engagement position sensor counts are outside of the
nominal range: 80 to 120 or 530 to 580.
The measured values should not drift or show signal
disturbances after engagement shifting. Values outside
range, exchange main transmission. If error occurs
sporadically: When submitting a warranty claim under
standard warranty conditions, the complete TCU should
be replaced and the entire unit submitted with warranty
claim. Out-of-warranty only and/or no warranty claim
submitted, replace the lower part of TCU.
For assistance contact OnTrac at 866-668-7221 and ask
for a transmission specialist.
46
Section 2
Fault Code Diagnostics
ISO Fault Code Diagnostics
NOTE: ISO display codes may not be available on vehicles built prior to January 2006.
Repair Instructions
ISO Display
ISO Fault Fault Codes
Identifier (J587 Display)
155
9B
Fault Description
Main transmission gear does not
engage
NOTE: The following repair instructions pertain to
active faults only. For information and instructions
about inactive faults, please contact OnTrac at
866-668-7221 and request a transmission
specialist.
Complete the pneumatic requirements flowchart.
The engagement actuator did not correctly engage into
the rail. Using TransSoft, verify that the engagement
position sensor counts are outside of the nominal range:
80 to 120 or 530 to 580.
The measured values should not drift or show signal
disturbances after engagement shifting. Values outside
range, exchange main transmission. If error occurs
sporadically: When submitting a warranty claim under
standard warranty conditions, the complete TCU should
be replaced and the entire unit submitted with warranty
claim. Out-of-warranty only and/or no warranty claim
submitted, replace the lower part of TCU.
For assistance contact OnTrac at 866-668-7221 and ask
for a transmission specialist.
156
9C
Engagement of wrong gear
Using TransSoft, check the main TCU for programming
mistakes (the programming is gear-dependent and must
reflect the actual transmission model). For assistance,
contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist. If the
programming is incorrect, an OnTrac representative will
assist you.
157
9D
Selector position sensor signal leaves
engaged position during driving
If the TCU has just been installed, the actuators and rails
may not have engaged correctly. Use TransSoft to verify
that the gate selector position sensor counts are outside
of the nominal range: 70 to 120 or 500 to 580.
If so, remove and reinstall the TCU.
NOTE: The selector position sensor has
traveled out of the engage position
without a shift being requested. This
issue is most likely the result of a broken
TCU but may be the result of
programming or a mis-installation. If
active, the transmission attempts to shift
back into its previous gear. If in neutral, a
suitable gear is selected. If the sensor is
broken and relaying bad information to
the TCU, the vehicle will stay in gear and
not shift. At the next stop, the
transmission will still be in gear with the
clutch open and the vehicle unable to
move.
158
9E
Gear engage position sensor signal
leaves engaged position during driving
If the TCU has recently been installed, verify that the
detent springs and detent balls were installed. If not,
remove and reinstall the TCU correctly (with the detent
springs and detent balls).
Using TransSoft, verify that the engagement position
sensor counts are outside of the nominal range: 80 to
120 or 530 to 580.
The measured values should not drift or show signal
disturbances after engagement shifting. Values outside
range, exchange main transmission. If error occurs
sporadically: When submitting a warranty claim under
standard warranty conditions, the complete TCU should
be replaced and the entire unit submitted with warranty
claim. Out-of-warranty only and/or no warranty claim
submitted, replace the lower part of TCU.
For assistance contact OnTrac at 866-668-7221 and ask
for a transmission specialist.
47
Section 2
Fault Code Diagnostics
ISO Fault Code Diagnostics
NOTE: ISO display codes may not be available on vehicles built prior to January 2006.
Repair Instructions
ISO Display
ISO Fault Fault Codes
Identifier (J587 Display)
159
9F
Fault Description
Range position sensor signal leaves
engaged position during driving
NOTE: The following repair instructions pertain to
active faults only. For information and instructions
about inactive faults, please contact OnTrac at
866-668-7221 and request a transmission
specialist.
Using TransSoft, verify that the range position sensor
counts are outside of the nominal range: 80 to 130 or
490 to 590.
The measured values should not drift or show signal
disturbances after range shifting. Values outside range,
exchange main transmission. If error occurs
sporadically: When submitting a warranty claim under
standard warranty conditions, the complete TCU should
be replaced and the entire unit submitted with warranty
claim. Out-of-warranty only and/or no warranty claim
submitted, replace the lower part of TCU.
For assistance contact OnTrac at 866-668-7221 and ask
for a transmission specialist.
160
A0
Splitter position sensor signal leaves
engaged position during driving
Using TransSoft, verify that the splitter position sensor
counts are outside of the nominal range: 70 to 140 or
500 to 620.
The measured values should not drift or show signal
disturbances after splitter shifting. Values outside range,
exchange main transmission. If error occurs
sporadically: When submitting a warranty claim under
standard warranty conditions, the complete TCU should
be replaced and the entire unit submitted with warranty
claim.
Out-of-warranty only and/or no warranty claim
submitted, replace the lower part of TCU.
For assistance, contact OnTrac at 866-668-7221 and ask
for a transmission specialist.
163
A3
Engine does not react to torque
intervention
The ECM did not react correctly to an SAE J1939
message. Follow your OEM’s SAE J1939 diagnostic
procedures to correct for a fault SAE J1939 data link.
Check for engine codes that would cause the engine to
go into derate mode. (Fuel restriction, air restriction,
high temp, low coolant etc).
164
A4
The main TCU has not received
communication from the engine. Error
on driver’s demand engine percent
torque message: EEC1
The TCU received the SAE J1939 message from the ECM
but the information within the message was not within
specifications. Verify that the ECM software level is
approved with the ZF-FreedomLine transmission and
that all settings are correct.
If necessary, contact OnTrac at 866-668-7221 and request
a ZF-FreedomLine transmission specialist.
165
A5
The main TCU has not received
communication from the engine. Error
on accelerator pedal position message:
EEC2
The TCU received the SAE J1939 message from the ECM
but the information within the message was not within
specifications. Verify that the ECM software level is
approved with the ZF-FreedomLine transmission and
that all settings are correct.
If necessary, contact OnTrac at 866-668-7221 and request
a ZF-FreedomLine transmission specialist.
48
Section 2
Fault Code Diagnostics
ISO Fault Code Diagnostics
NOTE: ISO display codes may not be available on vehicles built prior to January 2006.
Repair Instructions
ISO Display
ISO Fault Fault Codes
Identifier (J587 Display)
Fault Description
166
Permanent idle signal
A6
NOTE: The idle switch is built into the
accelerator pedal and is wired into the
engine controller, not the transmission
controller or main TCU. The TCU
receives the status of the idle switch over
the SAE J1939 bus. The transmission is
receiving contradictory messages
indicating that the idle switch is open
(truck is idling) and the accelerator pedal
is pressed (truck is not idling).
167
A7
The main TCU has not received expected
communications from the engine (error
on percent load at current speed
message EEC2)
NOTE: The following repair instructions pertain to
active faults only. For information and instructions
about inactive faults, please contact OnTrac at
866-668-7221 and request a transmission
specialist.
Using TransSoft, troubleshoot the idle switch and the
status of the pedal. Refer to the OEM for details should
repair work be necessary.
The TCU received the SAE J1939 message from the ECM
but the information within the message was not within
specifications. Verify that the ECM software level is
approved with the ZF-FreedomLine transmission and
that all settings are correct.
If necessary, contact OnTrac at 866-668-7221 and request
a ZF-FreedomLine transmission specialist.
168
A8
No idle signal or error on idle validation
switch signal (EEC2)
NOTE: The idle switch is built into the
accelerator pedal and is wired into the
engine controller, not the transmission
controller, or main TCU. The main TCU
receives the status of the idle switch over
the SAE J1939 bus. The transmission is
receiving contradictory messages
indicating that the idle switch is closed
(truck is not idling) and the accelerator
pedal is not pressed (truck
is idling).
169
A9
Cut-off relay in ECU does not switch off
Using TransSoft, troubleshoot the idle switch and the
status of the pedal. Refer to the OEM for details should
repair work be necessary.
The transmission TCU top half requires replacement.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
170
171
AA
AB
No voltage supply at pin 30 or cut-off
relay in ECU does not switch on
The transmission TCU top half requires replacement.
Error on “Actual engine percent torque”
signal (EEC1)
The TCU received the SAE J1939 message from the ECM
but the information within the message was not within
specifications. Verify that the ECM software level is
approved with the ZF-FreedomLine transmission and
that all settings are correct.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
If necessary, contact OnTrac at 866-668-7221 and request
a ZF-FreedomLine transmission specialist.
172
AC
The main TCU has not received
communication from the engine.
Permanent engine brake request
message
The TCU received the SAE J1939 message from the ECM
but the information within the message was not within
specifications. Troubleshoot the engine brake switch. It is
being reported as permanently depressed.
If necessary, contact OnTrac at 866-668-72210 and
request a ZF-FreedomLine transmission specialist.
49
Section 2
Fault Code Diagnostics
ISO Fault Code Diagnostics
NOTE: ISO display codes may not be available on vehicles built prior to January 2006.
Repair Instructions
ISO Display
ISO Fault Fault Codes
Identifier (J587 Display)
173
AD
Fault Description
The main TCU has not received
communication from the engine. Error
on brake switch message: CCVS
NOTE: The following repair instructions pertain to
active faults only. For information and instructions
about inactive faults, please contact OnTrac at
866-668-7221 and request a transmission
specialist.
The TCU received the SAE J1939 message from the ECM
but the information within the message was not within
specifications. Troubleshoot the brake switch. It is being
reported as permanently depressed.
If necessary, contact OnTrac at 866-668-7221 and request
a ZF-FreedomLine transmission specialist.
175
AF
Error on “Ignition lock” signal
(terminal 15)
Verify voltage at pin 6/7 of the doubler.
Key on voltage should be 24 volts nominal. If < 18 volts,
replace the transmission voltage doubler.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
177
B1
The main TCU has not received
communication from the engine. Error:
system CAN busoff
Due to an issue with the vehicle’s SAE J1939 data link,
the TCU did not receive an expected SAE J1939
message. Follow your OEM’s SAE J1939 diagnostic
procedures to correct the issue.
178
B2
The main TCU has identified CAN error
frames not severe enough to cause a
busoff situation
Due to an issue with the vehicle’s SAE J1939 data link,
the TCU did not receive an expected SAE J1939
message. Follow your OEM’s SAE J1939 diagnostic
procedures to correct the issue.
179
B3
The SAE J1939 bus is not functioning
correctly
Due to an issue with the vehicle’s SAE J1939 data link,
the TCU did not receive an expected SAE J1939
message. Follow your OEM’s SAE J1939 diagnostic
procedures to correct the issue.
NOTE: The backbone of the SAE J1939
bus is terminated at each end with a
120 ohm resistor. Each component
communicating over the bus must
connect into the backbone.
NOTE: The resistance across pins C and D of the 9 pin
diagnostic connector will be about 60 ohms if both
terminating resistors are in place (120 ohms if only one
is installed).
180
B4
The main TCU has not received
communication from the engine
(CAN EEC1 timeout)
Due to an issue with the vehicle’s SAE J1939 data link,
the TCU did not receive an expected SAE J1939
message. Follow your OEM’s SAE J1939 diagnostic
procedures to correct the issue.
181
B5
The main TCU has not received
communication from the engine
(CAN EEC2 timeout)
Due to an issue with the vehicle’s SAE J1939 data link,
the TCU did not receive an expected SAE J1939
message. Follow your OEM’s SAE J1939 diagnostic
procedures to correct the issue.
182
B6
The main TCU has not received
communication from the engine
(CAN CCVS timeout)
Due to an issue with the vehicle’s SAE J1939 data link,
the TCU did not receive an expected SAE J1939
message. Follow your OEM’s SAE J1939 diagnostic
procedures to correct the issue.
183
B7
The main TCU has not received
communication from the engine
(CAN ERC1_ER timeout)
Due to an issue with the vehicle’s SAE J1939 data link,
the TCU did not receive an expected SAE J1939
message. Follow your OEM’s SAE J1939 diagnostic
procedures to correct the issue.
188
BC
ECU fault — wrong interrupt
If issue occurs during transmission software upgrade,
the TCU is incompatible with the level of software.
Replace the upper part of the transmission TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
189
BD
ECU fault — stack watch
Replace the upper part of the transmission TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
50
Section 2
Fault Code Diagnostics
ISO Fault Code Diagnostics
NOTE: ISO display codes may not be available on vehicles built prior to January 2006.
Repair Instructions
ISO Display
ISO Fault Fault Codes
Identifier (J587 Display)
190
BE
Fault Description
EOL EEPROM parameter out of valid
range
NOTE: The following repair instructions pertain to
active faults only. For information and instructions
about inactive faults, please contact OnTrac at
866-668-7221 and request a transmission
specialist.
The EOL parameters need to be updated. This can be
accomplished with TransSoft. Contact OnTrac at
866-668-7221 and request a ZF-FreedomLine
transmission specialist.
Should the EOL parameter values check out, and the
code not clear, replace the upper part of the
transmission TCU.
191
BF
EOL EEPROM parameter checksum error
If the transmission has just been programmed, cycle the
key (remain in the off position for 10 seconds)
If the transmission has not just been programmed, then
the EOL parameters need to be updated. This can be
accomplished with TransSoft. Contact OnTrac at
866-668-7221 and request a ZF-FreedomLine
transmission specialist.
Should the EOL parameter values check out, and the
code not clear, replace the upper part of the
transmission TCU.
192
C0
ECU fault — EEPROM access failure
Verify that power is correctly supplied to the
transmission and cycle the power. Cycling the key off
and then back on too quickly can cause this fault to log
active
Ensure that the key is left in the off position at least
5 seconds before turning it back on.
If this does not resolve the issue, complete the electrical
requirements flowchart.
If no issues are found replace the upper part of the
transmission TCU.
Contact OnTrac at 866-668-7221 and request a
ZF-FreedomLine transmission specialist.
193
C1
ECU temperature too high
If an ISO fault code 128 exists, address it first.
Check for obstructions within the transmission cooler,
cooler lines and by-pass valve. Check the oil level (both
low and high oil levels may lead to overheating).
Address any issue found as necessary.
194
C2
Both sources of vehicle speed are faulty
Due to an issue with the vehicle’s SAE J1939 data link,
the TCU did not receive an expected SAE J1939
message. Follow your OEM’s SAE J1939 diagnostic
procedures to correct the issue.
197
C5
The main TCU has not received
communication from the ABS. Error on
front axle speed message: WSI
The TCU received the SAE J1939 message from the ABS
controller but the information within the message was
not within specifications. Using the appropriate ABS
diagnostic tool, verify active and inactive fault codes
logged. Repair or replace associated wheel end speed
sensors. If necessary, contact OnTrac at 866-668-7221
and request a ZF-FreedomLine transmission specialist.
198
C6
The main TCU has not received
communication from the ABS. Error on
relative wheel speeds message: WSI
The TCU received the SAE J1939 message from the ABS
controller but the information within the message was
not within specifications. Using the appropriate ABS
diagnostic tool, verify active and inactive fault codes
logged. Repair or replace associated wheel-end speed
sensors.
If necessary, contact OnTrac at 866-668-7221 and request
a ZF-FreedomLine transmission specialist.
51
Section 2
Fault Code Diagnostics
ISO Fault Code Diagnostics
NOTE: ISO display codes may not be available on vehicles built prior to January 2006.
Repair Instructions
ISO Display
ISO Fault Fault Codes
Identifier (J587 Display)
Fault Description
NOTE: The following repair instructions pertain to
active faults only. For information and instructions
about inactive faults, please contact OnTrac at
866-668-7221 and request a transmission
specialist.
199
C7
The main TCU has not received
communication from the ABS (CAN WSI
timeout)
Due to an issue with the vehicle’s SAE J1939 data link,
the TCU did not receive an expected SAE J1939
message. Follow your OEM’s SAE J1939 diagnostic
procedures to correct the issue. In conjunction with an
active or logged ISO 91 fault code, verify that the ABS
controller is connected properly to the SAE J939.
211
D3
CAN TC1 timeout
Due to an issue with the vehicles SAE J1939 data link,
the TCU did not receive an expected message from the
SAE J1939 push-button shift lever. (CAN TC1 timeout)
follow the OEM’s SAE J1939 diagnostic procedures to
correct the issue.
Verify power and ground circuits to the ABS controller.
52
Section 3
Maintenance
Release Fork Greasing Procedure (Standard and Roller Fork
Applications)
Section 3
Maintenance
Step 1
For Standard Fork Applications only
NOTE: The ZF-FreedomLine does not require a
regular maintenance program. However, to
ensure maximum performance and quality,
ensuring that the release mechanism is
lubricated in regular intervals is beneficial.
In most cases, lubricating the parts twice per
year is sufficient. In some cases, however,
lubricating the parts quarterly is normal. Thus if
there is a bump noticed when going from
neutral into gear at standstill or when coming to
a stop, this is a signal that the lubrication is
required.
4002081a
4002081a
Using a 13 mm wrench, remove the clutch
inspection cover.
앫 GO TO THE NEXT STEP.
Step 2
WARNING
The vent plug will vent the vehicle’s air supply
down to approximately 75 psi. Wear eye
protection when completing this step.
Using a 17 mm wrench, remove the clutch
actuator vent plug.
앫 GO TO THE NEXT STEP.
4002086a
4002086a
53
Section 3
Maintenance
Release Fork Greasing Procedure (Standard and Roller Fork
Applications)
Section 3
Maintenance
Step 3
With the clutch fork pried back, reinstall the vent
plug. This will compress the return spring and
eliminate the load on the fasteners.
앫 GO TO THE NEXT STEP.
4002086a
Step 4
Using a 13 mm wrench, remove the four nuts
that secure the clutch actuator to the
transmission housing. Remove clutch actuator.
앫 GO TO THE NEXT STEP.
4002033a
54
Section 3
Maintenance
Release Fork Greasing Procedure (Standard and Roller Fork
Applications)
Step 5
Working through the clutch inspection cover, use
a 19 mm socket and ratchet to remove the two
fasteners that secure the release fork assembly
to the transmission.
앫 GO TO THE NEXT STEP.
4005603a
Step 6
Remove the clutch actuator rod from the clutch
fork.
앫 GO TO THE NEXT STEP.
55
Section 3
Maintenance
Release Fork Greasing Procedure (Standard and Roller Fork
Applications)
Step 7
For Standard Fork Applications only
TWO INSIDE LATERAL
SURFACES OF THE
FORK TIPS
TWO FORK TIPS
CROSS
SHAFT
NOTE: This procedure is for standard fork
applications only.
Lightly grease the fork in six locations using
Optimol Olista Longime 3 EP grease. (ONLY USE
APPROVED GREASE.) NOTE: If cross shaft is
reused, clean thoroughly before applying
grease.
Grease the two fork tips, the two inside surfaces
of the fork (where the release bearing slides), the
cross shaft, and the ball joint.
BALL JOINT
4005006a
Step 7a
앫 GO TO THE NEXT STEP.
For Roller Fork Installations
RELEASE BEARING
CAUTION
Do not grease the following parts:
앫 Cam rollers on release fork
앫 Release flange
앫 Cross shaft (NOTE: The cross shaft in the
bearing bushing has clearance.)
RELEASE
FLANGE
앫 Release bearing bushing
RELEASE
SHAFT
RELEASE
FORK
56
WARNING
4007246a
This procedure is to be used for new
installations only. No maintenance is required
for roller fork applications already in service.
Section 3
Maintenance
Release Fork Greasing Procedure (Standard and Roller Fork
Applications)
Step 8
Install the clutch actuator rod into the ball joint.
앫 GO TO THE NEXT STEP.
4002089a
Step 9
Working through the clutch inspection cover, use
a 19 mm socket and torque wrench to tighten the
fasteners to 85 lb-ft (115 N•m). T
GO TO THE NEXT STEP.
4005603a
57
Section 3
Maintenance
Release Fork Greasing Procedure (Standard and Roller Fork
Applications)
Step 10
Use a 13 mm wrench to install the clutch
actuator housing onto the transmission case
with four nuts and washers.
앫 GO TO THE NEXT STEP.
4002033a
Step 11
Use a 13 mm socket and torque wrench to
tighten the fasteners to 17 lb-ft (23 N•m). T
앫 GO TO THE NEXT STEP.
4002051a
58
Section 3
Maintenance
Release Fork Greasing Procedure (Standard and Roller Fork
Applications)
Step 12
Use a 13 mm socket and torque wrench to
tighten the fasteners to 17 lb-ft (23 N•m). T
앫 GO TO THE NEXT STEP.
4002079a
4002079a
Step 13
Charge the air system to 120 psi.
30
90
60
0
The vehicle may not start after draining the air
system if transmission was in gear. Charging the
system with shop air will correct this issue.
PSI
120
150
4002090a
59
Section 3
Maintenance
SAE J1939 Requirements Flowchart
Notice
The ZF-FreedomLine transmission actively diagnoses SAE J1939 data bus faults and reacts accordingly when
the data bus or devices on the data bus, such as engine ECM, VECU (Vehicle Electronic Control Unit), and
ABS, that FreedomLine depends on, are not operating properly. The ZF-FreedomLine transmission
recognizes two types of SAE J1939 data bus faults, message faults and hardware faults. Message faults are
triggered when an SAE J1939 message is either missing or contains information that is out of limits.
Hardware faults are triggered when the SAE J1939 data bus fails. Hardware faults include shorted wires,
open wires, and improper assembly.
Is the ABS
light on?
Yes
The issue
lies within
the ABS
system.
No
Is the
check engine
light on?
Yes
Troubleshoot the
ABS paying close
attention to the
wheel-end speed
sensors.
Follow the ABS
supplier's
troubleshooting.
Check the
engine codes.
No
Is the
fault a
VSS fault?
Yes
The engine has
not received the
necessary
messages from
the transmission
via the SAE
J1939 data bus.
Are any
of them logged
and active?
Yes
No
Using TransSoft,
plug into the truck
and obtain the active
and inactive ISO
fault codes.
Are any
of them logged
and active?
The issue lies within
the OEM-installed
SAE J1939 data bus.
Consult the OEM
for proper repair
procedures.
The issue lies
within the
engine ECM.
None of the
messages from
the engine ECM
have been
received by the
transmission
TCU.
The engine ECM
may not have
power or the
SAE J1939 data
bus may be
disconnected.
Contact the
OEM or
engine supplier
as necessary.
No
Yes
A
Check for the
following
active codes.
• ISO 178
• ISO 179
• ISO 163
• ISO 177
Are any
of them logged
and active?
The ABS may
not have power
or the
SAE J1939
data bus may be
disconnected.
Contact the
OEM or
ABS supplier
as necessary.
Check for the
following
active codes.
• ISO 26
• ISO 180
• ISO 181
• ISO 182
• ISO 183
No
Troubleshoot the
engine. Follow the
engine OEM
troubleshooting.
The issue lies
with the
ABS controller.
None of the
messages sent
from the ABS
controller have
been received
by the
transmission
TCU.
This flowchart continues
on the next page.
Yes
The issue lies within the
OEM-installed SAE J1939
data bus. Consult the
OEM for proper repair
procedures.
No
Check for the
following
active codes.
• ISO 199
• ISO 91
4004243a
60
Section 3
Maintenance
SAE J1939 Requirements Flowchart
This flowchart continues
from the previous page.
Check for the
following active codes.
A
• ISO 95
• ISO 96
• ISO 97
• ISO 103
• ISO 164
• ISO 165
Check for the
following
active codes.
• ISO 92
• ISO 197
• ISO 198
Are any
of them logged
and active?
Yes
No
The issue lies
with the ABS.
The ABS
dash light
is probably
lit as well.
Troubleshoot
the ABS
paying close
attention to
the wheel-end
speed sensors.
Follow the ABS
supplier's
troubleshooting.
Are any
of the codes
logged and
active?
• ISO 166
• ISO 167
• ISO 168
• ISO 171
• ISO 172
• ISO 173
Yes
No
The issue lies
with the
engine ECM.
The information
contained
within the
engine
messages
is out of range.
Follow the
engine OEM's
troubleshooting.
The issue lies
with the
engine retarder.
The
information
contained within
the engine
retarder
messages
is out of range.
Contact
the engine
retarder
supplier.
Check for the
following
active code.
• ISO 27
Is the
code logged
and active?
Yes
No
The issue lies
with the
engine ECM.
The information
contained
within the
engine
configuration
message is
out of range.
Check for the
following
active codes.
• ISO 31
• ISO 32
Contact
the engine
supplier.
Are any
of the codes
logged and
active?
Check for the
following
active codes.
• ISO 93
• ISO 94
Are any
of them logged
and active?
No
No
Yes
The issue lies
with the ABS.
The information
contained
within the ABS
messages is
out of range.
Contact
the ABS
supplier.
Yes
The transmission
does not detect
any issues with
the SAE J1939
data bus.
4004245a
61
Section 3
Maintenance
Electrical Requirements Flowchart
Unplug the 21-pin OEM
interface connector, J7.
Turn the key on but do not
start the engine.
Disconnect the batteries.
Check the DC voltage
between pin A of the OEM
interface connector, J7,
and battery ground.
Check the resistance
between pin D of the OEM
interface connector, J7, and
the battery ground connector.
No
Is the resistance
0.0 to 0.5 Ohms?
The issue lies
within the OEM
power supply
circuit. Repair as
necessary.
Yes
No
The issue lies
within the OEM
power supply
circuit. Repair as
necessary.
Yes
No
The issue lies
within the OEM
power supply
circuit. Repair as
necessary.
The issue lies
within the OEM
power supply
circuit. Repair as
necessary.
Is the voltage
9.0 to 16.0
VDC?
No
The issue lies
within the OEM
power supply
circuit. Repair as
necessary.
No
The issue lies
within the OEM
power supply
circuit. Repair as
necessary.
Yes
Is the voltage
9.0 to 16.0
VDC?
Yes
Turn off the key.
Yes
Check the DC voltage
between pin A of the OEM
interface connector, J7,
and battery ground.
Check the resistance
between pin G of the OEM
interface connector, J7, and
the battery power
connector.
Is the resistance
0.0 to 0.5 Ohms?
No
Yes
Check the DC voltage
between pin G of the OEM
interface connector, J7,
and battery ground.
Check the resistance
between pin B of the OEM
interface connector, J7, and
the battery power
connector.
Is the resistance
0.0 to 0.5 Ohms?
No
Check the DC voltage
between pin B of the OEM
interface connector, J7,
and battery ground.
Check the resistance
between pin E of the OEM
interface connector, J7, and
the battery ground connector.
Is the resistance
0.0 to 0.5 Ohms?
Is the voltage
9.0 to 16.0
VDC?
The issue lies
within the OEM
power supply
circuit. Repair as
necessary.
No
The issue lies
within the OEM
power supply
circuit. Repair as
necessary.
Is the voltage
0.0 to 0.5
VDC?
Yes
Yes
Re-connect the batteries
but leave the 21-pin OEM
interface connector, J7,
unplugged.
62
This flowchart continues
on the next page.
4004157a
Section 3
Maintenance
Electrical Requirements Flowchart
This flowchart continues
from previous page.
With the
OSS #1 disconnected,
is the issue
resolved?
Check the DC voltage
between pin B of the OEM
interface connector, J7, and
battery ground.
Is the voltage
9.0 to 16.0
VDC?
Yes
Replace the
output shaft
speed sensor #1.
No
No
The issue lies
within the OEM
power supply
circuit. Repair as
necessary.
Reconnect the output
shaft speed sensor #1.
Turn the key off.
Yes
Disconnect the output
shaft speed sensor #2, J5
(the four-wire speed sensor
with convoluted tubing).
Check the DC voltage
between pin G of the OEM
interface connector, J7, and
battery ground.
Is the voltage
9.0 to 16.0
VDC?
No
The issue lies
within the OEM
power supply
circuit. Repair as
necessary.
With the OSS #2
disconnected, is the issue
resolved?
Yes
Re-connect the OEM
interface connector, J7.
Yes
Replace the
output shaft
speed sensor #2.
No
Check the DC voltage level
between pins 1 and 2
of the output shaft speed
sensor #2, J5.
Disconnect the TCU
connector, J1.
Check the DC voltage
level between pin 1 of the
TCU connector, J1, and
battery ground.
Is the voltage
18.0 to 32.0
VDC?
Turn the key on but do not
start the engine.
Is the voltage
18.0 to 32.0
VDC?
No
Replace the
voltage
doubler.
Replace the
voltage
doubler.
No
Yes
Did the new
voltage doubler
fix the truck?
Yes
Reconnect the TCU
connector, J1.
Disconnect the output
shaft speed sensor #1
(the three wire speed sensor
without convoluted tubing).
Reconnect the output
shaft speed sensor #2
connector, J5.
‚
The transmission s
electrical system is
operating correctly.
No
Replace the
transmission
wire harness.
Release
the vehicle.
Yes
Turn the key on but do not
start the engine.
4004193c
63
Section 3
Maintenance
Electrical Requirements
Step 1
Unplug the 21-pin OEM interface connector, J7.
4002016a
Step 2
Disconnect the batteries. Use a disconnect
switch if available.
4004150a
Step 3
H
X
J
Check the resistance between pin D of the OEM
interface connector, J7, and the battery ground
connector.
K
W
B
G
V
L
A
F
C
M
U
E
Is the resistance 0.0-0.5 Ohms?
D
T
앫 YES ➞ GO TO STEP 4.
N
S
R
P
앫 NO
➞ THE ISSUE LIES WITHIN THE OEM
GROUND CIRCUIT. REPAIR AS NECESSARY.
OEM INTERFACE CONNECTOR
4004163a
64
Section 3
Maintenance
Electrical Requirements
Step 4
H
X
Check the resistance between pin E of the OEM
interface connector, J7, and the battery ground
connector.
J
K
W
B
G
V
L
A
F
Is the resistance 0.0-0.5 Ohms?
C
M
U
E
앫 YES ➞ GO TO STEP 5.
D
N
T
S
앫 NO
➞ THE ISSUE LIES WITHIN THE OEM
GROUND CIRCUIT. REPAIR AS NECESSARY.
P
R
OEM INTERFACE CONNECTOR
4004164a
Step 5
H
X
Check the resistance between pin B of the OEM
interface connector, J7, and the battery power
connector.
J
K
W
G
B
V
L
A
F
Is the resistance 0.0-0.5 Ohms?
C
M
U
E
앫 YES ➞ GO TO STEP 6.
D
T
N
S
앫 NO
➞ THE ISSUE LIES WITHIN THE OEM
12V BATTERY + CIRCUIT. REPAIR AS NECESSARY.
P
R
OEM INTERFACE CONNECTOR
4004165a
Step 6
H
X
Check the resistance between pin G of the OEM
interface connector, J7, and the battery power
connector.
J
K
W
G
B
V
L
A
F
Is the resistance 0.0-0.5 Ohms?
C
M
U
E
앫 YES ➞ GO TO STEP 7.
D
T
N
S
R
앫 NO
➞ THE ISSUE LIES WITHIN THE OEM
12V BATTERY + CIRCUIT. REPAIR AS NECESSARY.
P
OEM INTERFACE CONNECTOR
4004166a
65
Section 3
Maintenance
Electrical Requirements
Step 7
NOTE: The voltage ranges referenced in the
following steps are based on voltage ranges of
a system with serviceable batteries. This
procedure also assumes that a battery charger
is not connected to the batteries.
Reconnect the batteries but leave the 21-pin
OEM interface connector, J7, unplugged.
4004150a
Step 8
Turn the key on but do not start the engine.
4004154a
Step 9
H
X
Check the DC voltage between pin A of the OEM
interface connector, J7, and the battery ground
connector.
J
K
W
B
G
V
A
F
U
E
L
Is the DC voltage 9.0 to 16.0 VDC?
M
앫 YES ➞ GO TO STEP 10.
C
D
T
➞ THE ISSUE LIES WITHIN THE OEM
SUPPLY/IGNITION CIRCUIT. REPAIR AS
NECESSARY.
R
P
OEM INTERFACE CONNECTOR
66
앫 NO
N
S
4004167a
Section 3
Maintenance
Electrical Requirements
Step 10
H
X
Check the DC voltage between pin B of the OEM
interface connector, J7, and the battery ground
connector.
J
K
W
B
G
V
A
F
U
E
L
Is the DC voltage 9.0 to 16.0 VDC?
M
앫 YES ➞ GO TO STEP 11.
C
D
T
앫 NO
➞ THE ISSUE LIES WITHIN THE OEM
BATTERY POSITIVE + CIRCUIT. REPAIR AS
NECESSARY.
N
S
P
R
OEM INTERFACE CONNECTOR
4004165a
Step 11
H
X
Check the DC voltage between pin G of the OEM
interface connector, J7, and the battery ground
connector.
J
K
W
B
G
V
L
A
F
Is the DC voltage 9.0 to 16.0 VDC?
C
M
U
E
앫 YES ➞ GO TO STEP 12.
D
T
N
S
R
앫 NO
➞ THE ISSUE LIES WITHIN THE OEM
BATTERY POSITIVE + CIRCUIT. REPAIR AS
NECESSARY.
P
OEM INTERFACE CONNECTOR
4004166a
Step 12
Turn the key off.
4004153a
67
Section 3
Maintenance
Electrical Requirements
Step 13
H
X
Check the DC voltage between pin A of the OEM
interface connector, J7, and the battery ground
connector.
J
K
W
B
G
V
A
F
U
E
L
Is the DC voltage 0.0 to 0.5 VDC?
M
앫 YES ➞ GO TO STEP 14.
C
D
T
앫 NO
➞ THE ISSUE LIES WITHIN THE OEM
SUPPLY/IGNITION CIRCUIT. REPAIR AS
NECESSARY.
N
S
P
R
OEM INTERFACE CONNECTOR
4004167a
Step 14
H
X
Check the DC voltage between pin B of the OEM
interface connector, J7, and the battery ground
connector.
J
K
W
B
G
V
L
A
F
C
Is the DC voltage 9.0 to 16.0 VDC?
M
U
E
앫 YES ➞ GO TO STEP 15.
D
T
N
S
앫 NO
➞ THE ISSUE LIES WITHIN THE OEM
BATTERY + CIRCUIT. REPAIR AS NECESSARY.
P
R
OEM INTERFACE CONNECTOR
4004165a
Step 15
H
X
Check the DC voltage between pin G of the OEM
interface connector, J7, and the battery ground
connector.
J
K
W
B
G
V
A
F
U
E
L
Is the DC voltage 9.0 to 16.0 VDC?
M
앫 YES ➞ GO TO STEP 16.
C
D
T
S
R
➞ THE ISSUE LIES WITHIN THE OEM
BATTERY POSITIVE + CIRCUIT. REPAIR AS
NECESSARY.
P
OEM INTERFACE CONNECTOR
68
앫 NO
N
4004166a
Section 3
Maintenance
Electrical Requirements
Step 16
Reconnect the OEM interface connector, J7.
4002016a
Step 17
VEHICLE
Disconnect the TCU connector, J1 (this
connector is located on the passenger side of
the TCU).
TRANSMISSION
4002006a
Step 18
Check the DC voltage between pins 1, 4 and 5 of
the TCU connector, J1, and the battery ground
connector.
1 2
3
6
10
15
7
11
4
12
16
5
Is the DC voltage 18.0 to 32.0 VDC?
9
8
13
앫 YES ➞ GO TO STEP 19.
14
앫 NO
➞ REPLACE THE VOLTAGE DOUBLER
IF THE VOLTAGE IS FROM 9.0 TO 16.0 VDC.
REPLACE THE TRANSMISSION WIRING HARNESS
IF THE VOLTAGE IS 0 VDC. IF THE VOLTAGE IS
THE SAME AS BATTERY, REPLACE THE DOUBLER.
IF NO VOLTAGE IS PRESENT, REPLACE
TRANSMISSION HARNESS.
17
18 19 20
MAIN TCU
CONNECTOR
4004169a
69
Section 3
Maintenance
Electrical Requirements
Step 19
VEHICLE
Reconnect the TCU connector, J1.
GO TO STEP 20.
TRANSMISSION
4002006a
Step 20
Disconnect the output shaft speed sensor #1
(the three wire speed sensor without convoluted
tubing).
4002024a
Step 21
Turn the key on but do not start the engine.
With the OSS #1 disconnected, is the issue
resolved except for an active ISO 99?
앫 YES ➞ REPLACE THE OUTPUT SHAFT SPEED
SENSOR #1.
앫 NO
4004154a
70
➞
GO TO STEP 22.
Section 3
Maintenance
Electrical Requirements
Step 22
Reconnect the output shaft speed sensor #1.
4002024a
Step 23
Turn the key off.
4004154a
Step 24
Disconnect the output shaft speed sensor #2, J5
(the four-wire sensor with convoluted tubing).
71
Section 3
Maintenance
Electrical Requirements
Step 25
Turn the key on but do not start the engine.
4004154a
Step 26
With the output shaft speed sensor #2
disconnected, is the issue resolved except for an
active ISO 100?
앫 YES ➞ REPLACE THE OUTPUT SHAFT SPEED
SENSOR #2.
앫 NO
➞
GO TO STEP 27.
Step 27
Check the DC voltage between pin 1 of the
output shaft speed sensor #1, J5, and the battery
ground connector.
2
4
3
Is the DC voltage 18.0 to 32.0 VDC?
1
앫 YES ➞ GO TO STEP 29.
앫 NO
OUTPUT SHAFT
SPEED
SENSOR CONNECTOR
72
➞ IF VOLTAGE IS < 6 VOLTS, REPLACE THE
TRANSMISSION TCU TOP HALF.
4004168a
Section 3
Maintenance
Electrical Requirements
Step 28
Reconnect the output shaft speed sensor #2, J5.
The transmission’s electrical system is operating
correctly.
Step 29
Reconnect the output shaft speed sensor #1.
4002024a
Step 30
Turn the key off.
4004154a
73
Section 3
Maintenance
Pneumatic Requirements Flowchart
Measure the air pressure in
the air tank that supplies
the transmission air tank.
Is the air
pressure 100 PSI
or more?
Build up the
system air
pressure
to 120 PSI.
No
Yes
Did building
up the air pressure
resolve the
issue?
No
Yes
The vehicle air
pressure was
low. Release
the truck.
Verify that the air routed
to the transmission air tank
is run through a dryer at
some point in the system,
just not immediately
before the transmission
air tank.
Is the air
properly routed
through a
dryer?
No
Contact the OEM
and arrange for the
proper routing of
the air to the
transmission air tank.
Yes
Measure the air pressure in
the transmission TCU
using TransSoft™.
Does the
transmission air
tank have 100 to
108 PSI?
Verify that the transmission
is prioritized after the air
brakes but before all
other air options.
No
Contact the OEM and
troubleshoot the
pressure protection
valve, air line, and
check valve that are
used to supply air to
the transmission
air tank.
No
Verify that the two supply
lines running from the
transmission air tank
to the transmission
are 5/8" OD.
Verify the presence of a
10 Liter (approx.)
transmission air tank.
No
Contact the OEM
and arrange for the
installation of a
transmission
air tank.
Are the supply
lines 5/8" OD?
No
Yes
Contact the OEM
and arrange for the
installation of 5/8"
OD supply lines.
Yes
Verify that the transmission
air tank is supplied from
either the wet or dry tank.
Is the
transmission air tank
properly supplied?
Contact the OEM
and arrange for the
proper prioritizing
of the truck's
pneumatic system.
Yes
Yes
Is the
transmission air tank
installed?
Is the
transmission air tank
properly supplied?
This flowchart continues
on the next page.
No
Contact the OEM
and arrange for the
transmission air
tank to be properly
supplied.
Yes
4004158a
74
Section 3
Maintenance
Pneumatic Requirements Flowchart
This flowchart continues
from previous page.
Verify that no “T” fittings
are used to supply the
transmission with air. Two
separate lines must be routed
from the transmission air
tank to the transmission.
Are “T”
fittings used to supply
the transmission
with air?
At what
pressure does the
pressure protection
valve close?
Yes
Contact the OEM
and arrange for the
installation of two
separate 5/8" air
lines.
No
Verify that the transmission
air tank is protected with a
one-way check valve.
Is a one-way
check valve
installed?
No
Yes
Is the driver
complaining about
getting stuck in
gear?
Yes
Contact the OEM
and arrange for
the installation of
a one-way
check valve
that performs as
suggested in the
FreedomLine
Installation
Considerations.
Contact the OEM and
arrange for the
replacement of the
pressure protection
valve with one that
performs as suggested
in the FreedomLine
Installation
Considerations.
Contact the OEM
and arrange for the
replacement of the
pressure protection
valve with one
that closes at
80 PSI or lower.
Contact the OEM
and arrange for the
replacement of the
one-way check
valve.
No
The one-way check valve
does not require
replacement.
Verify that the transmission
air tank is protected with a
pressure protection valve.
Is a pressure
protection valve
installed?
Yes
No
Contact the OEM and arrange
for the installation of a
pressure protection valve with
one that performs as suggested
in the FreedomLine Installation
Considerations.
4004194c
75
Section 3
Maintenance
Pneumatic Requirements
Step 1
Measure the air pressure in the vehicle air tanks.
Is the air pressure 100 psi or more?
앫 YES ➞ GO TO STEP 3.
앫 NO
➞
GO TO STEP 2.
4004151a
Step 2
Build up the air pressure to 120 psi.
30
60
0
Does this resolve the issue?
90
PSI
앫 YES ➞ RELEASE THE TRUCK.
120
150
앫 NO
➞
GO TO STEP 3.
4002090a
Step 3
Measure the air pressure at the transmission
using TransSoftTM.
Is the air pressure 95 to 108 psi?
앫 YES ➞ GO TO STEP 4.
앫 NO
➞ CONTACT THE OEM AND
TROUBLESHOOT THE PRESSURE PROTECTION
VALVE, AIR LINE, AND CHECK VALVE THAT ARE
USED TO SUPPLY AIR TO THE TRANSMISSION
AIR TANK.
4004155a
76
Section 3
Maintenance
Pneumatic Requirements
Step 4
Verify the presence of a 10 L (approximately)
transmission air tank.
Is the transmission air tank installed?
10 L Minimum
Trans. Reservoir
앫 YES ➞ GO TO STEP 5.
앫 NO
➞ CONTACT THE OEM AND ARRANGE FOR
THE INSTALLATION OF A TRANSMISSION AIR
TANK.
4004170a
Step 5
Verify that the transmission air tank is being
supplied by either the wet or dry tank.
Is the air supply properly routed?
앫 YES ➞ GO TO STEP 6.
앫 NO
➞ CONTACT THE OEM AND ARRANGE FOR
THE TRANSMISSION AIR TANK TO BE PROPERLY
SUPPLIED.
Step 6
Verify that the air routed to the transmission air
tank is run through a dryer at some point in the
system.
Is the air run through a dryer?
앫 YES ➞ GO TO STEP 7.
앫 NO
➞ CONTACT THE OEM AND ARRANGE FOR
THE PROPER ROUTING OF THE AIR TO THE
TRANSMISSION AIR TANK.
4004182a
77
Section 3
Maintenance
Pneumatic Requirements
Step 7
Verify that the transmission is prioritized after
the air brakes but before all other air options.
Is the transmission prioritized correctly?
앫 YES ➞ GO TO STEP 8.
앫 NO
➞ CONTACT THE OEM AND ARRANGE
FOR THE CORRECT PRIORITIZING OF THE
TRUCK’S PNEUMATIC SYSTEM.
Step 8
Verify that the two supply lines running from the
transmission air tank to the transmission are
5/8” OD.
Are the supply line 5/8” OD?
앫 YES ➞ GO TO STEP 9.
앫 NO
➞ CONTACT THE OEM AND ARRANGE FOR
THE INSTALLATION OF 5/8” OD AIR SUPPLY
LINES.
5/8"
4004173a
Step 9
Verify that no “T” fittings are used to supply the
transmission with air.
10 L Minimum
Trans. Reservoir
NOTE: ZF does not recommend the use of a
“T-fitting” between the dedicated air tank and
the transmission air lines, instead the use of a
separate line for the clutch actuator and for the
transmission control unit is recommended.
Are two separate lines installed?
Transmission Shift Module
앫 YES ➞ GO TO STEP 10.
앫 NO
➞ CONTACT THE OEM AND ARRANGE FOR
THE INSTALLATION OF TWO SEPARATE AIR
SUPPLY LINES.
Transmission Clutch Actuator
4004174a
78
Section 3
Maintenance
Pneumatic Requirements
Step 10
ONE-WAY
CHECK
VALVE
Verify that the transmission air tank is protected
with a one-way check valve.
Is a one-way check valve installed?
앫 YES ➞ GO TO STEP 11.
앫 NO
➞ CONTACT THE OEM AND ARRANGE FOR
THE REPLACEMENT OF THE PRESSURE
PROTECTION VALVE WITH ONE THAT PERFORMS
AS SUGGESTED IN THE FREEDOMLINE
INSTALLATION CONSIDERATIONS.
10 L Minimum
Trans. Reservoir
4004175a
Step 11
Is the driver complaining about getting stuck in
gear?
앫 NO
➞ THE ONE-WAY CHECK VALVE DOES NOT
REQUIRE REPLACEMENT. GO TO STEP 12.
앫 YES ➞ CONTACT THE OEM AND ARRANGE FOR
Step 13
Does the pressure protection valve function
correctly?
앫 CONTACT THE OEM TO DETERMINE WHAT THE
CORRECT OPENING AND CLOSING VALUES ARE
FOR THE INSTALLED VALVE.
THE REPLACEMENT OF THE PRESSURE
PROTECTION VALVE WITH ONE THAT PERFORMS
AS SUGGESTED IN THE FREEDOMLINE
INSTALLATION CONSIDERATIONS.
Step 12
Step 14
Verify that the vehicle’s air tanks are protected
with a pressure protection valve.
Is the driver complaining about getting stuck in
gear?
Is a pressure protection valve installed?
앫 NO
앫 YES ➞ GO TO STEP 13.
앫 NO
➞ CONTACT THE OEM AND ARRANGE
FOR THE REPLACEMENT OF THE PRESSURE
PROTECTION VALVE WITH ONE THAT PERFORMS
AS SUGGESTED IN THE FREEDOMLINE
INSTALLATION CONSIDERATIONS.
➞ THE PRESSURE PROTECTION VALVE
DOES NOT REQUIRE REPLACEMENT. THE
VEHICLE’S AIR SUPPLY TO THE TRANSMISSION
IS INSTALLED CORRECTLY.
앫 YES ➞ CONTACT THE OEM AND ARRANGE
FOR THE REPLACEMENT OF THE PRESSURE
PROTECTION VALVE WITH ONE THAT PERFORMS
AS SUGGESTED IN THE FREEDOMLINE
INSTALLATION CONSIDERATIONS.
79
Section 3
Maintenance
No-Start Troubleshooting Flowchart
Yes
Is “AL” on the
transmission display
when the key
is turned on?
Charge the air
system and then
attempt to start
the engine.
Attempt to bump the engine
with the starter.
DO NOT ATTEMPT TO START
THE ENGINE,
JUST BUMP IT.
No
Yes
Does the starter
engage?
Is “--” on the
transmission display
when the key
is turned on?
Yes
Verify the
electrical
requirements.
This issue was a
contaminated
OEM interface
connector, J7.
Release the
vehicle.
No
Disconnect the neutral
switch connector, J2.
No
Is “SM” on the
transmission display
when the key
is turned on?
Yes
Use TransSoftTM to
retrieve the ISO
diagnostic codes
and call
‚
ArvinMeritor s
OnTrac customer
service center at
(800) 535-5560.
Verify that the neutral
switch connector, J2, is clean
and that all pins are firmly
held in place. Use contact
cleaner as necessary.
Is the neutral switch
damaged?
No
With the key off,
disconnect the 21-pin OEM
interface connector, J7.
Yes
Replace the
neutral switch.
No
Reconnect the neutral
switch connector, J2.
Jumper pins C and D of the
OEM side of the OEM
interface connector, J7.
Attempt to bump the engine
with the starter.
DO NOT ATTEMPT TO START
THE ENGINE,
JUST BUMP IT.
Attempt to bump the engine
with the starter.
DO NOT ATTEMPT TO START
THE ENGINE,
JUST BUMP IT.
Does the starter
engage?
Does the starter
engage?
No
Yes
Remove the jumper wire.
Verify that the OEM interface
connector, J7, is clean and
that all pins are firmly
held in place.
Reconnect the OEM
interface connector, J7.
Contact the OEM
and trouble shoot
the OEM side
of the starter
interlock circuit,
including the
starter
Yes
No
Jumper pins 1 and 2 of the
neutral pin connector, J2.
Attempt to bump the engine
with the starter.
DO NOT ATTEMPT TO START
THE ENGINE,
JUST BUMP IT.
Yes
Does the starter
engage?
No
This issue was a
contaminated
neutral switch
connector, J2.
Release the
vehicle.
Either the neutral
switch or the
neutral push pin
are broken or the
transmission is
in gear.
Using a 27 mm
wrench, remove
the neutral
switch.
With the plunger
in the rest
position, measure
the resistance
across pins 1 and
2 of the neutral
switch.
A
This flowchart continues
on the next page.
80
B
4004159a
Section 3
Maintenance
No-Start Troubleshooting Flowchart
B
This flowchart continues from the previous page.
A
Is the resistance
0.0 to 0.5
Ohms?
Disconnect the OEM interface connector, J7,
the neutral switch connector, J2, and the
ZMTEC connector, J3.
No
Yes
With the plunger pushed in, measure
the resistance across pins 1 and 2
of the neutral switch.
Check the resistance between pin C1 of the
ZMTEC connector, J3 and pin C of the OEM
interface connector, J7. (The neutral switch
must still be jumpered.)
No
Is the circuit open?
Is the
resistance 0.0 to
0.5 Ohms?
No
Replace the
neutral switch and
inspect the
neutral push pin
‚
to make sure it s
not seized in
the bore.
Replace the
transmission
wire harness.
Yes
Replace the
neutral switch and
inspect the
neutral push pin
‚
to make sure it s
not seized in
the bore.
Inspect the neutral push pin in the
transmission and make sure it
‚
isn t seized.
Yes
Check for shorts from the starter interlock circuit
(pin C1 of the ZMTEC connector, J3 and pin C
of the OEM interface connector, J7) to all
other circuits in the wire harness.
Is the neutral
push pin seized?
Yes
Repair the pin
as necessary.
No
Is the
starter interlock circuit
shorted to any other
pins?
Yes
Replace the
transmission
wire harness.
Remove the jumper wire
and inspect the neutral switch
connector, J2 and the neutral switch
pins for signs of damage.
Do any of the
pins show signs of
damage?
Before replacing ZMTEC, check for power
to the ZMTEC. With key in the "OFF" position,
disconnect J3 (ZMTEC connector) and
verify voltage across pins A1
(battery 12 VDC) and A3 (battery ground).
Yes
Replace the
transmission wire
harness and/or
the neutral switch
as necessary.
No
Reassemble and reconnect the
neutral switch and neutral push pin.
Is the DC voltage
between 9.0 to 16.0
VDC?
The transmission may be in gear.
Using shop air, build up 120 PSI
air pressure in the tanks.
No
Verify the ground
circuit to the
ZMTEC.
Is the resistance
0.0 to 0.5
Ohms?
No
The problem lies
within the OEM
ground circuit.
Yes
Verify ZMTEC
ignition circuit.
Turn key to the
"ON" position/
engine "OFF".
Verify voltage
across pins A2
(12 VDC ignition)
and A3 (battery
ground).
Is the DC
voltage between
9.0 and
16.0 VDC?
Turn the key on for 10 seconds and
then bump the engine.
DO NOT ATTEMPT TO START
THE ENGINE,
JUST BUMP IT.
Does the
starter engage?
Yes
No
Yes
The transmission
was in gear
without enough
air pressure to
attain neutral.
Release the vehicle.
Replace the
ZMTEC.
No
Call OnTrac at
866-668-7221.
Call OnTrac at
866-668-7221.
4004195b
81
Section 3
Maintenance
No-Start Troubleshooting
Step 1
Is “AL” on the transmission display when the key
is turned on?
AL
앫 NO
➞
GO TO STEP 2.
앫 YES ➞ CHARGE THE AIR SYSTEM AND THEN
ATTEMPT TO START THE ENGINE.
4004156a
Step 2
__
Is “--” on the transmission display when the key
is turned on?
앫 NO
➞
GO TO STEP 3.
앫 YES ➞ VERIFY THE ELECTRICAL
REQUIREMENTS OF THE TRANSMISSION.
4004160a
Step 3
Is “SM” on the transmission display when the
key is turned on?
앫 NO
sm
GO TO STEP 4.
앫 YES ➞ USE TRANSSOFTTM TO RETRIEVE
THE ISO DIAGNOSTIC CODES AND
TROUBLESHOOT ACTIVE FAULT CODES.
IF ASSISTANCE IS NEEDED, CALL ONTRAC
AT 866-668-7221.
4004161a
82
➞
Section 3
Maintenance
No-Start Troubleshooting
Step 4
With the key off, disconnect the 21-pin OEM
interface connector, J7.
4002016a
Step 5
H
J
X
K
WARNING
W
B
G
L
Before performing this step, ensure that the
transmission air system is working properly
and that the transmission is in neutral.
V
A
C
F
M
U
D
E
N
T
P
R
S
OEM INTERFACE CONNECTOR
Jumper pins C and D of the OEM side of the
OEM interface connector, J7.
4004162b
Step 6
Attempt to bump the engine with the starter. DO
NOT ATTEMPT TO START THE ENGINE, JUST
BUMP IT.
Does the starter engage?
앫 YES ➞ GO TO STEP 7.
앫 NO
➞ CONTACT THE OEM AND
TROUBLESHOOT THE OEM SIDE OF THE STARTER
INTERLOCK CIRCUIT, INCLUDING THE STARTER.
4004152a
83
Section 3
Maintenance
No-Start Troubleshooting
Step 7
H
J
X
K
W
B
G
L
V
A
C
Remove the jumper wire from the OEM side of
the OEM interface connector, J7.
F
M
U
D
E
N
T
P
S
R
OEM INTERFACE CONNECTOR
4004162b
Step 8
H
X
J
K
W
B
G
V
Verify that the OEM interface connector, J7, is
clean and that all pins are firmly held in place.
L
A
F
C
M
U
E
Use contact cleaner as necessary.
D
T
N
S
R
P
OEM INTERFACE CONNECTOR
4001982b
Step 9
Reconnect the OEM interface connector, J7.
4002016a
84
Section 3
Maintenance
No-Start Troubleshooting
Step 10
Attempt to bump the engine with the starter. DO
NOT ATTEMPT TO START THE ENGINE, JUST
BUMP IT.
Does the starter engage?
앫 NO
➞
GO TO STEP 11.
앫 YES ➞ THE ISSUE WAS A CONTAMINATED
OEM INTERFACE CONNECTOR, J7.
4004152a
Step 11
Disconnect the neutral switch connector, J2.
Step 12
Verify that the neutral switch connector, J2, and
the neutral switch are clean and that all pins are
firmly held in place.
Use contact cleaner as necessary.
Do any of the pins show signs of damage?
앫 NO
➞
GO TO STEP 13.
앫 YES ➞ REPLACE THE TRANSMISSION WIRING
HARNESS AND/OR THE NEUTRAL SWITCH AS
NECESSARY.
85
Section 3
Maintenance
No-Start Troubleshooting
Step 13
Reconnect the neutral switch connector, J2.
Step 14
Attempt to bump the engine with the starter. DO
NOT ATTEMPT TO START THE ENGINE, JUST
BUMP IT.
Does the starter engage?
앫 NO
➞
GO TO STEP 15.
앫 YES ➞ THE NEUTRAL SWITCH CONNECTOR
AND/OR THE NEUTRAL SWITCH WAS
CONTAMINATED.
4004152a
Step 15
1
4
3
2
Jumper pins 1 and 2 of the neutral pin
connector, J2.
NEUTRAL SWITCH CONNECTOR
4004179a
86
Section 3
Maintenance
No-Start Troubleshooting
Step 16
Attempt to bump the engine with the starter. DO
NOT ATTEMPT TO START THE ENGINE, JUST
BUMP IT.
Does the starter engage?
앫 NO
➞
GO TO STEP 12.
앫 YES ➞ GO TO STEP 17.
4004152a
Step 17
Either the neutral switch or the neutral push pin
is broken.
Using a 27 mm 12 point wrench or chrome
12 point socket, remove the neutral switch.
Step 18
1
4
3
2
With the plunger of the neutral switch in the rest
position, measure the resistance across pins 1
and 2 of the neutral switch.
Is the resistance 0.0-0.5 Ohms?
앫 YES ➞ GO TO STEP 19.
앫 NO
➞ REPLACE THE NEUTRAL SWITCH AND
INSPECT THE NEUTRAL PUSH PIN TO MAKE SURE
IT’S NOT SEIZED IN THE BORE.
NEUTRAL SWITCH CONNECTOR
4004179a
87
Section 3
Maintenance
No-Start Troubleshooting
Step 19
With the plunger of the neutral switch pushed in,
measure the resistance across pins 1 and 2 of
the neutral switch.
1
4
Is the circuit open?
3
2
앫 YES ➞ GO TO STEP 20.
앫 NO
➞ REPLACE THE NEUTRAL SWITCH AND
INSPECT THE NEUTRAL PUSH PIN TO MAKE SURE
IT’S NOT SEIZED IN THE BORE.
NEUTRAL SWITCH CONNECTOR
4004179a
Step 20
NEUTRAL
PUSH PIN
Inspect the neutral push pin in the transmission
and make sure it isn’t seized.
Is the neutral push pin seized?
앫 NO
➞
GO TO STEP 21.
앫 YES ➞ REPAIR THE PIN AS NECESSARY.
4004181a
Step 21
Remove the jumper and inspect the neutral
switch connector, J2, and the neutral pins for
signs of damage.
Do any of the pins show signs of damage?
앫 NO
➞
GO TO STEP 22.
앫 YES ➞ REPLACE THE TRANSMISSION WIRING
HARNESS AND/OR THE NEUTRAL SWITCH AS
NECESSARY.
88
Section 3
Maintenance
No-Start Troubleshooting
Step 22
Reassemble and reconnect the neutral switch
and neutral push pin.
Tighten the neutral switch to 37 lb-ft (50 N•m)
and make sure the sealing ring is installed. T
Step 23
30
90
60
0
If not already done, build up the vehicle air
pressure to 120 psi using shop air.
PSI
120
150
4002090a
Step 24
Attempt to bump the engine with the starter. DO
NOT ATTEMPT TO START THE ENGINE, JUST
BUMP IT.
Does the starter engage?
앫 NO
➞
GO TO STEP 25.
앫 YES ➞ THE VEHICLE’S AIR PRESSURE WAS
TOO LOW.
4004152a
89
Section 3
Maintenance
No-Start Troubleshooting
Step 25
Disconnect the OEM interface connector, J7, the
neutral switch connector, J2, and the ZMTEC
connector, J3.
4004183a
Step 26
H
X
J
K
W
B
G
V
L
A
F
C
M
U
E
D
T
N
S
R
P
K1
A1
Check the resistance across pin C1 of the ZMTEC
connector, J3 and pin C of the OEM interface
connector, J7. (The neutral switch must still be
jumpered.)
Is the resistance 0.0 to 0.5 Ohms?
OEM
INTERFACE
CONNECTOR
앫 YES ➞ GO TO STEP 27.
앫 NO
➞ REPLACE THE TRANSMISSION WIRING
HARNESS.
K3
A3
ZMTEC CONNECTOR
4004180a
Step 27
Check for shorts from the starter interlock circuit
(pin C1 of the ZMTEC connector, J3, and pin C
of the OEM interface connector, J7) to all other
circuits in the transmission wiring harness.
Refer to the system schematic on page 93.
Is the wiring harness shorted?
앫 NO
➞
REPLACE THE ZMTEC.
앫 YES ➞ REPLACE THE TRANSMISSION WIRING
HARNESS.
90
Section 3
Maintenance
PTO Requirements Flowchart
Notice
The ZF-FreedomLine transmission is delivered pre-programmed to accept both a stationary PTO (for use in
neutral) and a non-stationary PTO (for use in the default PTO gear only). The installation of the PTO is the
responsibility of the owner. An improperly installed PTO may damage the transmission gearing, requiring
a transmission replacement.
The Transmission Controller Unit (TCU) actively monitors the PTO and acts accordingly. Pin A of the PTO
connector must be wired into the PTO switch. Pin C of the PTO connector must be wired into the series of
relays that activate the PTO. Pin B of the PTO connector must be wired into the ball switch that
acknowledges the engagement of the PTO.
Using a Volt-Ohm meter, check
for 9.0 to 16.0 VDC on pin A of
the transmission side of
the PTO connector.
Is the voltage
in spec?
No
Using a Volt-Ohm meter,
check that the voltage at
pin A of the PTO connector, J9,
drops to 0.0 to 0.5 VDC
when the circuit is grounded.
Using a Volt-Ohm meter, check
for continuity (0.0 to 0.5 ohms)
between pin A of the PTO
connector, J9, and pin G1
of the ZMTEC connector, J3.
Yes
Using a
Volt-Ohm meter,
check for 9.0 to 16.0 VDC
on pin B of the
transmission side of
the PTO connector.
Is the
resistance in
spec?
Is the voltage
in spec?
No
Replace the
wire harness.
No
Using a Volt-Ohm meter, check
for continuity (0.0 to 0.5 ohms)
between pin B of the PTO
connector, J9, and pin G2
of the ZMTEC connector, J3.
Yes
Is the voltage
in spec?
No
Replace the
ZMTEC.
Yes
Yes
Is the
resistance in
spec?
Using a Volt-Ohm
meter, check for
9.0 to 16.0 VDC
on pin C of the
transmission side of
the PTO connector.
Is the voltage
in spec?
Replace the
ZMTEC.
Using a Volt-Ohm meter,
check that the voltage at
pin B of the PTO connector, J9,
drops to 0.0 to 0.5 VDC
when the circuit is grounded.
Yes
Replace the
ZMTEC.
Is the voltage
in spec?
No
No
Using a Volt-Ohm meter,
check that the voltage at
pin C of the PTO connector, J9,
drops to 0.0 to 0.5 VDC
when the circuit is grounded.
Replace the
ZMTEC.
Yes
No
Replace the
wire harness.
Using a Volt-Ohm meter, check
for continuity (0.0 to 0.5 ohms)
between pin C of the PTO
connector, J9, and pin B1
of the ZMTEC connector, J3.
Yes
Is the voltage
in spec?
No
Replace the
ZMTEC.
Yes
The transmission is
functioning properly.
Is the
resistance in
spec?
Yes
No
Replace the
wire harness.
Replace the
ZMTEC.
Contact Muncie at
(800) FOR PTOS or
(800) 367-7867 for
diagnostic assistance.
4005005b
91
Section 4
Wiring/Pneumatic Diagrams
Section 4
Wiring/Pneumatic
Diagrams
Wiring/Pneumatic Diagrams
Resistance Specifications
Diagnostic Connector
Connector Pin Assignments
Diagnostic Connector
Section
Wiring/Pneumatic
4
Diagrams
Resistance
Specifications
Resistance (Measured
Across Pins 1 and 2)
Component
Not in
Neutral
Neutral Switch
In Neutral
0.0-0.5 ohms open circuit
Connector Pin Assignments
1 2
3
6
10
15
12
8
13
A1
2
9
4
7
11
K1
5
4
14
Pin A
Battery (–)
Pin B
Battery (+)
Unswitched — with
Unconditioned 10 A fuse
Pin C
CAN_H
Tractor Bus
Pin D
CAN_L
Tractor Bus
Pin E
CAN_SHLD (for SAE J1939/11)
Pin F
SAE J1708 (+)
Pin G
SAE J1708 (–)
Pin H
Proprietary OEM Use
Pin J
Proprietary OEM Use
3
1
16
17
18 19 20
Output Shaft
Speed
Sensor Connector
(Both Harnesses)
Main TCU
Connector
(Both Harnesses)
K1
K3
ZMTEC A3
Connector
(New Style)
A1
12 11 10 9 8 7
1 2 3 4 5 6
K3
ZMTEC
Connector
(Old Style)
A3
Voltage Doubler Connector
H
X
J
K
W
B
G
1
V
4
L
A
F
C
M
U
3
E
2
N
T
S
Neutral Switch Connector
R
P
OEM Interface Connector
C
C
A
D
A
B
SAE J1939
Connector
12
11
B
Private CAN
Connector
10
9
8
5
4
3
B
A
D
E
F
PTO
Connector
7
2
6
C
2
1
Shifter or Turtle Wire
Harness Connector
1
2-Pin Connector
(J6) J1939
Deutsch DTM Series
4005609a
92
J20
SAE J1939-CAN H
SAE J1939-CAN L
SAE J1939-CAN SH
FUNCTION
PTO 1 SWITCH
PTO 1 ACKNOWLEDGE
PTO 1 ENGAGE RELAY
PTO 2 SWITCH
PTO 2 ACKNOWLEDGE
PTO 2 ENGAGE RELAY
J12
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6
120
J6
J9
J7
A
B
C
A
B
C
D
E
F
E
G
B
D
A
J
H
C
F
P
R
S
K
N
M
L
V
W
X
T
U
A
B
C
J8
J3
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
J1
1
2
3
4
5
6
7
8
9
10
11
12
J4
1
2
3
4
J5
1
2
3
4
J2
TRANSMISSION
HARNESS
GND
GND
ACC
J1939-
24V ING
DIAG
CAN H
+24V
+24V
CAN L
SPEEDO
J1939+
DISPLAY
VIN
GND
GND
GND
VOUT
VOUT SW
VOUT SW
VOUT
12V EN
24V EN
VIN
VIN
VOLTAGE DOUBLER
FUNCTION
ANALOG SH LEVER 1
ANALOG SH LEVER 2
ANALOG SH LEVER GND
OPTIONAL OEM LEVER
FUNCTION
BATTERY (+) 30A FUSE
12 GAUGE
IGNITION (+)
BATTERY (-) 12 GAUGE
SAE J1587B (-)
SAE J1587A (+)
NEUTRAL RELAY
REVERSE RELAY
1 2 3 4 5 6
ZFM DISPLAY
1 2 3 4 5 6
SEAT HARNESS
SHIFT-N-CRUISE
KEYPAD
J11
SHIFT MODULE
1 2 3 4 5 6 7 8 9 10 11 12
SPEED
SENSOR
FUNCTION
BLACK-COMMON
WHITE-SET
GREEN-RESUME
YELLOW-PAUSE
YELLOW-PAUSE
FUNCTION
OEM WIRING
SCHEMATIC
AND NOTES
J10
AN GRD
RELAY
RELAY
12V
IGN
GND
RELAY
RELAY
A1
A2
A3
B1
B2
B3
C1
C2
C3
D1
D2
D3
E1
E2
E3
F1
F2
F3
G1
G2
G3
H1
H2
H3
J1
J2
J3
K1
K2
K3
CAN H
CAN L
CAN SH
J1587+
J1587 SL SW
SH LEV
ZF DISP
ISO
DIG I/O
DIG I/O
SL POW
DIG I/O
DIG I/O
DIG I/O
AN SH
AH SH
ZMTEC
Section 4
Wiring/Pneumatic Diagrams
ZF TCU
NEUTRAL
INTERLOCK
4005601a
93
Section 4
Wiring/Pneumatic Diagrams
ZF-FREEDOMLINE AIR SYSTEM OVERVIEW
TRANSMISSION DEDICATED AIR CIRCUIT
VEHICLE AIR
TANKS, DRYER,
COMPRESSOR,
PRESSURE
PROTECTION
VALVES, ETC.
TRANSMISSION ACTUATOR
Integrated into Transmission
AIR LINES
AIR FITTINGS
4
3
DEDICATED
TRANSMISSION
AIR TANK
5
2
1
SINGLE CHECK VALVE
CLUTCH ACTUATOR
Integrated into Transmission
Protects air in dedicated
transmission air tank if
brake system has leak or
line to reservoir breaks.
4005610a
94
Section 5
Removal and Installation
Step 1
Section 5 and Installation
Removal
WARNING
To prevent serious eye injury, always wear safe
eye protection when you perform vehicle
maintenance or service.
Transmission
Removal
Place a pan beneath the transmission drain plug.
앫 GO TO THE NEXT STEP.
Step 2
WARNING
When you install a fill plug and a drain plug into
a transmission, first manually position the plug,
and then install and tighten it by hand. When
you’ve hand tightened the plug, use a torque
wrench to tighten it to 44 lb-ft (60 N•m). Do not
overtighten the plug. Damage to the aluminum
housing can result. T
Use a 22 mm wrench to remove the drain plug.
Drain the oil. Manually position the drain plug
and install it into the transmission by hand.
Hand tighten the plug, and then use a torque
wrench to tighten the drain plug to 44 lb-ft
(60 N•m). Do not overtighten the drain plug. T
앫 GO TO THE NEXT STEP.
Step 3
WARNING
Always remove the clutch actuator housing
BEFORE you remove the transmission, so that
the transmission does not rest on the actuator
housing. Damage to the transmission will
result.
Remove the clutch actuator housing. Refer to
Clutch Actuator Housing and Wiring Harness in
this section.
CLUTCH
ACTUATOR
HOUSING
앫 GO TO THE NEXT STEP.
95
Section 5
Removal and Installation
Step 4
Disconnect the air supply line from the air filter
regulator. Disconnect the cooler lines as
required.
WARNING
Use care when disconnecting the line as it still
may be under pressure.
앫 GO TO THE NEXT STEP.
Step 5
Use a 13 mm socket and ratchet to remove the
four fasteners that secure the clutch inspection
cover.
앫 GO TO THE NEXT STEP.
4002079a
Step 6
Remove the clutch inspection cover.
앫 GO TO THE NEXT STEP.
400208
96
Section 5
Removal and Installation
Step 7
If the release bearing retainer clip is not visible,
the starter may need to be bumped to turn
clutch so that retainer clip is visible as shown
in Step 7.
Unsnap the release bearing retainer clip.
앫 GO TO THE NEXT STEP.
Step 8
Loosen the release bearing retainer clip by
prying the release fork BACKWARD.
앫 GO TO THE NEXT STEP.
Step 9
Use a 13 mm socket and ratchet to install the
clutch inspection cover. Tighten the fasteners to
17 lb-ft (23 N•m). T
앫 GO TO THE NEXT STEP.
4002079a
97
Section 5
Removal and Installation
Step 10
SAE J-1939
CONNECTOR
Disconnect the SAE J-1939 and the OEM
connectors.
앫 GO TO THE NEXT STEP.
OEM
CONNECTOR
Step 11
Remove the driveline. Follow the guidelines
specified by both the original equipment
manufacturer (OEM) and driveline manufacturer.
앫 GO TO THE NEXT STEP.
Step 12
Remove the oil cooler lines if vehicle has
OEM installed cooler.
앫 GO TO THE NEXT STEP.
BY-PASS
VALVE
98
Section 5
Removal and Installation
Step 13
Remove the rear support if one is installed.
앫 GO TO THE NEXT STEP.
Step 14
WARNING
SAFETY
STRAPS
Support the transmission securely with a
transmission jack and safety straps. If the
transmission is not securely supported, it can
fall. Serious personal injury and damage to
components can result.
Support the transmission with a transmission
jack and safety straps.
앫 GO TO THE NEXT STEP.
Step 15
Remove the 12 fasteners that secure the
transmission to the flywheel housing.
앫 GO TO THE NEXT STEP.
FASTENER —
TYPICAL
99
Section 5
Removal and Installation
Step 16
With the transmission supported by a
transmission jack, remove the transmission by
carefully pulling it straight back and lowering it
out of the vehicle.
앫 GO TO THE NEXT STEP.
Step 17
SAFETY
STRAPS
Roll the transmission out from under the vehicle.
100
Section 5
Removal and Installation
Step 1
WARNING
To prevent serious eye injury, always wear safe
eye protection when you perform vehicle
maintenance or service.
Installation
CLOSED
Install the clutch. Refer to Clutch Actuator
Housing and Wiring Harness in this section.
Verify that the release bearing retainer clip is
snapped.
앫 GO TO THE NEXT STEP.
Step 2
Inspect the release bearing and release fork
assembly. Replace damaged components.
NOTE: Replace with new roller fork kit if
standard fork is installed.
A. Check that the release fork assembly
turns freely and radial (side-to-side).
B. Check that the release bearing slides
freely on the release flange.
앫 GO TO THE NEXT STEP.
4005603a
Step 3
Check the bottom of the transmission for an
inspection cover.
앫 If an inspection cover is missing: Install a
cover to prevent dirt and contaminants from
entering the clutch housing and damaging the
clutch.
앫 GO TO THE NEXT STEP.
101
Section 5
Removal and Installation
Step 4
Inspect the splines on the input shaft for wear
and damage. Use an emery cloth to remove
small scratches from the input shaft.
앫 GO TO THE NEXT STEP.
Step 5
Inspect the end of the input shaft where the pilot
bearing is installed. Use an emery cloth to
remove small scratches. Replace the pilot
bearing as necessary.
앫 GO TO THE NEXT STEP.
Step 6
SAFETY
STRAPS
WARNING
Support the transmission securely with a
transmission jack and safety straps. If the
transmission is not securely supported, it can
fall. Serious personal injury and damage to
components can result.
Support the transmission with a transmission
jack and safety straps.
앫 GO TO THE NEXT STEP.
102
Section 5
Removal and Installation
Step 7
Position the transmission so that the input shaft
aligns with the pilot bearing.
앫 GO TO THE NEXT STEP.
Step 8
WARNING
Carefully install the transmission input shaft
into the clutch disc hub. Do not force or jam the
input shaft into the hub. Damage to the clutch
disc or clutch housing will result.
NOTE: When you install the transmission, you
may have to slightly turn the input shaft. Use
SPX Kent-Moore input shaft turning tool (part
number J-45556). To obtain this tool, refer to
the Service Notes page on the front inside cover
of this manual.
Move the input shaft into the clutch housing
and into the hub of the clutch disc.
앫 GO TO THE NEXT STEP.
Step 9
Push the transmission against the flywheel
housing.
앫 GO TO THE NEXT STEP.
103
Section 5
Removal and Installation
Step 10
Use 12 fasteners to secure the transmission to
the flywheel. Tighten them in a star pattern to
OEM specifications.
앫 GO TO THE NEXT STEP.
FASTENERS
(TYPICAL)
Step 11
If necessary, reinstall the rear support. Tighten
the fasteners to 145 lb-ft (195 N•m). T
앫 GO TO THE NEXT STEP.
Step 12
SAFETY
STRAPS
Remove the safety straps. Remove the
transmission jack from the transmission.
앫 GO TO THE NEXT STEP.
104
Section 5
Removal and Installation
Step 13
Use a 13 mm socket and ratchet to remove
the four fasteners that secure the clutch
inspection cover.
앫 GO TO THE NEXT STEP.
4002079a
Step 14
Remove the clutch inspection cover.
앫 GO TO THE NEXT STEP.
4002081a
Step 15
Secure the release bearing to the release
bearing retainer clip by prying the release fork
BACKWARD.
NOTE: Clutch actuator vent plug may need to be
removed to vent air from the clutch actuator.
Please refer to Step 8 in the Clutch Actuator
Removal instructions.
앫 GO TO THE NEXT STEP.
105
Section 5
Removal and Installation
Step 16
Use a 13 mm socket and ratchet to install the
clutch inspection cover. Tighten the fasteners
to 17 lb-ft (23 N•m). T
앫 GO TO THE NEXT STEP.
4002079a
Step 17
Install the clutch actuator housing and connect
the air supply line to the TCU air filter regulator.
Refer to Clutch Actuator Housing and Wiring
Harness installation instructions.
앫 GO TO THE NEXT STEP.
Step 18
Connect the air supply line to the clutch actuator
housing.
앫 GO TO THE NEXT STEP.
CLUTCH
ACTUATOR
AIR LINE
4005602a
106
Section 5
Removal and Installation
Step 19
SAE J-1939
CONNECTOR
Connect the SAE J-1939 connector and the OEM
connector to the transmission.
앫 GO TO THE NEXT STEP.
OEM
CONNECTOR
4002015b
Step 20
Connect the driveshaft to the output yoke on the
transmission. Install and tighten the fasteners to
the vehicle manufacturer’s specifications.
앫 GO TO THE NEXT STEP.
107
Section 5
Removal and Installation
Step 21
Use a 22 mm wrench to remove the fill plug
from the transmission. Check that the oil is even
with the bottom of the fill plug hole.
If necessary, add an approved full-synthetic
oil through the fill plug hole until the oil is even
with the bottom of the fill plug hole.
Manually position the fill plug and install it into
the transmission by hand. Hand tighten the plug,
and then use a torque wrench to tighten the fill
plug to 44 lb-ft (60 N•m). Do not overtighten the
plug. Start the engine and run it for 30 seconds.
Use a 22 mm wrench to remove the fill plug.
Check the oil level. Add oil as necessary. T
앫 GO TO THE NEXT STEP.
Step 22
WARNING
When you install a fill plug and a drain plug into
a transmission, first manually position the plug,
and then install and tighten it by hand. When
you’ve hand tightened the plug, use a torque
wrench to tighten it to 44 lb-ft (60 N•m). Do not
overtighten the plug. Damage to the aluminum
housing can result. T
Manually position the fill plug and install it into
the transmission by hand. Hand tighten the
plug, and then use a torque wrench to tighten
the plug to 44 lb-ft (60 N•m). Do not overtighten
the fill plug. T
앫 GO TO THE NEXT STEP.
108
Section 5
Removal and Installation
Step 23
Charge the air system to 120 psi.
30
0
The vehicle may not start after installing the
transmission due to low air pressure. Charge the
system using shop air if necessary.
90
60
PSI
120
150
앫 GO TO THE NEXT STEP.
4002090a
Step 24
NOTE: If the display reads “CH” after the
engine is started and the transmission will not
engage, verify that the release bearing retainer
clip is correctly installed and that the release
bearing is engaged into it.
Operate the vehicle. Check for correct operation.
109
Section 5
Removal and Installation
Step 1
Clutch
Removal
Remove the transmission. Refer to Transmission
in this section.
앫 GO TO THE NEXT STEP.
Step 2
WARNING
Do not use an input shaft to support the clutch
during removal. The clutch can fall from the
input shaft, or the input shaft can damage the
pilot bearing. Always use a clutch caddy or an
equivalent device to prevent serious personal
injury and damage to components.
Support the clutch with a clutch caddy or an
equivalent device. Do not use the input shaft as
a support. The clutch can fall, and the input
shaft can damage the pilot bearing.
앫 GO TO THE NEXT STEP.
Step 3
FASTENERS
Remove the two top fasteners from the clutch
housing cover.
앫 GO TO THE NEXT STEP.
110
Section 5
Removal and Installation
Step 4
GUIDE PINS
Install guide pins.
앫 GO TO THE NEXT STEP.
Step 5
FASTENERS
Remove the remaining fasteners from the clutch
housing.
앫 GO TO THE NEXT STEP.
Step 6
GUIDE PINS
Remove the clutch by sliding it straight back and
off the guide pins.
111
Section 5
Removal and Installation
Step 1
Installation
Clean the flywheel and bell housing surface.
앫 GO TO THE NEXT STEP.
Step 2
Check the flywheel and centering shoulder for
damage. Refer to the engine manufacturer’s
service procedures, if necessary.
앫 GO TO THE NEXT STEP.
Step 3
Replace the pilot bearing. Refer to the vehicle
manufacturer’s procedures.
앫 GO TO THE NEXT STEP.
112
Section 5
Removal and Installation
Step 4
Inspect the clutch housing, disc and release
bearing for damage.
앫 If the components are damaged: Call OnTrac
at 866-668-7221 for assistance.
앫 GO TO THE NEXT STEP.
4005019a
Step 5
GUIDE PINS
Install the guide pins into the TOP fastener
holes.
앫 GO TO THE NEXT STEP.
Step 6
WARNING
Do not use the input shaft to support the clutch
during installation. The clutch can fall from the
input shaft, or the input shaft can damage the
pilot bearing. Always use a clutch caddy or an
equivalent device to prevent serious personal
injury and damage to components.
With the clutch supported by a clutch caddy or
an equivalent device, install the clutch into the
vehicle.
앫 GO TO THE NEXT STEP.
113
Section 5
Removal and Installation
Step 7
Mad
ei
n
5380 1
56
S
CH
SA
any
rm
e
G
s ide
ee l -
49 18
78
0
1
66
e
wh
NOTE: The flywheel side of the clutch disc is
marked “Flywheel-Side.”
Verify that the flywheel side of the clutch disc
faces AWAY from the clutch housing.
앫 GO TO THE NEXT STEP.
03
Fl y
MCC
6304
9
Step 8
GUIDE PINS
Install the clutch housing onto the guide pins.
Ensure that clutch housing is fully seated on the
flywheel.
앫 GO TO THE NEXT STEP.
Step 9
FASTENERS
WARNING
Take care when you use Loctite® adhesive to
avoid serious personal injury. Read the
manufacturer’s instructions before using this
product. Follow the instructions carefully to
prevent irritation to the eyes and skin.
Apply Loctite® 222 liquid adhesive to the
12 clutch housing fasteners and/or use lock
washers. Install and hand tighten the bolts.
앫 GO TO THE NEXT STEP.
114
Section 5
Removal and Installation
Step 10
FASTENERS
Remove the guide pins. Install the remaining
fasteners.
앫 GO TO THE NEXT STEP.
Step 11
CLUTCH COVER MOUNTING
TOP
2
10
11
8
3
4
7
12
9
1
PASSENGER SIDE
DRIVER SIDE
6
Use a torque wrench to alternately tighten the
12 fasteners. Consult the OEM for exact
tightening torque requirements.
앫 GO TO THE NEXT STEP.
5
BOTTOM
400 611
Step 12
NOTE: The alignment shaft on the clutch caddy
should slide out freely.
Remove the clutch caddy.
앫 GO TO THE NEXT STEP.
115
Section 5
Removal and Installation
Step 13
CLOSED
Check that the release bearing retainer clip is
closed before you install the transmission.
앫 GO TO THE NEXT STEP.
OPEN
Step 14
Install the release bearing onto the transmission
input shaft. Refer to Release Bearing in this
section.
NOTE: The transmission control unit (TCU)
automatically adjusts the clutch. No further
adjustment is required.
116
Section 5
Removal and Installation
Step 1
Voltage Doubler
Removal
Unplug the voltage doubler connector.
앫 GO TO THE NEXT STEP.
Step 2
Use a 7/16-inch socket and ratchet to remove the
four fasteners.
앫 GO TO THE NEXT STEP.
Step 3
Remove the voltage doubler.
117
Section 5
Removal and Installation
Step 1
Installation
Use four fasteners with flat washers and a
7/16-inch socket and ratchet to install the
voltage doubler to the component mounting
plate.
앫 GO TO THE NEXT STEP.
Step 2
Tighten the fasteners to 12 lb-ft (16 N•m).
T
앫 GO TO THE NEXT STEP.
Step 3
Plug the electrical harness assembly into the
voltage doubler connector.
118
Section 5
Removal and Installation
Step 1
ZF-FreedomLine Transmission
Electronic Controller (ZMTEC)
Removal
Use a 1/4-inch socket and ratchet to remove the
ZMTEC connector.
앫 GO TO THE NEXT STEP.
Step 2
Use a 7/16-inch socket and ratchet to remove the
four ZMTEC fasteners.
앫 GO TO THE NEXT STEP.
Step 3
Remove the controller.
119
Section 5
Removal and Installation
Step 1
Installation
Use four fasteners with flat washers and a
7/16-inch socket and ratchet to install the
ZMTEC to the component mounting plate.
앫 GO TO THE NEXT STEP.
Step 2
Tighten the fasteners to 12 lb-ft (16 N•m).
T
앫 GO TO THE NEXT STEP.
Step 3
Plug the electrical harness assembly into the
ZMTEC. Tighten the 1/4-inch locking screw.
120
Section 5
Removal and Installation
Step 1
Transmission Yoke
Removal
Follow the driveline manufacturer’s instructions
to remove the driveshaft from the transmission
yoke.
앫 GO TO THE NEXT STEP.
Step 2
Use a 19 mm socket and ratchet to remove the
two fasteners that secure the retaining plate to
the output shaft.
앫 GO TO THE NEXT STEP.
Step 3
Remove the retaining plate and O-ring.
앫 GO TO THE NEXT STEP.
121
Section 5
Removal and Installation
Step 4
WARNING
Do not damage plug installed in center of
output shaft!
Refer to the Service Notes page on the front
inside cover of this manual for instructions to
order this tool.
Remove the yoke using an SPX Kent-Moore
puller (part number J-7804-01).
앫 GO TO THE NEXT STEP.
Step 5
Remove the transmission yoke.
122
Section 5
Removal and Installation
Step 1
Installation
WARNING
Do not overheat the yoke. Damage to the
output shaft seal can result.
Heat the yoke to 175°F (79.4°C) in an oven.
앫 GO TO THE NEXT STEP.
Step 2
WARNING
The yoke will be hot when you install it onto
the output shaft. Wear protective gloves to
prevent serious personal injury.
Put on protective gloves. Install the yoke onto
the output shaft, until the yoke contacts the
output shaft bearing.
앫 GO TO THE NEXT STEP.
Step 3
Use a 19 mm socket and ratchet to secure the
retaining plate and O-ring onto the output shaft
with two fasteners.
앫 GO TO THE NEXT STEP.
123
Section 5
Removal and Installation
Step 4
Tighten the fasteners to 89 lb-ft (120 N•m).
T
앫 GO TO THE NEXT STEP.
Step 5
Install the driveshaft. Refer to the manufacturer’s
instructions. Inspect for leaks.
124
Section 5
Removal and Installation
Step 1
Output Shaft Seal
Removal
Remove the transmission yoke. Refer to
Transmission Yoke in this section.
앫 GO TO THE NEXT STEP.
Step 2
Refer to the Service Notes page on the front
inside cover of this manual for instructions to
order this tool.
Use an SPX Kent-Moore seal remover (part
number J-24171-A or equivalent) to remove the
output shaft seal. Do not reuse the output shaft
seal after you remove it. Install a new seal.
125
Section 5
Removal and Installation
Step 1
Installation
Clean all loose debris from the output shaft
seal area.
앫 GO TO THE NEXT STEP.
Step 2
Apply a thin coat of transmission oil to the inner
diameter of the seal.
앫 GO TO THE NEXT STEP.
Step 3
Install the output shaft seal. Use SPX
Kent-Moore output shaft seal installer (part
number J-45247).
126
Section 5
Removal and Installation
Step 1
HEX-HEAD
SCREW
Input Shaft Seal
SEAL/
GASKET
Removal
SHAFT
SEALING
RING
RELEASE
FLANGE
4007230a
Remove the transmission: refer to Transmission
Removal in this section. The release fork and
bearing will need to be removed from the
transmission to perform this procedure.
Remove the four M8 hex-head screws and lift
off the release flange.
앫 GO TO THE NEXT STEP.
Step 2
If necessary, remove the seal/gasket.
앫 GO TO THE NEXT STEP.
Step 3
Use a suitable tool to remove the shaft sealing
ring from the release flange.
Installation
Coat the sealing lip of the shaft seal with
grease. Press the seal firmly into the flange. The
sealing lip must point towards the
transmission’s interior. Install gasket/seal onto
release flange.
Step 1
HEX-HEAD
SCREW
SEAL/
GASKET
SHAFT
SEALING
RING
RELEASE
FLANGE
4007230a
Use four M8 hex-head screws to secure the
release flange. Tighten the screws to 17 lb-ft
(23.05 N폷m). T
127
Section 5
Removal and Installation
Step 1
OUTPUT
COVER
Remove transmission yoke: reference
Transmission Yoke Removal in this section.
SHIM
Output Cover
Removal
SHAFT
SEALING
RING
HEX-HEAD
SCREW
4007231b
Step 2
If necessary, remove the shim.
앫 GO TO THE NEXT STEP.
NOTE: The shim is no longer needed for newer
transmissions since the output cover has been
modified accordingly.
Step 3
Use a suitable tool to remove the shaft sealing
ring.
128
Remove the 10 M10 hex-head screws and lift off
the output cover.
앫 GO TO THE NEXT STEP.
Section 5
Removal and Installation
Step 1
OUTPUT
COVER
SHIM
Installation
Coat the outer circumference of the shaft
sealing ring with grease. Use an appropriate
driver to press the sealing ring into the output
cover and ensure it is firmly seated. Slightly
grease the sealing lip.
SHAFT
SEALING
RING
앫 GO TO THE NEXT STEP.
HEX-HEAD
SCREW
4007231b
Step 2
Coat the sealing surface of the output cover
with Loctite® 574 or equivalent sealant.
앫 GO TO THE NEXT STEP.
Step 3
NOTE: The sealing surfaces must be clean and
free of oil and grease.
Fit the output cover with a shim, if necessary.
앫 GO TO THE NEXT STEP.
Step 4
Place the output cover in position and secure it
with the 10 M10 hex-head screws. Tighten the
screws to 34 lb-ft (46 N폷m). T
129
Section 5
Removal and Installation
Step 1
NUTS
Air Filter Regulator
NOTE: The repair kit contains four nuts, one
O-ring and the air filter regulator. Before
removing, mark the installation position of the
air filter regulator for fitting later on.
Removal
Remove the four nuts and take off the air filter
regulator. Remove the O-ring.
4007232a
Step 2
Installation
CAUTION
O-RING
Do not use grease to fit the O-ring.
Step 1
Insert the new O-ring.
앫 GO TO THE NEXT STEP.
Step 2
Install the air filter regulator as marked during
removal.
TRANSMISSION
ACTUATOR
PRESSURE
RELIEF VALVE
130
4007233a
앫 GO TO THE NEXT STEP.
Step 3
Install and tighten the four nuts to to 5 lb-ft
(7 N폷m). T
Section 5
Removal and Installation
Step 1
TCU Top Half/Top Cover
VEHICLE
Removal
Remove the electrical wiring harness from the
TCU connector marked “vehicle”.
앫 GO TO THE NEXT STEP.
TRANSMISSION
4007234a
Step 2
TRANSM
ISSION
Remove the electrical wiring harness from the
TCU connector marked “Transmission”.
앫 GO TO THE NEXT STEP.
4007235a
Step 3
Remove the air fitting from the air regulator.
WARNING
Use caution when disconnecting the line as it
still may be under pressure.
앫 GO TO THE NEXT STEP.
131
Section 5
Removal and Installation
Step 4
Use a 13 mm socket to remove the 15 fasteners
that secure the TCU to the transmission.
앫 GO TO THE NEXT STEP.
4007237a
Step 5
SCREWS
UPPER
SECTION
Remove both screws with a T-30 Torx tool.
Step 6
Raise the upper section.
WARNING
GASKET
PROFILE
SEAL
Use caution when lifting upper section. Do not
damage ribbon cables!
앫 GO TO THE NEXT STEP.
LOWER
SECTION
4007238a
132
Section 5
Removal and Installation
Step 7
PLUG
CONNECTION
PLUG
CONNECTION
Disconnect the plug connections.
앫 GO TO THE NEXT STEP.
4007239a
Step 8
Ensure the profile seal remains in the bottom
part of the TCU.
앫 GO TO THE NEXT STEP.
Step 9
Remove the gasket.
앫 GO TO THE NEXT STEP.
133
Section 5
Removal and Installation
Step 1
SCREWS
UPPER
SECTION
Installation
Place the new gasket seal on the upper section.
GASKET
앫 GO TO THE NEXT STEP.
PROFILE
SEAL
LOWER
SECTION
4007238a
Step 2
PLUG
CONNECTION
PLUG
CONNECTION
4007239a
134
Reconnect the plug connections.
앫 GO TO THE NEXT STEP.
Section 5
Removal and Installation
Step 3
Check that the plug connections are tight and
secure.
앫 GO TO THE NEXT STEP.
Step 4
Place the upper section on the lower section.
Ensure that the flat seal does not move. Fix the
seal if necessary.
앫 GO TO THE NEXT STEP.
Step 5
Install and tighten the two screws to 7.0 lb-ft
(9 N폷m). T
앫 GO TO THE NEXT STEP.
Step 6
Use a 13 mm socket and ratchet to secure the
TCU to the transmission with 15 fasteners.
Secure the wiring harness clip to the
transmission.
Tighten the fasteners to 17 lb-ft (23 N폷m) using a
star patter. T
앫 GO TO THE NEXT STEP.
4007237a
135
Section 5
Removal and Installation
Step 7
Install the air fitting into the air regulator.
앫 GO TO THE NEXT STEP.
4007236a
Step 8
TRANSM
Connect the electrical wiring harness into the
TCU connector marked “Transmission”.
ISSION
앫 GO TO THE NEXT STEP.
4007235a
136
Section 5
Removal and Installation
VEHICLE
Step 9
Connect the transmission vehicle wiring harness
to the TCU port marked “Vehicle.”
TRANSMISSION
4007234a
137
Section 5
Removal and Installation
Step 1
Transmission Control Unit
(TCU)
VEHICLE
Removal
Unplug the electrical wiring harness assembly
from the TCU port marked “Vehicle.”
앫 GO TO THE NEXT STEP.
TRANSMISSION
4002006a
Step 2
TRANSM
ISSION
Remove the transmission wiring harness
assembly from the port marked “Transmission.”
앫 GO TO THE NEXT STEP.
Step 3
WARNING
Use caution when disconnecting the line as it
still may be under pressure.
Disconnect the air supply line from the air filter
regulator.
앫 GO TO THE NEXT STEP.
138
Section 5
Removal and Installation
Step 4
Use a 13 mm socket and ratchet to remove the
15 fasteners that secure the TCU to the
transmission.
앫 GO TO THE NEXT STEP.
Step 5
WARNING
Do not rotate the transmission’s three shift rails
when you remove or install the transmission
control unit (TCU). Damage to the transmission
will result.
Remove the TCU by lifting it straight UP and
OUT of the transmission.
WARNING
Do not move or bump shift rails. The settings of
the rails will need to be transferred to the new
TCU.
앫 GO TO THE NEXT STEP.
Step 6
NOTE: The detent spring on the passenger side
of the center shift rail is higher than the other
two springs. However, the three detent springs
are identical.
Remove and discard the TCU gasket. Do not
reuse it.
139
Section 5
Removal and Installation
Step 1
Installation
Inspect the sealing surfaces of the TCU and
transmission for debris. If necessary, use a
scraper to clean the surfaces.
앫 GO TO THE NEXT STEP.
Step 2
DETENT
SPRINGS
SHIFT
FINGER
WARNING
OUTSIDE
RAIL
MIDDLE
SHIFT
RAIL
OUTSIDE
RAIL
Do not move the center rail forward or
rearward, only rotate it such that the shift
finger points straight up. Serious damage to
the transmission could result.
Rotate the center rail such that the shift finger
points straight up.
앫 GO TO THE NEXT STEP.
Step 3
WARNING
REMOVE
DETENT
SPRINGS
Use care not to drop springs into the
transmission.
NOTE: The detent spring on the passenger side
of the center shift rail is higher than the other
two springs. However, the three detent springs
are identical.
Remove the three detent springs.
앫 GO TO THE NEXT STEP.
140
Section 5
Removal and Installation
Step 4
/170
3
2
1
Transfer measurements for the shift rails from the
removed transmission actuator to piston rods a,
b, and c of the new transmission actuator.
Selector gate d and piston rod b must be
centered with the piston and groove inline.
Ensure that the profile seals (/170) on the
transmission actuator are inserted.
NOTE: With the 12-speed versions built prior to
2004, do not slide the center shift rail b too far
into the transmission, otherwise the gearshift
finger may fall into the transmission.
앫 GO TO THE NEXT STEP.
4
4005613a
Legend
a Piston Rod = Shifts the splitter group (GV)
b Piston Rod = Shifts the basic transmission
c Piston Rod = Shifts the range change group (GP)
d Selector Gate = Selects the shift gate
Step 5
LIGHT
TCU
Place the shift module onto the transmission.
The module should fully seat. Ensure that the
shift module pistons connect correctly with the
transmission shift rails.
앫 GO TO THE NEXT STEP.
141
Section 5
Removal and Installation
Step 6
WARNING
INSTALL
DETENT
SPRINGS
Use care not to drop springs into the
transmission.
NOTE: The detent spring on the passenger side
of the center shift rail is higher than the other
two springs. However, the three detent springs
are identical.
Remove the shift module from the transmission
and reinstall the three detent springs.
앫 GO TO THE NEXT STEP.
Step 7
Install a new gasket on the sealing surface.
앫 GO TO THE NEXT STEP.
142
Section 5
Removal and Installation
Step 8
Place the shift module onto the transmission.
앫 GO TO THE NEXT STEP.
Step 9
WIRING
HARNESS
CLIP
Use a 13 mm socket and ratchet to secure the
TCU to the transmission with 15 fasteners. Press
down the TCU while tightening fasteners.
TCU must be able to touch the gasket on all
sides while applying downward pressure with
the hand.
WARNING
Do not force together by tightening the
fasteners or damage to the TCU can result.
Secure the wiring harness clip to the
transmission.
앫 GO TO THE NEXT STEP.
Step 10
Tighten the fasteners to 17 lb-ft (23 N•m) using a
star pattern. T
앫 GO TO THE NEXT STEP.
143
Section 5
Removal and Installation
Step 11
VEHICLE
Connect the transmission vehicle wiring harness
to the TCU port marked “Vehicle.”
앫 GO TO THE NEXT STEP.
TRANSMISSION
4002006a
Step 12
TRANSM
ISSION
Connect the transmission wiring harness
assembly to the TCU.
앫 GO TO THE NEXT STEP.
Step 13
Connect the air supply line to the TCU air filter
regulator.
NOTE: If issues continue to occur with correctly
aligning rails, go to the next step.
144
Section 5
Removal and Installation
Shift Rail/TCU Cylinder
Adjustments for Installation
63 MM
51 MM
WARNING
53 MM
This procedure should only be performed if
pistons on the original TCU are moved or if the
procedure starting on page 134 is unsuccessful.
RANGE
RAIL
MAIN BOX
RAIL
SPLITTER
RAIL
4007240a
Adjustment of the shift rails is necessary before
installing the TCU. All three shift rails
(i.e., range, main box and splitter) must be
adjusted to a specific position.
Step 1
Adjust the range rail to 63 mm from the back of
the cavity wall to the front of the shift rail.
앫 GO TO THE NEXT STEP.
Step 2
Adjust the main box rail to 51 mm from the
back of the cavity wall to the front of the shift
rail.
앫 GO TO THE NEXT STEP.
Step 3
Adjust the splitter shift rail to 53 mm from the
back of the half moon feature to the front of the
shift rail.
Adjust the Cylinder Pistons
RANGE
PISTON
38 MM
35 MM
35 MM
Once all of the transmission shift rails have
been correctly lined up, the TCU to be installed
also must be adjusted. Each cylinder piston has
to be set to a correct length as shown.
Step 1
Adjust the splitter cylinder piston to 38 mm
from the cylinder bore entrance to the front of
the piston.
SPLITTER
PISTON
MAIN BOX
PISTON
4007241a
앫 GO TO THE NEXT STEP.
Step 2
Adjust the main box cylinder piston to 35 mm
from the cylinder bore entrance to the front of
the piston.
앫 GO TO THE NEXT STEP.
Step 3
Adjust the range cylinder piston to 35 mm from
the cylinder bore entrance to the front of the
piston.
145
Section 5
Removal and Installation
Step 1
Selector Cylinder
WARNING
CONNECTOR
LOWER
SECTION
This procedure is to be performed only with
out-of-warranty cases. During warranty period,
the complete TCU must be exchanged.
NOTE: The repair kit contains the selector
cylinder and a profile seal.
HEX-HEAD
BOLTS
Removal
Carefully raise the tab and pull the connector off
the sensor contact.
4007254a
앫 GO TO THE NEXT STEP.
Step 2
Remove the three hex-head bolts.
앫 GO TO THE NEXT STEP.
Step 3
Take out the selector cylinder and remove the
profile seal.
앫 GO TO THE NEXT STEP.
Step 4
PROFILE
SEAL
Inspect the parts and replace if necessary.
SELECTOR
CYLINDER
Installation
TAB
4007255a
Step 1
NOTE: Apply Uni-Silicon GLK112 grease to the
sealing and sliding faces.
Insert the profile seal on the TCU’s lower section.
앫 GO TO THE NEXT STEP.
Step 2
Place the selector cylinder on the TCU’s lower
section.
앫 GO TO THE NEXT STEP.
Step 3
Install and tighten the three hex-head bolts to
17 lb-ft (23 N폷m). T
앫 GO TO THE NEXT STEP.
Step 4
Plug the connector onto the sensor contacts.
146
Section 5
Removal and Installation
Disassembly Lower Section of TCU
Step 1
T40 TORX SCREWS
WARNING
This procedure is to be performed only with
out-of-warranty cases. During warranty period,
the complete TCU must be exchanged.
NOTE: The main transmission piston is
exchanged as a complete unit with separate kit.
Separate seal kit for range/splitter gear shift
cylinders.
Remove the selector cylinder. Refer to the
procedure in this section.
앫 GO TO THE NEXT STEP.
Step 2
SENSORS
4007248a
Remove the three travel sensors. Refer to the
procedure in this section.
앫 GO TO THE NEXT STEP.
CAUTION
The cylinder covers are numbered. They have to
be refitted in the same positions.
Step 3
Remove the T40 Torx screws from the cylinder
covers.
앫 GO TO THE NEXT STEP.
Step 4
CYLINDER
COVERS
Use a suitable tool to raise the cylinder covers
slightly and remove.
앫 GO TO THE NEXT STEP.
4007249a
147
Section 5
Removal and Installation
Step 5
BUSH
PISTON
PISTON
Use a suitable tool to raise the cylinder cover
slightly and remove.
PISTON
앫 GO TO THE NEXT STEP.
Step 6
Take the pistons and bushings out.
앫 GO TO THE NEXT STEP.
CYLINDER
COVER
Step 7
Replace the O-rings and grooved rings on the
components.
앫 GO TO THE NEXT STEP.
4007250a
Step 8
Use a suitable tool to remove the seal rings and
low-friction bearing bushings.
LOW-FRICTION
BEARING
BRUSHING
148
SEAL
RING
4007251a
Section 5
Removal and Installation
Assembly
Step 1
Use a suitable tool to insert the low-friction
bearings bushings flush with the bearing bore.
앫 GO TO THE NEXT STEP.
Step 2
Use a suitable tool to insert the new sealing
rings.
NOTE: Apply Uni-Silicon GLK 112 grease to the
sealing and sliding faces.
앫 GO TO THE NEXT STEP.
LOW-FRICTION
BEARING
BRUSHING
SEAL
RING
4007251a
Step 3
BUSH
PISTON
PISTON
PISTON
Insert new O-rings and grooved rings on the
components.
앫 GO TO THE NEXT STEP.
Step 4
CYLINDER
COVER
Insert the pistons and bushings in the
transmission actuator’s lower section.
앫 GO TO THE NEXT STEP.
4007250a
149
Section 5
Removal and Installation
Step 5
CYLINDER
COVERS
Fit the cylinder covers in the same position from
which you previously removed them and secure
each one with two T40 Torx screws tightening
the screws to 13 lb-ft (17 N폷m). T
앫 GO TO THE NEXT STEP.
4007249a
Assembly Check
Step 6
The cylinder covers are numbered for sensor
installation position (refer to the arrows).
SENSORS
Install the sensors. Refer to the procedure in
this section.
앫 GO TO THE NEXT STEP.
1
3
2
4007252a
Step 7
SELECTOR
CYLINDER
Install the selector cylinder.
앫 GO TO THE NEXT STEP.
Step 8
Re-check that the connector are tight and secure.
4007253a
150
Section 5
Removal and Installation
Travel Sensors Engage,
Splitter, Range and Select
WARNING
RETAINING
PLATE
O-RING
SCREWS
This procedure is to be performed only with
out-of-warranty cases. During warranty period,
the complete TCU must be exchanged.
TRAVEL
SENSOR
NOTE: The repair kit contains two screws, one
retaining plate, one travel sensor and one
O-ring.
4007256a
Removal
Step 1
Clean the area around the sensors.
앫 GO TO THE NEXT STEP
Step 2
Carefully raise the tab and pull the connector off
the sensor contact.
앫 GO TO THE NEXT STEP.
Step 3
CONNECTORS
Remove the two screws and take off the
retaining plate. Pull out the travel sensor
complete with the O-ring.
앫 GO TO THE NEXT STEP.
Step 4
Inspect the parts and replace if necessary.
NOTE: The sensors for the flange, splitter, main
transmission and select cylinder are identical.
TRAVEL SENSORS
4007257a
Installation
NOTE: Apply Uni-Silicon GLK 112 grease to the
sealing and sliding faces.
Step 1
Insert the O-ring on the travel sensor.
앫 GO TO THE NEXT STEP.
Step 2
Insert the travel sensor complete with the O-ring.
앫 GO TO THE NEXT STEP.
Step 3
Install and secure the retaining plate with two
screws. Tighten the screws to 5 lb-ft (6.78 N폷m).
T
앫 GO TO THE NEXT STEP.
Step 4
Plug the connector in to the sensor contacts.
151
Section 5
Removal and Installation
Step 1
Air Pressure Sensor
Removal
WARNING
VEHICLE
This procedure is to be performed only for
out-of-warranty repairs. During warranty
period, replace the TCU top half.
Remove the electrical wire harness from the
TCU connector marked “vehicle”.
앫 GO TO THE NEXT STEP.
TRANSMISSION
4007234a
Step 2
Remove the electrical wire harness from the
TCU connector marked “Transmission”.
TRANSM
ISSION
앫 GO TO THE NEXT STEP.
4007235a
Step 3
Remove the air fitting from the air regulator.
WARNING
Use caution when disconnecting the air line as
it still may be under pressure.
앫 GO TO THE NEXT STEP.
4007236a
152
Section 5
Removal and Installation
Step 4
Use a 13 mm socket to remove the 15 fasteners
that secure the TCU to the transmission.
앫 GO TO THE NEXT STEP.
4007237a
Step 5
SCREWS
UPPER
SECTION
Remove both screws with a T-30 Torx Tool.
앫 GO TO THE NEXT STEP.
Step 6
Raise the upper section.
GASKET
WARNING
PROFILE
SEAL
Use caution when lifting upper section. Do not
damage ribbon cables!
앫 GO TO THE NEXT STEP.
LOWER
SECTION
4007238a
153
Section 5
Removal and Installation
Step 7
Disconnect plug connections.
앫 GO TO THE NEXT STEP.
Step 8
PLUG
CONNECTION
PLUG
CONNECTION
Ensure the profile seal remains in the bottom
part of the TCU.
앫 GO TO THE NEXT STEP.
Step 9
Remove the gasket.
4007239a
Step 10
Remove the four locking tabs as shown.
WARNING
Do not damage or break studs.
Remove the cover.
앫 GO TO THE NEXT STEP.
Remove the locking tabs.
4007242a
Step 11
Remove the two T10 Torx screws.
Carefully unplug the sensor connector from
circuit board.
TORX
SCREWS
Remove the pressure sensor.
앫 GO TO THE NEXT STEP.
SENSOR
CONNECTOR
4007243a
154
Section 5
Removal and Installation
Step 12
Remove the old O-ring.
O-RING
4007244a
155
Section 5
Removal and Installation
Step 1
Installation
Inspect the sensor and ensure the O-ring is
installed.
Install the sensor.
앫 GO TO THE NEXT STEP.
O-RING
4007245a
Step 2
Install the two T-10 Torx screws.
Tighten the screws to 3 lb-ft (4 N폷m).
TORX
SCREWS
Connect the sensor ribbon connector to the
circuit board.
앫 GO TO THE NEXT STEP.
SENSOR
CONNECTOR
4007243a
Step 3
Install the four locking tabs.
앫 GO TO THE NEXT STEP.
Remove the locking tabs.
156
4007242a
T
Section 5
Removal and Installation
Step 4
Reconnect the plug connections (7 and 8).
PLUG
CONNECTION
PLUG
CONNECTION
Check that the plug connections are tight and
secure.
앫 GO TO THE NEXT STEP.
4007239a
Step 5
SCREWS
UPPER
SECTION
Place the new gasket seal on the upper section.
앫 GO TO THE NEXT STEP.
Step 6
Place the upper section on the lower section.
Ensure that the flat seal does not move. Fix the
seal if necessary.
GASKET
PROFILE
SEAL
앫 GO TO THE NEXT STEP.
Step 7
Tighten the two screws to 7.0 lb-ft (9 N폷m).
LOWER
SECTION
T
4007238a
157
Section 5
Removal and Installation
Step 8
Use a 13 mm socket and ratchet to secure the
TCU to the transmission with 15 fasteners.
Secure the wiring harness clip to the
transmission.
Tighten the fasteners to 17 lb-ft (23 N폷m) using a
star pattern. T
앫 GO TO THE NEXT STEP.
4007237a
Step 9
Install the air fitting into the air regulator.
앫 GO TO THE NEXT STEP.
4007236a
Step 10
TRANSM
ISSION
Connect the electrical wire harness into the TCU
connector marked “Transmission”.
앫 GO TO THE NEXT STEP.
4007235a
158
Section 5
Removal and Installation
VEHICLE
Step 11
Connect the transmission vehicle wiring harness
to the TCU port marked “Vehicle.”
TRANSMISSION
4007234a
159
Section 5
Removal and Installation
Step 1
Transmission Wiring Harness
Assembly
VEHICLE
Removal
Unplug the wiring harness assembly from the
TCU port marked “Vehicle.”
앫 GO TO THE NEXT STEP.
TRANSMISSION
4002006a
Step 2
Unplug the voltage doubler connector.
앫 GO TO THE NEXT STEP.
Step 3
Use a 1/4-inch socket and ratchet or nut driver to
remove the ZMTEC connector.
앫 GO TO THE NEXT STEP.
160
Section 5
Removal and Installation
Step 4
Unplug the OEM connector.
앫 GO TO THE NEXT STEP.
4002016a
Step 5
Unplug the output shaft speed sensor connector.
앫 GO TO THE NEXT STEP.
Step 6
Unplug the Neutral switch connector.
앫 GO TO THE NEXT STEP.
161
Section 5
Removal and Installation
Step 7
Remove the wiring harness from the clips.
162
Section 5
Removal and Installation
Step 1
Installation
VEHICLE
Connect the wiring harness assembly to the
TCU at the connector port marked “Vehicle.”
앫 GO TO THE NEXT STEP.
TRANSMISSION
4002006a
Step 2
Connect the wiring harness assembly to the
voltage doubler connector.
앫 GO TO THE NEXT STEP.
Step 3
Connect the wiring harness assembly to the
ZMTEC and secure the connection by tightening
the 1/4-inch screw to 7.0 lb-ft (9.5 N•m). T
앫 GO TO THE NEXT STEP.
163
Section 5
Removal and Installation
Step 4
Connect the wiring harness assembly to the
OEM wiring harness.
앫 GO TO THE NEXT STEP.
4002016a
Step 5
Connect the wiring harness assembly to the
output shaft speed sensor connector.
앫 GO TO THE NEXT STEP.
Step 6
Connect the wiring harness assembly to the SAE
J-1939 connector.
앫 GO TO THE NEXT STEP.
164
Section 5
Removal and Installation
Step 7
Connect the wiring harness assembly to the
Neutral switch connector.
앫 GO TO THE NEXT STEP.
Step 8
Secure the wiring harness assembly to the
transmission clips.
165
Section 5
Removal and Installation
Step 1
Cooler By-Pass Valve
Removal
Place a pan underneath the transmission to
collect the oil. Remove the hoses from the
by-pass valve.
앫 GO TO THE NEXT STEP.
BY-PASS
VALVE
Step 2
Use a 27 mm socket and ratchet to remove the
two fasteners that secure the by-pass valve to
the transmission.
앫 GO TO THE NEXT STEP.
Step 3
O-RINGS
Remove the by-pass valve.
166
Section 5
Removal and Installation
Step 1
O-RINGS
Installation
Install the cooler by-pass valve as shown.
앫 GO TO THE NEXT STEP.
Step 2
Use a 27 mm socket and ratchet to secure the
by-pass valve to the transmission with the two
fasteners, sealing rings and O-rings.
앫 GO TO THE NEXT STEP.
Step 3
Tighten the two fasteners to 36 lb-ft (50 N•m).
T
앫 GO TO THE NEXT STEP.
167
Section 5
Removal and Installation
Step 4
Fasten the hoses to the by-pass valve. Using a
torque wrench, tighten the oil line fitting to the
cooler-bypass to 66 lb-ft (90 N•m). Tighten the
cooler line to the fitting such that it does not
leak. T
BY-PASS
VALVE
168
Section 5
Removal and Installation
Step 1
Neutral Switch
Removal
Unplug the Neutral switch connector.
앫 GO TO THE NEXT STEP.
Step 2
Use a 1-1/16-inch (27 mm) box end wrench to
loosen the Neutral switch.
앫 GO TO THE NEXT STEP.
Step 3
Remove the Neutral switch, sealing ring and pin.
SEALING
RING
PIN
NEUTRAL
SWITCH
169
Section 5
Removal and Installation
Step 1
Installation
Use a 1-1/16-inch (27 mm) socket and ratchet to
install the Neutral switch and tighten to 33 lb-ft
(45 N•m). T
앫 GO TO THE NEXT STEP.
Step 2
Connect the electrical wiring harness to the
Neutral switch connector.
170
Section 5
Removal and Installation
Step 1
Output Shaft Speed Sensor
Removal
NOTE: The transmission’s upper and lower
output shaft speed sensors are identical and
use the same removal procedure. (Removal of
the UPPER output shaft speed sensor is shown
in Steps 1-3.) When removing lower speed
sensor, use container to capture excess oil
when sensor is removed.
Unplug the output shaft speed sensor
connector.
앫 GO TO THE NEXT STEP.
4002025a
Step 2
Use a 1-1/16-inch (27 mm) box end wrench to
loosen the output shaft speed sensor.
앫 GO TO THE NEXT STEP.
Step 3
Remove the output shaft speed sensor.
171
Section 5
Removal and Installation
Step 1
Installation
NOTE: The transmissions upper and lower
output shaft speed sensors are identical and
use the same installation procedure (installation
of the upper output shaft speed sensor is shown
in Steps 1 and 2). When removing lower speed
sensor, use container to capture excess oil
when sensor is removed.
Use a 1-1/16-inch (27 mm) socket and ratchet to
install the output shaft speed sensor and tighten
to 15 lb-ft (21 N•m). T
앫 GO TO THE NEXT STEP.
Step 2
Connect the wiring harness to the output shaft
speed sensor connector.
4002024a
172
Section 5
Removal and Installation
Section 5 and Installation
Removal
Step 1
WARNING
Always remove the clutch actuator housing
BEFORE you remove the transmission, so that
the transmission does not rest on the actuator
housing. Damage to the transmission will
result.
Clutch Actuator Housing and
Wiring Harness
Removal
Use a 17 mm socket and ratchet to remove the
vent plug.
4002086a
앫 GO TO THE NEXT STEP.
Step 2
Remove the transmission wiring harness
assembly from the TCU port marked
“Transmission.”
TRANSM
ISSION
앫 GO TO THE NEXT STEP.
Step 3
Unplug the output shaft speed sensor connector.
앫 GO TO THE NEXT STEP.
4002024a
173
Section 5
Removal and Installation
Step 4
Remove the transmission wiring harness from
the clips.
앫 GO TO THE NEXT STEP.
Step 5
Remove the air supply line.
앫 GO TO THE NEXT STEP.
CLUTCH
ACTUATOR
AIR LINE
4005602a
Step 6
Use a 13 mm wrench to remove the four nuts
that secure the clutch actuator housing.
앫 GO TO THE NEXT STEP.
4002033a
174
Section 5
Removal and Installation
Step 7
Remove the clutch actuator housing.
앫 GO TO THE NEXT STEP.
Step 8
Use a 17 mm socket and ratchet to install
the vent plug. Tighten the plug to 16 lb-ft
(22 N•m). T
4002086a
175
Section 5
Removal and Installation
Step 1
Installation
Use a 17 mm wrench to remove the vent plug
from the clutch actuator housing. The plug is
opposite the air line connection.
앫 GO TO THE NEXT STEP.
Step 2
Manually compress the air cylinder.
앫 GO TO THE NEXT STEP.
Step 3
With the air cylinder compressed, install the
vent plug.
앫 GO TO THE NEXT STEP.
176
Section 5
Removal and Installation
Step 4
Use a 13 mm wrench to install the clutch
actuator housing onto the transmission with
four nuts and washers.
앫 GO TO THE NEXT STEP.
4002033a
Step 5
Use a torque wrench to tighten the fasteners to
17 lb-ft (23 N•m). T
앫 GO TO THE NEXT STEP.
4002051a
Step 6
Remove the vent plug again. Allow the actuator
to engage the push rod.
앫 GO TO THE NEXT STEP.
177
Section 5
Removal and Installation
Step 7
Use a 17 mm wrench to install the vent plug.
Use a torque wrench to tighten the vent plug to
16 lb-ft (22 N•m). T
앫 GO TO THE NEXT STEP.
Step 8
TRANSM
ISSION
Connect the wiring harness to the TCU port
marked “Transmission.”
앫 GO TO THE NEXT STEP.
Step 9
Connect the wiring harness to the output shaft
speed sensor connector.
앫 GO TO THE NEXT STEP.
4002024a
178
Section 5
Removal and Installation
Step 10
Secure the wiring harness to the wiring harness
clips.
앫 GO TO THE NEXT STEP.
Step 11
Secure the air supply line to the clutch actuator
housing.
CLUTCH
ACTUATOR
AIR LINE
4005602a
179
Section 5
Removal and Installation
Step 1
Release Bearing
Removal
NOTE: YOU MUST REMOVE THE
TRANSMISSION FROM THE VEHICLE
TO REMOVE THE RELEASE BEARING
ASSEMBLY.
If the clutch actuator housing is removed: Slide
the release bearing off of the input shaft past
the release fork assembly.
앫 GO TO THE NEXT STEP.
Step 2
If the clutch actuator housing is not removed:
Remove the release fork assembly. Refer to
Release Fork, Standard and Roller Fork in this
section.
앫 GO TO THE NEXT STEP.
Step 3
Slide the release bearing off the input shaft.
180
Section 5
Removal and Installation
Step 1
Installation
Remove the clutch actuator housing. Refer to
Clutch Actuator Housing and Wiring Harness in
this section.
앫 GO TO THE NEXT STEP.
4002033a
Step 2
Install the release bearing onto the input shaft
without removing the release fork assembly.
앫 GO TO THE NEXT STEP.
Step 3
Install the clutch actuator housing onto the
transmission. Refer to Clutch Actuator Housing
and Wiring Harness in this section.
앫 GO TO THE NEXT STEP.
4002033a
181
Section 5
Removal and Installation
Step 4
Operate the vehicle. Check for correct operation.
182
ZF Friedrichshafen AG
Commercial Vehicle and Special
Driveline Technology
D-88038 Friedrichshafen
www.zf.com
Information contained in this publication was in effect at the time the publication was approved for printing and
is subject to change without notice or liability. ZF Friedrichshafen AG reserves the right to revise the
information presented or discontinue the production of parts described at any time.
Copyright 2009 by ZF
All Rights Reserved
Printed in the USA
Revised 06-09
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