wiring CHRYSLER VOYAGER 2001 Service Manual

Symptom List:
TRANSPONDER COMMUNICATION FAILURE
TRANSPONDER CYCLIC REDUNDANCY CHECK (CRC) FAILURE
TRANSPONDER ID MISMATCH
TRANSPONDER RESPONSE MISMATCH
Test Note: All symptoms listed above are diagnosed using the same tests.
The title for the tests will be TRANSPONDER COMMUNICA-
TION FAILURE.
When Monitored and Set Condition:
TRANSPONDER COMMUNICATION FAILURE
When Monitored: At ignition on and during Key Programming Mode.
Set Condition: When the SKIM does not receive a transponder response after 8 consec-
utive transponder read attempts within 2.0 seconds.
TRANSPONDER CYCLIC REDUNDANCY CHECK (CRC) FAILURE
When Monitored: At ignition on and during Key Programming Mode.
Set Condition: When 5 consecutive transponder signal transmissions are sent to the
SKIM with the correct message format but with invalid data.
TRANSPONDER ID MISMATCH
When Monitored: At ignition on and during Key Programming Mode.
Set Condition: When the transponder ID read by the SKIM does not match any of the
transponder ID's stored in the SKIM's memory.
TRANSPONDER RESPONSE MISMATCH
When Monitored: At ignition on and during Key Programming Mode.
Set Condition: When the transponder's crypto algorithm result fails to match the SKIM's
result.
POSSIBLE CAUSES
CHECKING MULTIPLE KEY OPERATION
SKIM
INTERMITTENT WIRING HARNESS PROBLEM
REPLACE IGNITION KEY
272
VEHICLE THEFT/SECURITY

TEST ACTION APPLICABILITY
6 If there are no possible causes remaining, view repair. All
Repair
Replace and program the Sentry Key Immobilizer Module in
accordance with the Service Information.
Perform SKIS VERIFICATION TEST.
7 Turn the ignition off.
Note: Visually inspect the related wiring harness. Look for any chafed,
pierced, pinched, or partially broken wires.
NOTE: Visually inspect the related wiring harness connectors. Look for
broken, bent, pushed out, or corroded terminals.
Note: Refer to any Technical Service Bulletins (TSB) that may apply.
Were any problems found?All
Ye s®Repair wiring harness/connectors as necessary.
Perform SKIS VERIFICATION TEST.
No®Test Complete.
274
VEHICLE THEFT/SECURITY
TRANSPONDER COMMUNICATION FAILURE ÐContinued

> Trailer towing in OD gear position (use 3 position
(or A/S 3rd) if frequent shifting occurs)
> Cooling system failure causing engine to operate
over 110C (230ÉF)
> Engine coolant temperature stays low too long -
If engine coolant temperature drops below 65C
(150ÉF), the transmission will disengage EMCC.
Extended operation with the EMCC disengaged
will cause the transmission to overheat.
> A brake switch issue will cause the EMCC to
disengage. Extended operation with the EMCC
disengaged will cause the transmission to over-
heat.
> Transmission fluid overfilled
> Transmission cooler or cooler lines restricted
> Transmission Temperature Sensor circuit
3.3 DIAGNOSTIC TROUBLE CODES
Diagnostic trouble codes (DTC's) are codes stored
by the Transmission Control Module (TCM) that
help us diagnose Transmission problems. They are
viewed using the DRBIIItscan tool.
Always begin by performing a visual inspection of
the wiring, connectors, cooler lines and the trans-
mission. Any obvious wiring problems or leaks
should be repaired prior to performing any diagnos-
tic test procedures. Some engine driveability prob-
lems can be misinterpreted as a transmission prob-
lem. Ensure that the engine is running properly
and that no PCM DTC's are present that could
cause a transmission complaint.
If there is a communication bus problem, trouble
codes will not be accessible until the problem is
fixed. The DRBIIItwill display an appropriate
message. The following is a possible list of causes
for a bus problem:
± open or short to ground/battery in PCI bus
circuit (pin 43).
± internal failure of any module or component on
the bus
Each diagnostic trouble code is diagnosed by
following a specific testing sequence. The diagnostic
test procedures contain step-by-step instructions
for determining the cause of a transmission diag-
nostic trouble code. Possible sources of the code are
checked and eliminated one by one. It is not neces-
sary to perform all of the tests in this book to
diagnose an individual code. These tests are based
on the problem being present at the time that the
test is run.All testing should be done with a
fully charged battery.
If the TCM records a DTC that will adversely
affect vehicle emissions, it will request (via the
communication bus) that the PCM illuminate the
Malfunction Indicator Lamp (MIL). Although theseDTC's will be stored in the TCM immediately as a 1
trip failure, it may take up to five minutes of
accumulated trouble confirmation set the DTC and
illuminate the MIL. Three consecutive successful
OBDII (EURO STAGE III OBD) trips or clearing
the DTC's with a diagnostic tool (DRBIIItor equiv-
alent) is required to extinguish the MIL. When the
TCM requests that the PCM illuminate the MIL,
the PCM sets a DTC P0700(89) to alert the techni-
cian that there are DTC's in the TCM. This must
also be erased in the PCM in order to extinguish the
MIL.
3.3.1 HARD CODE
Any Diagnostic Trouble Code (DTC) that is set
whenever the system or component is monitored is
a HARD code. This means that the problem is there
every time the TCM checks that system or compo-
nent. Some codes will set immediately at start up
and others will require a road test under specific
conditions. It must be determined if a code is
repeatable (Hard) or intermittent before attempt-
ing diagnosis.
3.3.2 ONE TRIP FAILURES
A One Trip Failure, when read from the TCM, is
a hard OBDII (EURO STAGE III OBD) code that
has not matured for the full 5 minutes. This applies
to codes that will only set after 5 minutes of
substituted gear operation.
3.3.3 INTERMITTENT CODE
A diagnostic trouble code that is not there every
time the TCM checks the circuit or function is an a
intermittent code. Some intermittent codes, such as
codes P1792(12), P1767(14), P1768(15), P0725(18),
P1716(19), P1781(21), P1782(22), P1724(24),
P0705(28), P0120(29), P0750(41), P0755(42),
P0760(43), P0765(44), P1793(48), P0715(56),
P0720(57), P1794(58), P1796(70), P1799(74),
P1739(76), P1717(77), and P0600(78) are caused by
wiring or connector problems. However intermit-
tent codes 50 - 54 are usually caused by intermit-
tent hydraulic seal leakage in the clutch and/or
accumulator circuits. Problems that come and go
like this are the most difficult to diagnose, they
must be looked for under the specific conditions
that cause them.
3.3.4 STARTS SINCE SET COUNTER
For the most recent code (Code 1), the Starts
Since Set counter counts the number of times the
vehicle has started since it was last set. The counter
will count up to 255 starts. Note that this code only
applies to the last code set.
When there are no diagnostic trouble codes stored
in memory, the DRBIIItwill display ``NO DTC'S
3
GENERAL INFORMATION

the L-R pressure switch does not indicate pressure.
A second detection of L-R pressure results in setting
the code.
Transmission Effects:At speeds above 72 Km/h
(45 MPH), EMCC is inhibited. Once speed falls
below 72 Km/h (45 MPH), the transmission will go
into relay open limp-in mode and the MIL will
illuminate.
Possible causes:
> Valve body - Solenoid valve stuck in L-R position
> Intermittent short to ground or open circuit in
L-R Pressure Switch Sense circuit (with code 24
only)
> Solenoid pack (with code P1784(24) only)
> TCM (with code P1784(24) only)
Name of Code:P1793(48) - Torque Reduction
(TRD) Link Communication Error
Note: The MIL may set on some engines (3.3L, 3.8L,
3.5L)
When Monitored:Whenever the engine is run-
ning
Set condition:This code is set when the TCM
sends multiple torque reduction messages to the
PCM and the TCM does not receive a response from
the PCM.
Theory of Operation:During high torque shifts
the TCM will send a message requesting that the
PCM reduce engine power until the shift is com-
pleted. This message is sent from the TCM to the
Powertrain Control Module across the Torque Man-
agement Request Sense Circuit. The PCM will
acknowledge the TCM request by sending a mes-
sage across the PCI bus within a specific amount of
time. The TRD Link communication is also tested
periodically for operation whenever the engine is
running and the vehicle is not moving with zero
degrees throttle.
Transmission Effects:Maximum throttle angle
used by TCM will be 54 degrees. As a result a
customer my complain about loss of performance or
of short shifting when driving aggressively.
Possible Causes:
> Sticky Throttle Position Sensor (TPS)
> Wiring or Connector problems in the Torque
Management Request Sense Circuit
> PCM
> TCM
Name of code:P0736(50) - Gear Ratio Error in
Reverse
P0731(51) - Gear Ratio Error in 1st
P0732(52) - Gear Ratio Error in 2nd
P0733(53) - Gear Ratio Error in 3rd
P0734(54) - Gear Ratio Error in 4th
P0715(56) - Input Speed Sensor Error
P0720(57) - Output Speed Sensor Error
P1794(58) - Speed Sensor Ground Error
When monitored:The transmission gear ratio is
monitored continuously while the transmission is in
gear.
Set condition:This code is set if the gear ratio is
not correct for a period of time.
± Codes 50 through 54 sets if the ratio of the
input RPM (Nt) to the output RPM (No) does
not match the given gear ratio.
± Code 56 sets if there is an excessive change in
input RPM in any gear
± Code 57 sets if there is an excessive change in
output RPM in any gear
± Code 58 sets after a TCM reset in neutral and
Nt/No equals a ratio of input to output of 2.50
A hard code sets within 3 seconds, an intermit-
tent code sets within 15 seconds.
Theory of operation:The transmission system
uses two speed sensors, one to measure input RPM
and one to measure output RPM. These inputs are
essential for proper transmission operation. There-
fore, the integrity of this data is verified through
the following checks:
1. When in gear, if the gear ratio does not compare
to a known gear ratio, the corresponding in-gear
trouble code is set (codes 50 through 54).
2. An excessive change in input or output speeds
indicating signal intermittent will result in
codes 56 and/or 57 being set.
3. After a TCM reset in neutral, observing erratic
output and input speed sensor signals indicates
a loss of the common speed sensors ground. This
sets a code 58.
Transmission Effects:The transmission will not
go into relay open limp-in mode until three gear
ratio error events occur in a given key start. This
allows for intermittent problems to correct them-
selves without opening the relay. However, if a gear
ratio error develops, a code is always set, but if the
condition corrects itself the transmission will con-
tinue without requiring the ignition key to be cycled
on and off. Many different events could occur given
the range of failures possible for codes 50 through
58. The following are a few examples:
± Codes 51, 52, 53, 54, 56, and 57 at speeds
above 72 Km/h (45 MPH) - The appropriate
code is set, EMCC is aborted and current gear
is maintained. If while still traveling above 72
Km/h (45 MPH), the gear ratio becomes valid
again, EMCC will reengage and normal oper-
ation will resume. If the gear ratio becomes
intermittent and recovers three times in a
given key start, the current gear will be main-
tained and EMCC inhibited, then the trans-
mission will go into relay open limp-in mode if
12
GENERAL INFORMATION

throttle is applied below 72 Km/h (45 MPH) or
at 35 Km/h (22 MPH) with closed throttle.
± Codes 51, 52, 53, 54, 56, and 57 (at speeds
between 35 and 72 Km/h (22 and 45 MPH) - If
one of these codes is set between 35 and 72
Km/h (22 and 45 MPH), the current gear will
be maintained until the gear ratio problem
corrects itself. If throttle is applied, the trans
will go to 2nd gear. If this happens and the
gear ratio problem goes away, normal opera-
tion will resume. If three gear ratio problems
are identified in a given key start, the current
gear will be frozen until throttle is applied.
The transmission will then go into relay open
limp-in mode with throttle applied at speeds
between 35 and 72 Km/h (22 and 45 MPH).
± Codes 51, 52, 53, 54, 56, and 57 (at speeds
below 35 Km/h (22 MPH) - If a gear ratio
problem is identified below 35 Km/h (22 MPH),
the transmission will immediately substitute
second gear for the current gear. If the gear
ratio problem goes away, normal operation will
resume. If three gear ratio problems are iden-
tified in a given key start, the transmission
will go into relay open limp-in mode.
Possible causes:
Code P0736(50) - Excludes geartrain failures which
should be obvious upon disassembly
> If code P1791(35) is also set, follow diagnostic
procedure for code P1791(35) first
> Valve body - #1 ball check or LR switch valve
sticking - may also set code P0731(51)
> Speed sensor or associated wiring
± may also set codes P0731(51), P0715(56), or
P0720(57)
> Failed or slipping LR clutch - may also set code
P0731(51)
> LR seal leakage (Intermittent no drive or re-
verse)
> Sticky LR accumulator seals (Intermittent no
drive or reverse)
> Failed reverse clutch (hard code)
± OD/Rev lip seal leakage
± Worn reaction shaft support seal rings
± Snap ring out of position
Code P0731(51) - Excludes geartrain failures which
should be obvious upon disassembly
> If code P1791(35) is also set, follow diagnostic
procedure for code P1791(35) first
> Valve body - #1 ball check or LR switch valve
sticking - may also set code P0736(56) or have no
Reverse
> Speed sensor or associated wiring - may also set
codes P0736(50), P0715(56), or P0720(57)> Failed or intermittent slipping UD clutch - may
also set P0732(52), or P0733(53)
± UD seal leakage (intermittent)
± Worn input clutch hub bushing (hard code at
heavy throttle)
± Sticky UD accumulator seals (intermittent)
± Worn reaction shaft support seal rings (hard
code at heavy throttle)
± Solenoid pack (UD pressure in 4th gear)
> Failed or slipping LR clutch - may also set code
P0736(56) or have no Reverse
± LR seal leakage (Intermittent)
± Sticky LR accumulator seals (Intermittent)
Code P0732(52) - Excludes geartrain failures which
should be obvious upon disassembly
> If code P1791(35) is also set, follow diagnostic
procedure for code P1791(35) first
> Failed or slipping 2-4 clutch - may also set code
P0734(54)
± 2-4 seal leakage (intermittent)
± Sticky accumulator seals (intermittent)
> Failed or intermittent slipping UD clutch - may
also set code P0731(51) and/or P0733(53)
± UD seal leakage (intermittent)
± Worn input clutch hub bushing (hard code at
heavy throttle)
± Sticky UD accumulator seals (intermittent)
± Worn reaction shaft support seal rings (hard
code at heavy throttle)
± Solenoid pack (UD pressure in 4th gear)
Code P0733(53) - Excludes geartrain failures which
should be obvious upon disassembly
> If code P1791(35) is also set, follow diagnostic
procedure for code P1791(35) first
> Failed or slipping OD clutch - may also set code
P0734(54)
± OD and Reverse inner and outer lip seal leak-
age (usually hard code)
± Sticky OD accumulator seals (intermittent)
± Worn reaction shaft support seal rings (hard
code at heavy throttle)
± Broken OD/UD tapered snap ring - (hard code
at heavy throttle)
> Failed or intermittent slipping UD clutch - may
also set code P0731(51) and/or P0732(52)
± UD seal leakage (intermittent)
± Worn input clutch hub bushing (hard code at
heavy throttle)
± Sticky UD accumulator seals (intermittent)
± Worn reaction shaft support seal rings (hard
code at heavy throttle)
13
GENERAL INFORMATION

± Solenoid pack (UD pressure in 4th gear)
Code P0734(54) - Excludes geartrain failures which
should be obvious upon disassembly
> If code P1791(35) is also set, follow diagnostic
procedure for code P1791(35) first
> Failed or slipping OD clutch - may also set code
P0733(53)
± OD and Reverse inner and outer lip seal leak-
age (usually hard code)
± Sticky OD accumulator seals (intermittent)
± Worn reaction shaft support seal rings (hard
code at heavy throttle)
± Broken OD/UD tapered snap ring - (hard code
at heavy throttle)
> Failed or slipping 2-4 clutch - may also set code
P0732(52)
± 2-4 seal leakage (intermittent)
± Sticky accumulator seals (intermittent)
Codes P0715(56) and P0720(57)
> Failed input or output speed sensor (intermittent
or hard code)
> Shorted or open wiring between TCM and speed
sensor(s) (intermittent)
> Connector problems at 60 TCM connector and/or
speed sensor connector
Code P1794(58)
> Open or shorted speed sensor ground (speed
sensor ground is different from chassis ground)
> Open or shorted Temperature Sensor wiring to
TRS
> TRS - Will also set code P1799(74)
> TCM
Name of code:P1796(70) - Autostick Sensor Cir-
cuit (If equipped)
Note: RS is a MUXED Autostick system
When monitored:Whenever the engine is run-
ning.
Set condition:
1) The transmission shift lever is not in AutoStick
and either the upshift or downshift switch is closed.
2) Upshift and downshift switches closed at the
same time.
Theory of operation:In the AutoStick Mode
(manual shift mode), upshifts and downshifts are
actuated manually. Shift requests are detected by
monitoring the MUXED upshift and downshift
switches. The Transmission Control Module (TCM)
monitors the above set conditions. A set condition
will be tolerated for up to 15 seconds before setting
a code.Transmission Effects:The OD position shift
schedule is substituted while operating in the au-
tostick gear selector position. No limp-in mode
occurs.
Possible causes:
> Wiring or connector problems
> AutoStick switch failure
> TCM
Name of code:P1797(71)- Manual Shift Overheat
When monitored:Whenever the engine is run-
ning.
Set condition:1) If the engine temperature ex-
ceeds 124C (255 ÉF) while operating in AutoStick
mode.
2) If the transmission temperature exceeds 135C
(275 ÉF) while in AutoStick mode
Theory of operation:Transmission and engine
temperatures are monitored during vehicle opera-
tion. If conditions occur causing the engine or
transmission to overheat, the AutoStick mode will
be canceled, and a code will be set.
Transmission Effects:The 3 position shift sched-
ule that is used in non-AutoStick applications is
substituted while operating in the AutoStick gear
selector position. No limp-in mode occurs.
Possible causes:
> Engine overheat - refer to service manual for
diagnosis and repair
> Transmission Overheat
± Restricted transmission cooling system
± Transmission fluid overfilled
± Radiator fan not functioning properly
± Extended driving in low gear
Note:Strenuous driving conditions may cause the
vehicle to overheat. If the driver operates in or
initiates AutoStick with an overheated vehicle, the
code will be set.
Name of code:P1798 (73) - Deteriorated Transaxle
Fluid
When monitored:At every Fully Electronically
Modulated Converter Clutch (FEMCC) to Partial
Electronically Modulated Converter Clutch (PEM-
CC) transition miles when A/C compressor clutch is
being cycled.
Set condition:The code will be set if vehicle
shudder is detected 20 times when the A/C clutch is
cycled.
Theory of operation:While in 3rd or 4th gear
FEMCC and just before the A/C clutch engages, the
Powertrain Control Module (PCM) requests the
Transmission Control Module (TCM) to momen-
tarily establish PEMCC operation. If vehicle shud-
der is detected during the FEMCC to PEMCC
transition, a counter is incremented. If the count
reaches 20, the trouble code is set. The driver may
14
GENERAL INFORMATION

then notice harsh bumps when the A/C clutch is
being cycled, but vehicle shudder will be elimi-
nated. After 35 OBDII (EURO STAGE III OBD)
warm-up starts or if the code is cleared, PEMCC
will be reactivated to see if shudder is still present.
If one shudder event occurs, the code will be reset.
Clearing the code and running battery disconnect
with the DRBIIItis the only way to reset the
shudder counter from 20 back to zero.
Transmission Effects:This code does not cause
the transmission to go into limp-in mode. However,
once the code is set, FEMCC to PEMCC operation
before the A/C clutch engagement will be disabled
for 35 OBDII (EURO STAGE III OBD) warm up
starts.
Possible causes:
> Degraded transmission fluid
> Wheels severely out of alignment
> Internal torque converter problem
Name of Code:P1799(74) - Calculated Oil Temper-
ature in Use
When Monitored:When ever the Engine is run-
ning.
Set condition:The code is set if any of the follow-
ing conditions exist for three consecutive key starts:
> The Temperature Sensor voltage is out of range
(below 0.07 volts or greater than 4.94 volts)
> If continuous erratic Temperature Sensor voltage
is sensed.
> The Temperature Sensor temperature stays be-
low 27C (80ÉF) for an extended period of time.
Theory of Operation:The TCM uses a Tempera-
ture Sensor to monitor the transmission sump tem-
perature. This temperature is used to determine
which shift schedule the TCM is to use. (See Trans-
mission Operation and Shift Scheduling at Various
Sump Temperatures in this diagnostic manual) If
the Temperature Sensor circuit fails to operate
properly the TCM will use the calculated oil tem-
perature routine found in prior model year TCM. If
this occurs for three consecutive key starts, the code
will be set. The TCM will then test the Temperature
Sensor circuit after every 35 OBDII (EURO STAGE
III OBD) warm-up starts. If the Temperature Sen-
sor circuit is OK, the Temperature Sensor data is
used in place of the Calculated Oil Temperature
data.
Transmission Effects:If the Temperature Sensor
indicates a temperature below -18C (0É F) or above
115C (240É F) at start up, The TCM compares the
calculated oil temperature to the indicated Temper-
ature Sensor oil temperature. If the calculated oil
temperature differs significantly from the Temper-
ature Sensor value, the calculated oil temperature
will be used for that key start.Possible Causes:
> Wiring or Connector problems in the transmis-
sion temperature sensor signal circuit.
> TRS
> TCM
Name of Code:P1738(75) - High Temperature
Operation Activated.
When Monitored:Whenever the engine is running.
Set Condition:Immediately once the Overheat
Shift Schedule is activated.
Theory of Operation:If the transmission oil tem-
perature rises above 115C (240ÉF), the overheat
shift schedule is activated refer to Transmission
Operation as a function of Transmission Oil Tem-
perature and the code is set. The DTC is an infor-
mation code only and is being set to aid the techni-
cian in determining root cause of a customer
driveability issue. The code is also intended to alert
the technician to determine if a cooling system
malfunction has occurred or if an additional trans-
mission air to oil cooler should be added to the
vehicle if the customer regularly drives in a manner
that overheats the transmission. Extended opera-
tion above 115C (240ÉF) will reduce the durability of
the transmission and should be avoided. Correcting
the cooling system malfunction or installing an
additional transmission oil cooler will improve
transmission durability especially for customers
who operate in city/construction stop and go traffic,
tow trailers regularly, drive aggressively in low gear
or drive regularly in mountainous areas.
Transmission Effects:Information only code. -
Overheat shift schedule was activated, no limp-in
condition occurs. 2nd gear partial EMCC above 40
Km/h (25 MPH), 3rd gear EMCC from 45-69 Km/h
(28-43 MPH), delayed 3-4 upshift at 69 Km/h (43
MPH), early 4-3 coastdown at 66 Km/h (41 MPH),
EMCC operation under all conditions above 40
Km/h (25 MPH) except at closed throttle or 1st gear.
Possible Causes:
± Transmission Overfilled with Oil
± Engine cooling fan failure
± Engine thermostat stuck closed
± Radiator corroded or packed with dirt
± Transmission Oil Cooler Plugged
± Customer driving pattern requires additional
transmission cooling
Name Of Code:P1739(76) - Power-Up at Speed
When Monitored:When TCM (transmission con-
trol module) initially powers-up.
Set Condition:If the TCM powers up while in the
9Drive9position and the vehicle is going above 32
Km/h (20 MPH), the code is set.
Theory of Operation:If a vehicle loses power to
the TCM, the vehicle will go to the 2nd gear mode
15
GENERAL INFORMATION

3.4 USING THE DRBIIIT
Refer to the DRBIIItusers guide for instructions
and assistance with reading trouble codes, erasing
trouble codes, and other DRBIIItfunctions.
3.5 DRBIIITERROR MESSAGES
Under normal operation, the DRBIIItwill dis-
play one of only two error messages:
± User-Requested WARM Boot
± User-Requested COLD Boot
If the DRBIIItshould display any other error
message, record the entire display and call the
S.T.A.R.. Center. This is a sample of such an error
message display:
ver: 2.14
date: 26 Jul93
file: key_itf.cc
date: Jul 26 1993
line: 548
err: 0x1
User-Requested COLD Boot
Press MORE to switch between this
display and the application screen.
Press F4 when done noting information.
3.5.1 DRBIIITDOES NOT POWER UP
(BLANK SCREEN)
If the LED's do not light or no sound is emitted at
start up, check for loose cable connections or a bad
cable. Check the vehicle battery voltage. A mini-
mum of 11 volts is required to adequately power the
DRBIIIt.
If all connections are proper between the DRBIIIt
and the vehicle or other devices, and the vehicle
battery is fully charged, an inoperative DRBIIIt
may be the result of faulty cable or vehicle wiring.
For a blank screen, refer to the appropriate Body
Diagnostic manual.
3.5.2 DISPLAY IS NOT VISIBLE
Low temperatures will affect the visibility of the
display. Adjust the contrast to compensate for this
condition.
3.6 TRANSMISSION SIMULATOR
(MILLER TOOL # 8333) AND FWD
ADAPTER (MILLER TOOL #8333-1)
The transmission simulator, simply put, is an
electronic device that simulates the electronic func-
tions of any EATX controlled transmission (41TE,
42LE, 45RFE, and 545RFE). It's basic function is toaid the technician in determining if an internal
transmission problem exists or if the problem re-
sides in the vehicle wiring or Transmission Control
Module (TCM). It is only useful for electrical prob-
lems. It will not aid in the diagnosis of a failed
mechanical component, but it can tell you that the
TCM and wiring are working properly and that the
problem is internal.
The ignition switch should be in the lock position
before attempting to install the simulator. Follow
all instructions included with the simulator. If the
feedback from the simulator is in doubt, you can
verify it's operation by installing it on a known good
vehicle. A9known good vehicle9would be defined as
a vehicle that does not set any DTC's and drives and
shifts as expected.
One important point to remember is that the
Simulator receives it's power from the Trans Relay
Output circuit. If the transmission system is in
Limp-in (Relay open), the simulator will not oper-
ate. This is not really an indication of a problem,
but an additional symptom. If the simulator does
not power up (9P9led lit), this is an indication that
the problem is still present with the simulator
hooked up. This indicates that the problem is in the
wiring or TCM and not the transmission.
Miller Tool # 8333-1 consists of the adapter cables
and overlay necessary to adapt the simulator to
41TE and 42LE transmissions.
4.0 DISCLAIMERS, SAFETY,
AND WARNINGS
4.1 DISCLAIMERS
All information, illustrations and specifications
contained in this manual are based on the latest
18
GENERAL INFORMATION

Symptom:
P0120-THROTTLE POSITION SENSOR SIGNAL CIRCUIT
When Monitored and Set Condition:
P0120-THROTTLE POSITION SENSOR SIGNAL CIRCUIT
When Monitored: Whenever the engine is running.
Set Condition: This code is set if the throttle angle goes out of range or if throttle angle
changes abruptly (i.e.: faster than the throttle body motion could occur).
POSSIBLE CAUSES
RELATED PCM DTC'S PRESENT
INTERMITTENT WIRING & CONNECTORS
SENSOR GROUND CIRCUIT OPEN TO TCM
TPS SIGNAL CIRCUIT OPEN TO TCM
TPS VOLTAGE CHANGE NOT SMOOTH
TCM - TPS SIGNAL CIRCUIT
TEST ACTION APPLICABILITY
1NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low locate and repair the leak then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
With the DRBIIIt, read the engine DTC's. Check and repair all engine DTC's prior
to performing Transmission Symptom Diagnostics.
With the DRBIIIt, read Transmission DTC's. Record all DTC's and 1 Trip Failures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Using the wiring diagram/schematic as a guide, inspect the wiring and connectors.
Repair as necessary.
Perform the Shift Lever Position Test. If the test does not pass, refer to Symptom test
for P0705 Check Shifter Signal.
For Gear Ratio DTC's, check and record all CVI's.
Most DTC's set on start up but some must be set by driving the vehicle such that all
diagnostic monitors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB's related to the symptom.
Perform this procedure prior to Symptom diagnosis.All
Continue
Go To 2
2 With the DRBIIIt, check Powertrain Control Module DTC's.
Are any of the following P-codes P0122, P0123, P0121 stored in the PCM?All
Ye s®Refer to the Driveability category for the related symptom(s).
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
No®Go To 3
24
TRANSMISSION

TEST ACTION APPLICABILITY
3 Start the engine. Allow the engine to idle.
With the DRBIIIt, Check the Throttle Position Sensor Voltage under Transmission
Sensors.
Is the Throttle Position Sensor voltage below 0.3 or above 1.0 volts?All
Ye s®Go To 4
No®Go To 7
4 Turn the ignition off.
Disconnect the TPS harness connector.
Disconnect the TCM harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resistance of the Sensor Ground circuit between the TPS harness
connector and the Transmission Control Module harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 5
No®Repair the Sensor Ground circuit for an open.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
5 Turn the ignition off.
Disconnect the Throttle Position Sensor harness connector.
Disconnect the Transmission Control Module harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resistance of the TPS Signal Circuit from the TCM harness connector to
the TPS harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 6
No®Repair the TPS signal circuit for an open.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
6 If there are no possible causes remaining, view repair. All
Repair
Replace the TCM. WITH THE DRBIIItPERFORM QUICK
LEARN AND REPROGRAM PINION FACTOR.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
7 The conditions necessary to set this DTC are not present at this time. Using the
schematics as a guide, inspect the wiring and connectors specific to this circuit.
Wiggle the wires while checking for shorts and open circuits.
Pay particular attention to the the point where the TPS signal and sensor ground
circuits splice off from the engine circuits.
Were any problems found?All
Ye s®Repair wiring and/or connector as necessary.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
No®Go To 8
8 Turn the ignition on.
With the DRBIIIt, read TPS VOLTS.
While monitoring the DRBIIIt, slowly open and close the Throttle.
Is the voltage change smooth?All
Ye s®Test Complete.
No®Replace the Throttle Position Sensor.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
25
TRANSMISSION
P0120-THROTTLE POSITION SENSOR SIGNAL CIRCUIT ÐContinued