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Control Valve Solenoid Replacement (PCS1 and PCS2)




Control Valve Solenoid Replacement (PCS1 and PCS2)

Removal Procedure




1. Remove the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (Allison - Automatic Transmission).
2. Disconnect the internal wiring harness from the solenoid being changed.
3. Remove the 2 bolts that fasten reverse signal pipe (1) to the control valve assembly. Remove the reverse signal pipe.





Note:
* When the pressure control valve retaining bracket (5) is removed, there are 2 sets of accumulators (3) and springs (6) which may fall from the bores. Be sure to catch the accumulators and springs so as to prevent damage to these parts.
* The pressure control valve retaining bracket (5) must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more.

4. To remove the pressure control solenoid 1 (PCS1) or PCS2, remove three bolts (4) and the pressure control valve retaining bracket (5). Remove accumulators (3) and springs (6) if they do not fall out when the bracket (5) is removed.
5. Note the position of the solenoid connector and pull the solenoid (1) or (8) out of the bore in the control valve assembly. The O-ring on the solenoid provides the resistance felt during removal.

Installation Procedure




1. Obtain the new solenoid (1) or (8). Lubricate new O-ring (2) or (7) with clean transmission fluid. Install the O-ring and push the new solenoid into the control valve body bore with the wiring harness connector in the correct position.
2. Install the 2 accumulators (3) and springs (6) before installing the pressure control valve retaining bracket (5). The valve (3) goes in the bore first with the hollow end facing outward, followed by the spring (6) which goes inside the hollow portion of the valve.

Caution: Refer to Fastener Caution (Fastener Caution).

3. Install the pressure control valve retaining bracket (5), and install the 3 bolts (4).

Tighten the bolts to 12 Nm (108 lb in).




4. Install the reverse signal pipe (1). Install the 2 bolts that fasten reverse signal pipe to the control valve assembly.

Tighten the bolts to 12 Nm (108 lb in).

5. Reconnect the internal wiring harness to the solenoid.
6. Install the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (Allison - Automatic Transmission).

Note: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission.

7. Perform the FastLearn procedure. Refer to FastLearn Procedure (Allison - Automatic Transmission).

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