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Test KJ: KICKDOWN Solenoid Relay (ALLISON At545): Testing

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    NOTE: For additional testing information, see DIAGNOSTIC AIDS .

  1. 1) KOEO & Continuous Memory DTC P1902: Check VPWR Circuit For Open
    DTC P1902 indicates PCM detected kickdown solenoid relay control circuit failure. Possible causes are:
    • VPWR Circuit To Downshift Relay Open
    • Downshift Relay Control Circuit Open
    • Faulty Downshift Relay
    • Faulty PCM

    Turn ignition off. Remove downshift solenoid relay from battery junction box. Battery junction box is located in left rear corner of engine compartment. Turn ignition on. Using DVOM, measure voltage between chassis ground and downshift solenoid relay cavity No. 1 (White/Light Blue wire). See Figure. If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 volts or less, repair open in VPWR circuit (White/Light Blue wire) between battery junction box and downshift solenoid relay. Retest system.

  2. 2) Check PCM Control Circuit

    Turn ignition off. Reinstall downshift solenoid relay. Disconnect PCM connector. Connect a jumper wire between chassis ground and PCM harness connector terminal No. 94 (Orange/Yellow wire). Turn ignition on, then off. If an audible click is heard from downshift solenoid relay when ignition is on, replace PCM. Retest system. If an audible click is not heard from downshift solenoid relay, go to next step.

  3. 3) Check Downshift Solenoid Relay Control Circuit For Open

    Turn ignition off. Disconnect PCM connector and inspect for damaged pins, corrosion and loose wires. PCM is located in rear of engine compartment. Repair connector as necessary. Install Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance between downshift solenoid relay cavity No. 2 (Orange/Yellow wire) and test pin No. 94 at breakout box. See Figure. If resistance is less than 5 ohms, replace downshift solenoid relay. Retest system. If resistance is 5 ohms or more, repair open in Orange/Yellow wire between PCM and downshift solenoid relay. Retest system.
    4. NOTE: For additional testing information, see DIAGNOSTIC AIDS .

  4. 4) KOEO DTC P1903: Check Fuse
    DTC P1903 indicates downshift solenoid circuit low voltage. Downshift solenoid relay was commanded ON by PCM and a low voltage was present at B+ terminal of downshift solenoid. Possible causes are:
    • Blown Fuse
    • Open Circuit In Battery Junction Box
    • B+ Circuit To Downshift Relay Open
    • B+ Circuit To PCM Or Downshift Solenoid Open
    • Faulty PCM

    Remove and inspect downshift solenoid relay B+ fuse No. 10 (15-amp) located in battery junction box. Battery junction box is located in left rear corner of engine compartment. If fuse is okay, go to next step. If fuse is blown, replace fuse. Retest system.

  5. 5) Check Downshift Solenoid Relay B+ Circuit For Voltage

    Turn ignition off. Remove downshift solenoid relay from battery junction box. Turn ignition on. Using DVOM, measure voltage between chassis ground and downshift solenoid relay cavity No. 3 (White/Violet wire). See Figure. If voltage is more than 10.5 volts, go to step  7). If voltage is 10.5 volts or less, go to next step.

  6. 6) Check Downshift Solenoid Relay B+ Circuit For Open

    Using DVOM, measure resistance of White/Violet wire between output side of downshift solenoid relay B+ circuit fuse No. 10 and downshift solenoid relay cavity No. 3. If resistance is less than 5 ohms, check battery feed circuit to fuse No. 10. Repair circuit or replace battery junction box as necessary. See appropriate POWER DISTRIBUTION article in WIRING DIAGRAMS. If resistance is 5 ohms or more, repair open in B+ circuit (White/Violet wire). Retest system.

  7. 7) Check Downshift Relay ASSM Circuit To PCM

    Turn ignition off. Disconnect PCM connector and inspect for damaged pins, corrosion and loose wires. PCM is located in rear of engine compartment. Repair connector as necessary. Install Rotunda Breakout Box (014-00950), leaving PCM disconnected. Connect a jumper wire between downshift relay cavities No. 3 (White/Violet wire) and No. 5 (Black/Yellow wire). See Figure. Using DVOM, measure voltage between chassis ground and test pin No. 40 at breakout box. Observe DVOM voltage reading and listen for an audible "click" from downshift solenoid while ignition is cycled on, then off. Proceed as follows:
    • If voltage is 10.5 volts or more and downshift solenoid does not "click" when ignition is cycled on, go to next step.
    • If voltage is 10.5 volts or more and downshift solenoid "clicks" when ignition is cycled on, replace PCM. Retest system.
    • If voltage is less than 10.5 volts and downshift solenoid "clicks" when ignition is cycled on, repair open in Black/Yellow wire between splice S139 and PCM. Splice S139 is located on left side of engine compartment. Retest system.

  8. 8) Check Downshift Solenoid Relay Output Circuit To Downshift Solenoid

    Using DVOM, measure resistance of Black/Yellow wire between downshift relay cavity No. 5 and downshift solenoid harness connector. If resistance is less than 5 ohms, check for automatic transmission concern. See 4R100 DIAGNOSIS article in AUTOMATIC TRANSMISSIONS for further diagnostic and repair procedures. If resistance is 5 ohms or more, repair open in Black/Yellow wire between downshift solenoid and splice S139. Splice S139 is located on left side of engine compartment. Retest system.
    9. NOTE: For additional testing information, see DIAGNOSTIC AIDS .

  9. 9) KOEO & Continuous Memory DTC P1904: Check Downshift Solenoid Relay Resistance
    DTC P1904 indicates downshift solenoid circuit high voltage. Downshift solenoid relay was commanded OFF by PCM and a high voltage was present at B+ terminal of downshift solenoid. Possible causes are:
    • Downshift Solenoid Relay Control Circuit Shorted To Ground
    • B+ Circuit To PCM & Downshift Solenoid Shorted To PWR
    • Faulty Downshift Solenoid Relay
    • Faulty PCM

    Turn ignition off. Remove downshift solenoid relay from battery junction box. Using DVOM, measure resistance between downshift solenoid relay terminals No. 3 and 5. If resistance is less than 5 ohms, replace downshift solenoid relay. Retest system. If resistance is 5 ohms or more, leave downshift solenoid removed and go to next step.

  10. 10) Check Downshift Solenoid Relay Control Circuit For Short To Ground

    Ensure ignition is off. Disconnect PCM connector and inspect for damaged pins, corrosion and loose wires. PCM is located in rear of engine compartment. Repair connector as necessary. Install Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance between chassis ground and test pin No. 94 at breakout box. See Figure. If resistance is less than 10 k/ohms, repair short to ground in downshift solenoid relay control circuit (Orange/Yellow wire). If resistance is 10 k/ohms or more, go to next step.

  11. 11) Check Downshift Solenoid B+ Circuit For Short To Power

    Using DVOM, measure voltage between chassis ground and test pin No. 40 at breakout box. If voltage is more than 10.5 volts, repair short to voltage in Black/Yellow wire. If voltage is 10.5 volts or less, replace PCM. Retest system.
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