Pcs Catalog Revc 02042013 412f60

FULL LINE CATALOG

Powertrain Control Solutions

Table of Contents Transmission Controller Application Chart ..................................................................................................................... 1 Transmission Controller Overview .............................................................................................................................. 2-3 Simple Shift .................................................................................................................................................................... 4 Simple Shift Tuner and Software ................................................................................................................................... 5 TCM-2000 ...................................................................................................................................................................... 6 TCM-2000 Software and Android App ........................................................................................................................... 7 TCM-2600 ...................................................................................................................................................................... 8 TCM-2400 ...................................................................................................................................................................... 9 TCM-2200/2210 ........................................................................................................................................................... 10 TCM-2100 .................................................................................................................................................................... 11 TCM-2005 .................................................................................................................................................................... 12 TCM-2500 .................................................................................................................................................................... 13 Valve Bodies..................................................................................................................................................................14 Factory New Transmissions ......................................................................................................................................... 15 GSM Push Button Shifter ............................................................................................................................................. 16 Paddle Shifters.............................................................................................................................................................. 17 D200 Dash Logger .................................................................................................................................................. 18-19 D200 Kits ..................................................................................................................................................................... 20 Boost Controller ........................................................................................................................................................... 21 Data Logging Modules and Sensors ...................................................................................................................... 22-23 Transmission Reference ......................................................................................................................................... 24-27 Manufacturing Capabilities .......................................................................................................................................... 28 Engineering Capabilities .............................................................................................................................................. 29 OEM or Aftermarket? PCS is an engineering/manufacturing firm dedicated to developing the most comprehensive, advanced driveline controls and data logging modules. Our products serve customers ranging from the OEM building thousands of vehicles on an assembly line to the enthusiast building a hot rod in the garage. The car enthusiast benefits from the extensive research, military-grade testing, exacting quality control standards, and volume of production that come as an OEM supplier. These factors directly contribute to a lower cost and higher quality product to the aftermarket. This catalog contains both the OEM product line and the aftermarket offerings. Refer to the ‘intended use’ row to determine if the product is available for your desired market.

Powertrain Control Solutions, LLC. was founded in 2003 to design and manufacture electronic control systems for automotive powertrain applications. Our knowledgeable staff combines over 50 years of electronic design and manufacturing experience. Since our inception, our product line has grown to include complete vehicle data acquisition systems, automatic transmission controllers and accessory products. In the Spring of 2012, PCS opened a new headquarters and engineering center. The new facility provides extensive engineering space and features a large, temperature controlled shop for research and development. The new building also has a large training room for dealer education and transmission information workshops. We believe that long term growth and profitability comes from a strong foundation of reliable, well ed products rather than marketing flash. We focus on engineering the highest quality products at the lowest possible cost. Our unique approach combines hard work and years of experience to deliver excellent products. At PCS, we test every electronic part we manufacture rigorously and we’ll proudly stand behind our products.

All PCS manufactured modules are proudly made in the USA.

www.powertraincontrolsolutions.com

Transmission Control TCM-2000

TCM-2005

TCM-2100

TCM-2200

TCM-2210

TCM-2300

TCM-2400

TCM-2500

• • •

• • •

• • •

• • •

• • •

• •

•

• • • • • • • • • •

TCM-2600

GM

Transmission Controller Application Chart

4L60/65/70E 4L80/85E 5L40/50 6L45/50 6L80/90 4T40/45E 4T60/65E 4T80E

• • •

• • •

• • •

• • •

• • •

6T30/40/45 6T70/75

• •

• •

Ford AODE AXODE AX4S 4EAT 4R44 4R70W E4OD 4R100 4R75 CD4E 5R55 S/W/N 5R55E 4F27E 5R110 6R80 6R140

• • • • • • • • • • • • • • • ••

• • • • • • • • • • • • • • • •

• • • • • • • • • • • • •

• • • • • • • • • • • • • • • •

• • • • • • • • • • • • • • • •

• • • • • •

• • • • • •

• • • • • •

• • • • • •

• • • • • •

• • • • • • • • • •

• • • • • • • • • •

• •

• •

• • • • • • • •

• • • • • • • • • • • • • • • •

Chrysler 41TE 42LE 42RLE 545RFE 68RFE 722.6/NAG 1

• • • • • •

Other Aisin A340E Aisin A540E Aisin A650E Aisin AB60E Toyota U140F Toyota U340E Nissan RE4R03A/01A Nissan RE5R05A Misubishi F4A3/W4A3 Mazda R4A-EL Allison 1000 (5 and 6 spd) ZF 4HP ZF 5HP

• •

• •

ZF 6HP

804.227.3023

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• • • • • • • • • • • • • •

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1

Powertrain Control Solutions All PCS TCM’s are: • Manufactured at our ISO 9001 Facility • 1-Year Warranty (parts and labor) • Factory Tested and Burned In

TCM-2000

TCM-2005

TCM-2100

Intended Use

Aftermarket

OEM

OEM

Physical

Transmission Controller Overview

Weight Dimensions (L x W x H inches) Case Material & Finish

2.94 lbs.

0.87 lbs

7.2 x 7.3 x 2.5

4.9 x 6.1 x 1.5

Extruded Aluminum Blue Anodized

Aluminum Black Anodized

Extruded Aluminum

Operating Conditions Voltage Range

8 – 18 VDC standard. 24 VDC models available as an option.

Current (device only, not including outputs)

On: 100 mA Quiescent: 0 mA

On: 100 mA Quiescent: 0 mA

On: 100 mA Quiescent: 9 mA

Operating Temperature

-40 to 125°C

-40 to 125°C

-50 to 125°C

Storage Temperature

-40 to 125°C

-40 to 125°C

-55 to 125°C

Yes

Yes

Yes

Reverse/Transient Protections Ingress Protection

IP62

IP67

IP50

Harness Interface

63-pin C

37-pin Mil spec 6-pin Mil spec

Delphi 56-pin

EMI Immunity

All modules are designed for robust EMI immunity. PCS offers certification testing for the desired controller/transmission package as a cost option.

Communication Interface

1 x CAN 2.0b, 1 x RS-232

1 x CAN 2.0b, 1 x RS-232

1 x CAN 2.0b, 1 x RS-232, 1 x GM ALDL

Real-time tuning and data logging with a PC

Yes

Yes

Yes

Real-time tuning and data logging with PCS handheld interface

Yes

Yes

Yes

In-Field Flash Upgradable

Yes

Yes

Yes

4

4

3

Yes

Yes

2 Channels

6 total 2 with 1kΩ 5V pull-ups

4 total 2 with 1kΩ 5V pull-ups

2 total 1 with 1kΩ 5V pull-up

Programmable Input Parameters

Yes

Yes

Yes

Failure Diagnostics for each Anaput

Yes

Yes

Yes

Inputs Frequency (Range 0 – 10 kHz) Programmable Trigger Levels and Filtering for Frequency Inputs Analog Voltage (0-5VDC)

Digital (programmable active high or low)

16

11

6

Overvoltage Protection for Each Input

Yes

Yes

Yes

9

9

7

Outputs PWM

3

2

1

3.5 Amp

3.5 Amp

3.5 Amp

Short Circuit, Overcurrent & Thermal Protection

Yes

Yes

Yes

Selectable Output Drive Type (Battery Voltage or Ground)

Yes

Yes

Ground Only

Programmable Output Type/Parameter for PWM and Digital Outputs

Yes

Yes

Yes

No

No

1 Dedicated high-side measured output

Digital PWM & Digital Maximum Current

Output Channel Current Monitoring

2

0.89 lbs 6.0 x 5.2 x 1.7

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Transmission Control TCM-2200 -2200

TCM-2210 M-221

TCM2300

TCM-2400

TCM-2500

TCM-2600

OEM O

OEM O

Aftermarket

OEM

OEM

OEM

0.64 lbs

0.64 lbs

0.87 lbs

0.70 lbs

1.72 lbs

0.82 lbs

5.3 x 3.7 x 1.4

5.3 x 3.7 x 1.4

5.1 x 6 x 1.5

4.6 x 3.7 x 1.0

5.8 x 9.9 x 2.2

5.3 x 3.7 x 1.5

Aluminum Black Anodized or CARC

Aluminum Black Anodized or CARC

Aluminum Black Anodized

Aluminum

White Polycarbonate with Clear Lid

Aluminum Black Anodized

On: 100 mA Quiescent: 9 mA

On: 100 mA Quiescent: 9 mA

8 – 18 VDC standard. 24 VDC models available as an option. On: 100 mA Quiescent: 9 mA

On: 100 mA Quiescent: 9 mA

On: 100 mA Quiescent: 9 mA

8 - 36 VDC On: 100 mA Quiescent: 0 mA

-50 to 125°C

-50 to 125°C

-50 to 125°C

-50 to 135°C

-40 to 85°C

-50 to 125°C

-55 to 125°C

-55 to 125°C

-55 to 125°C

-55 to 150°C

-40 to 85°C

-55 to 150°C

Yes

Yes

Yes

Yes

Yes

Yes

IP69K

IP69K

IP50

N/A

IP50

IP69K

35-pin Sealed C

36-pin Mil-spec

Delphi 56-pin

Screw terminals

Molex 56-pin

Currently certified for MIL-STD 461. Certification for other standards available as a cost option.

All modules are designed for robust EMI immunity. PCS offers certification testing for the desired controller/transmission package as a cost option.

2 x CAN 2.0b, 1 x RS-232, 1 x GM ALDL

2 x CAN 2.0b, 1 x RS-232, 1 x GM ALDL

1 x CAN 2.0b, 1 x RS-232, 1 x GM ALDL

2 x CAN 2.0b

2 x CAN 2.0b, 1 x USB, 1 x J1850

2 x CAN 2.0b, 1 x RS-232, 1 x J1850

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

3

3

3

4

4

2

2 Channels

2 Channels

2 Channels

No

Yes

Yes

2 total 1 with 1kΩ 5V pull-up

2 total 1 with 1kΩ 5V pull-up

2 total 1 with 1kΩ 5V pull-up

2

6 total 2 with 1kΩ 5V pull-ups

4, all with software selectable 1kΩ 5V pull-ups

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

8

9

6

8

16

8

Yes

Yes

Yes

Yes

Yes

Yes

7

7

7

7

9

4

1

1

1

1

3 digital + 2 relay

0

3.5 Amp

3.5 Amp

3.5 Amp

3.5 Amp

3.5 Amp

3.5 Amp

Yes

Yes

Yes

Yes

Yes

Yes

Ground Only

Ground Only

Ground Only

Ground Only

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

4 PWM Channels 0 - 2 Amp

4 PWM Channels 0 - 2 Amp

1 Dedicated high-side measured output

8

12

No

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Powertrain Control Solutions

Simple Shift Model: TCM-2300

Product Description Simple Shift is the latest breakthrough in electronic overdrive transmission control. No laptops or expensive technicians are required to completely control shift points, shift firmness, and torque converter lockup. All parameters are simply adjusted with easy-to-use dials on the end of the Simple Shift unit. Complete control of how and when your transmission shifts is at your fingertips. Included are complete diagnostic capabilities communicated via simple flashing LED’s that can tell you what gear you’re in, and whether or not your torque converter is locked up.

Application Simple Shift is the perfect solution if you want to use an overdrive electronic transmission in your project car, but don’t want to worry about the controller. After initially adjusting the knobs, you can forget about the controller and enjoy your car. Simple Shift is available for most domestic four speed automatic transmissions.

Ordering

Quick Facts

Simple Shifts are packaged as a kit to make ordering simple. Just choose the part number for your application and you will receive everything you need to get it done right the first time. All Simple Shift kits come with a complete wiring harness tailored to your specific transmission, not a universal harness that fits most transmissions. Each connector on the harness is clearly labeled to make the installation very easy to accomplish in your garage or workshop.

Intended Use

Aftermarket

Weight

0.87 lbs

Case Material & Finish

Aluminum Black Anodized

Voltage Range

8-18 VDC standard

Operating Temperature

-50 to 125°C

Storage Temperature

-55 to 125°C

Ingress Protection

IP50

Communication Interface

1 x CAN 2.0b, 1 x RS-232, 1 x GM ALDL

Input Frequency (Range 0-10kHz)

3

Analog Voltage (0-5VDC)

2 total - 1 with 1kΩ 5V pull-up

Digital (programmable active high or low)

6

Output

4

PWM

7

Digital

1

Output Channel Current Monitoring

1 Dedicated high-side measured output

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Transmission Control

Simple Shift Tuner & Software Simple Shift is designed with knobs to calibrate shift points, shift firmness and torque converter lockup. However, there may be a customer who would prefer to use a more visual device for calibrating or desire to fine tune the TCM. For those customers, PCS offers PC software or a hand held tuner. The PC software provides a tuning interface to make adjustments, a monitor screen to view transmission parameters, data logging, and the ability to view and clear trouble codes. The hand held tuner provides all of the functionality of the PC software in a convenient package. The hand held tuner can remain connected to Simple Shift to serve as a gauge or be removed from the vehicle once programming is complete.

Simple Shift Tuner Calibration Table Simple Shift Software Part #

Description

TCM-6300

Software and USB Cable to Communicate with Single Serial Number Simple Shift Transmission Controller

TCM-6310

Software and USB Cable to Communicate with Unlimited Number of Simple Shift Transmission Controllers

TCM-6315

Simple Shift Hand Held Tuner

Simple Shift Tuner

Part Number

Description

Part Number

Description

TCM-5310

GM 4L60/65E 1993+ Simple Shift EFI Kit including TCM-5335 TCU and Harness

GM 4L80/85E 1993+ Simple Shift EFI Kit including TCU and Harness

TCM-5311

GM 4L60/65E 1993+ Simple Shift Carb Kit including TCU, Harness, and TPS Kit

TCM-5336

GM 4L80/85E 1993+ Simple Shift Carb Kit including TCU, Harness, and TPS Kit

TCM-5320

GM 4L70E 2006-2008 Simple Shift EFI Kit including TCU and Harness

TCM-5350

Ford 4R70/75 1998+ Simple Shift EFI Kit including TCU and Harness

TCM-5321

GM 4L70E 2006-2008 Simple Shift Carb Kit including TCU, Harness, and TPS Kit

TCM-5351

Ford 4R70/75 1998+ Simple Shift Carb Kit including TCU, Harness, and TPS Kit

TCM-5325

GM 4L70E 2009+ Simple Shift EFI Kit including TCU and Harness

TCM-5360

Ford AODE 1993-1997 Simple Shift EFI Kit including TCU and Harness

TCM-5326

GM 4L70E 2009+ Simple Shift Carb Kit including TCU, Harness, and TPS Kit

TCM-5361

Ford AODE 1993-1997 Simple Shift Carb Kit including TCU, Harness, and TPS Kit

TCM-5330

GM 4L80/85E 1991-1992 Simple Shift EFI Kit including TCU and Harness

TCM-5370

Ford 4R100 1998+ Simple Shift EFI Kit including TCU and Harness

TCM-5331

GM 4L80/85E 1991-1992 Simple Shift Carb Kit including TCU, Harness, and TPS Kit

TCM-5371

Ford 4R100 1998+ Simple Shift Carb Kit including TCU, Harness, and TPS Kit

* Add “PS” suffix to Simple Shift kit part number to include Paddle Shifter with Display for 5/6 bolt, part number PS-2001 * Add “P9” suffix to Simple Shift kit part number to include Paddle Shifter with Display for 9-bolt, part number PS-2006

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Powertrain Control Solutions

TCM-2000 Product Description The TCM-2000 is our most powerful aftermarket controller. Similar to all PCS controllers, the TCM-2000 features dual calibrations (sport mode, tow-haul mode, etc.), programmable shift points, shift firmness, and torque converter lockup. Unique to TCM-2000, PWM outputs are programmable either active high or low ing a wide range of transmissions from GM, Ford, Chrysler, Nissan, Toyota, and others. The CAN interface allows seamless integration with CAN based vehicles or ECU’s. Compatible with J1939 and other CAN standards. The CAN connection also simplifies the connection to a PCS Paddle Shifter or GSM-2100 Gear Select Module so you can eliminate the shift lever in your car.

Application The TCM-2000 s most conventional automatic transmissions on the market. Its friendly yet powerful software interface allows the to have full control over transmission operation.

Quick Facts Ordering

Intended Use

Aftermarket

To purchase a controller kit, specify the controller (TCM-2000) and the harness for the transmission (see table). If this is a fuel injected application you may be able to share the throttle position sensor already on the engine. If your vehicle does not have a throttle position sensor, a remote mount TPS kit, TCM-6000 is available from PCS.

Weight

0.89 lbs

Case Material & Finish

Extruded Aluminum Blue Anodized

Voltage Range

8-18 VDC standard. 24 VDC models available as option.

Operating Temperature

-40 to 125°C

Storage Temperature

-40 to 125°C

Ingress Protection

IP62

Communication Interface

1 x CAN 2.0b, 1 x RS-232

Input Frequency (Range 0-10kHz)

4

Analog Voltage (0-5VDC)

6 total - 2 with 1kΩ pull ups

Digital (programmable active high or low)

16

Output

6

PWM

9

Digital

3

Output Channel Current Monitoring

No

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Transmission Control

TCM-2000 Software & Android App Our -friendly PC Windows Software allows complete control of all transmission parameters via our completely programmable input and output setup tables, whether it is a pulse-width modulated solenoid type or clutch to clutch type. This universal architecture also gives the the ability to change connector pin locations and whether the input/output is activated by power or ground, simplifying installation and virtually eliminating wiring mistakes.

Android App

PC Software

PCS offers an app for Android phones and tablets to provide a tuning interface without a bulky laptop. The interface provides all calibration and tuning functionality available in the PC software including shift points, shift firmness, torque converter lockup, and more Part Number

Description

Application

Year

TCM-2000

Universal Transmission Controller

All

All

TCM-4108

FORD 4R100 Harness

4R100

1998-Current

TCM-4133

FORD 5R55E Harness

5R55E

All

TCM-4116

FORD AODE/4R70 Harness (Early Model)

AODE, 4R70

1992-1997

TCM-4115

FORD AODE/4R70 Harness (Late Model)

AODE, 4R70

1998-2007

TCM-4112

FORD E4OD Harness (Early Model)

E4OD

1989-1994

TCM-4109

FORD E4OD Harness (Late Model)

E4OD

1995-1997

TCM-4100

GM 4L80E Harness

4L80/85E*

1991-Current

TCM-4118

GM 4L80/85E Adapter for TCM-4100

4L80E

1991-1992

TCM-4134

GM 4T4X Harness

4T40/ 45E

1997-2007

TCM-4101

GM 4T60E Harness

4T60E

All

TCM-4120

GM 4T65E Harness

4T65E

All

TCM-4104

GM 4T80E Harness (Late Model)

4T80E

2000-Current

TCM-4102

GM 4T80E Harness (Early Model)

4T80E

1996-1999

TCM-4000

Universal Transmission Harness 5’

All

All

TCM-4156

GM 4L60/65/70E

4L60/65/70E

1993-2008

TCM-4166

GM 4L70E

4L70E

2009+

Note: This table includes the most common domestic transmission harnesses. Many other transmissions are ed (See page 1). PCS for part number and ordering information. *TCM-4118 is required for 1991-1992 GM 4L80E

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Powertrain Control Solutions

TCM-2600 Product Description The TCM-2600 is designed for situations where a standalone transmission controller cannot control the transmission directly. Newer transmissions, including the GM 6L80, contain the factory transmission control module inside the valve body. These mechatronic valve body designs make it nearly impossible to directly control the transmission solenoids with a standalone transmission controller. It is also very difficult to remove the transmission and controller from the factory powertrain since all of the transmission parameters are received from other vehicle modules including the engine controller, body control module, etc. The PCS TCM-2600 is an all-in-one solution that will allow the transmission and factory controller to be installed in any vehicle with any engine combination and maintain a fully functional transmission. The TCM-2600 can also be programmed with 2 additional calibrations, each including shift tables and torque converter lockup table.

Quick Facts

Application The TCM-2600 is compatible with the GM 6L45/50, 6L80/90, 6T30/40/45, 6T70/75, Allison 1000 (5 and 6 speeds), the 2nd generation ZF 6HP and the Volkswagen DSG.

Intended Use

OEM

Weight

0.82 lbs

Case Material & Finish

Aluminum Black Anodized

Voltage Range

8-36 VDC standard

Operating Temperature

-50 to 125°C

Storage Temperature

-55 to 125°C

Ingress Protection

IP69K

Communication Interface

2 x CAN 2.0b, 1 x RS-232, 1 x J1850

Input Frequency (Range 0-10kHz)

2

Analog Voltage (0-5VDC)

4, all with software selectable 1kΩ 5V pull-ups

Digital (programmable active high or low)

6

Output

8

PWM

4

Digital

0

Output Channel Current Monitoring

No

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Transmission Control

TCM-2400 Product Description The TCM-2400 is installed directly on a late model GM 4L60/65/70 valve body. This internal TCM reduces packaging and wire harness complexity. On CANbased vehicles, the only required connections to the transmission are power, ground, and CAN. The TCM and harness are also configurable for discrete inputs such as TPS and RPM to accommodate virtually every installation configuration. The new internal harness uses the typical 20-pin 4L70 transmission connector with a different pin out.

Application The TCM-2400 is targeted for applications using the 4L60/65/70 transmission that require ultracompact TCM packaging. Since the TCM is inside the transmission, no additional vehicle space is required to fully control the electronic transmission.

Quick Facts Intended Use

OEM

Weight

0.70 lbs

Case Material & Finish

Aluminum

Voltage Range

8-18 VDC standard. 24 VDC models available as option.

Operating Temperature

-50 to 135°C

Storage Temperature

-55 to 150°C

Ingress Protection

N/A

Communication Interface

2 x CAN 2.0b

Input Frequency (Range 0-10kHz)

4

Analog Voltage (0-5VDC)

2

Digital (programmable active high or low)

8

Output PWM

7

Digital

1

Output Channel Current Monitoring

8

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Powertrain Control Solutions

TCM-2200/2210 Product Description The TCM-2200 is our most robust and rugged transmission control module. This controller was designed for vehicles where space and weight are at a . The TCM-2200 is sealed to an IP69K ingress protection level which enables the OEM to package the module directly on the transmission below the fording line of the vehicle. Installation on the transmission greatly reduces wire harness complexity, weight, and cost. This also provides the ability to ship transmission or powertrain packages complete with the controller and harness already installed. Installation into a vehicle would only require installing the transmission, and connecting the vehicle interface connector – no complicated harness to run in and out of the cabin. TCM to transmission mounting brackets are available for some transmissions. PCS can assist in deg a bracket for a specific application.

Quick Facts Intended Use

OEM

Weight

0.64 lbs

Case Material & Finish

Aluminum Black Anodized or CARC

Voltage Range

8-18 VDC standard. 24 VDC models available as option.

Operating Temperature

-50 to 125°C

Storage Temperature

-55 to 125°C

Ingress Protection

IP69K

Communication Interface

2 x CAN 2.0b, 1 x RS-232, 1 x GM ALDL

Application The TCM-2200/10 is designed for harsh environments such as military vehicles, airport ground vehicles, and industrial equipment. Transmission coverage includes most domestic transmissions.

Input Frequency (Range 0-10kHz)

3

Analog Voltage (0-5VDC)

2 total - 1 with 1kΩ 5V pull-up

Digital (programmable active high or low)

8 (9 optionally)

Output

10

PWM

7

Digital

1

Output Channel Current Monitoring

4 PWM Channels 0 - 2 Amp

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Transmission Control

TCM-2100 Product Description The TCM-2100 is targeted for a vehicle that does not require the TCM to be sealed against water ingress. The extruded aluminum case and automotive style connector can be mounted in a dry location or placed into a sealed enclosure if necessary.

Application The TCM-2100 is targeted for the OEM that requires a budget friendly transmission controller without rigorous environmental requirements. Similar to all of PCS’ OEM controllers the TCM-2100 features a full suite of diagnostic trouble codes and will use a failsafe condition if certain damaging, error states are encountered.

Quick Facts Intended Use

OEM

Weight

0.87 lbs

Case Material & Finish

Extruded Aluminum

Voltage Range

8-18 VDC standard. 24 VDC models available as option

Operating Temperature

-50 to 125°C

Storage Temperature

-55 to 125°C

Ingress Protection

IP50

Communication Interface

1 x CAN 2.0b, 1 x RS-232, 1 x GM ALDL

Input Frequency (Range 0-10kHz)

3

Analog Voltage (0-5VDC)

2 total - 1 with 1kΩ 5V pull-up

Digital (programmable active high or low)

6

Output PWM

7

Digital

1

Output Channel Current Monitoring

1 Dedicated high-side measured output

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Powertrain Control Solutions

TCM-2005 Product Description Designed for rugged environments this black anodized, billet aluminum TCM features a mil-spec connector and separate on-board mil-spec diagnostic connector, eliminating the need for additional wiring to a remote mounted diagnostic connector. The TCM-2005 is fully sealed to IP67 standards.

Application The TCM-2005 is designed for the OEM that requires mil-spec connectors, a rugged case, and a dedicated on-board diagnostic cable. This is also the only PCS OEM controller with both low and high side PWM drivers enabling it to control domestic transmissions as well as Aisin, Toyota, Nissan, and Mazda.

Quick Facts Intended Use

OEM

Weight

2.94lbs

Case Material & Finish

Aluminum Black Anodized

Voltage Range

8-18 VDC standard. 24 VDC models available as option.

Operating Temperature

-40 to 125°C

Storage Temperature

-40 to 125°C

Ingress Protection

IP67

Communication Interface

1 x CAN 2.0b, 1 x RS-232

Input Frequency (Range 0-10kHz)

4

Analog Voltage (0-5VDC)

4 total - 2 with 2kΩ 5V pull-ups

Digital (programmable active high or low)

11

Output

12

PWM

9

Digital

2

Output Channel Current Monitoring

No

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Transmission Control

TCM-2500 Product Description Transmission dynamometer manufacturers quickly realized the power of our TCM-2000’s versatile hardware and open communication interface to equip their dynamometers. The TCM-2000 served the market well, but it was designed for vehicle use. The TCM-2500 was designed from the ground up for the dynamometer and transmission testing market. The plastic case provides easy computer cabinet mounting and clear lid allows for quick output channel monitoring.

Application The TCM-2500 is designed as an engineer’s tool for non-vehicle use, including transmission development and dynamometer testing. The hardware is the most versatile in our product line enabling you to have one controller that is quickly configurable from one transmission to another.

Quick Facts Intended Use

OEM

Weight

1.72bs

Case Material & Finish

White Polycarbonate with Clear Lid

Voltage Range

8-36 VDC

Operating Temperature

-40 to 85°C

Storage Temperature

-40 to 85°C

Ingress Protection

IP50

Communication Interface

2 x CAN 2.0b, 1 x USB, 1 x J1850

Input Frequency (Range 0-10kHz)

4

Analog Voltage (0-5VDC)

6 total 2 with 1kΩ 5V pull-ups

Digital (programmable active high or low)

16

Output PWM

9

Digital

3 digital + 2 relay

Output Channel Current Monitoring

No

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13

Powertrain Control Solutions

6-Speed 4L80E Valve Body The PCS 6-speed 4L80E valve body enables the 4L80E to operate as a 5-speed or 6-speed and provides electronically controlled engine braking. The process of engineering the 6-speed 4L80E began by studying the fluid flow diagrams of the stock 4L80E. The PCS engineers studied every pressure, every orifice, every shift time, until a design was reached that produced factory shift quality in every gear. When evaluating the gear ratio steps using the stock gear set and the new valve body, it becomes apparent that the step from fourth to fifth of 1.11 may not be a large enough ratio change for most applications. However, using the valve body as a 5 speed (skip the 1.11 ratio) creates more balanced gear steps and better drivability. In situations where the gear set can be changed, PCS offers a gear set that results in optimum gear ratio steps for most 6-speed applications. This gear set is manufactured using the factory process, not a welded modification to an existing gear set. When combined with an optimized gear set, the 6-speed transmission maintains the engine in its most efficient operating range, thus improving performance and fuel efficiency. Shift quality is also improved by reducing the engine RPM drop during the shift. PCS can perform simulations using your engine data to evaluate the optimum gear set for your application.

Part #

Description

VBM-2000

PCS valve body kit including valve body, solenoids, plates, gaskets, and internal harness

VBM-5000

TCM-2000 Kit including valve body kit, TCM-2000, and external harness

VBM-5300

Simple Shift Kit including valve body kit, Simple Shift, and external harness

Stock Gear Set Gear

Ratio

1

2.48

5-Spd Step

New Gear Set

6-Spd Step

6-Spd Step

2.98

2

1.86

1.33

1.33

2.24

1.33

3

1.48

1.26

1.26

1.57

1.43

4

1.11

-

1.33

1.18

1.33

5

1.00

1.48

1.11

1.00

1.18

6

0.75

1.33

1.33

0.75

1.33

R

2.07

2.46

While the engineers were studying the valve body, they also added a solenoid that enables electronically controlled engine braking. This enables modes such as tow/haul, and greatly increases the performance and driving experience when using paddle shifters to downshift. The PCS valve body kit contains a 100% factory new valve body, not a remanufactured unit. All solenoids, plates, gaskets, and internal harness are designed and manufactured to specifications that meet or exceed factory specifications.

Fluid Flow Diagram

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Ratio

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Transmissions

Factory New Transmissions Through the past several years of supplying transmission controllers, PCS has often encountered a scenario where a new vehicle manufacturer has difficultly purchasing factory new transmissions in small to medium volumes. Typically remanufactured transmissions are available but the end requires that all vehicle components are factory new. Purchasing new transmissions from a large manufacturer can be difficult and expensive, if not impossible for a small production run. To eliminate this project-ending scenario, PCS now offers factory new GM 4L60/65/70E and GTP 4L80/85E transmissions. These are only available to qualified OEM’s.

Transmission Specs

GM 4L60/65/70E

GTP 4L80/85E

Type

Four speed, longitudinal rear-wheel drive, electronically controlled, automatic overdrive transmission with torque converter clutch

Four, five, or six speed, longitudinal rear-wheel drive, electronically controlled, automatic overdrive transmission with torque converter clutch and optional electronic engine braking

Engine Range

2.2L – 6.2L Gasoline/Diesel

4.8L – 6.0L Gasoline, 6.5L – 6.6L Diesel

Maximum Engine Torque (no torque management)

4L60E: 350 lb-ft (475 Nm) 4L65E: 380 lb-ft (515 Nm) 4L70E: 400 lb-ft (542 Nm)

4L80E: 440 lb-ft (597 Nm) 4L85E: 460 lb-ft (624 Nm)

Maximum Gearbox Torque

4L60E: 610 lb-ft (827 Nm) 4L65E: 670 lb-ft (908 Nm) 4L70E: 670 lb-ft (908 Nm)

885 lb-ft (1200 Nm)

Available Gear Ratio (1,2,3,4,5*,6*,R) * When available

3.059, 1.625, 1.0, 0.696, 2.294

2.48, 1.48, 1.00, 0.75, 2.07 2.48, 1.86, 1.48, 1.00, 0.75, 2.07 2.98, 1.57, 1.00, 0.75, 2.46 2.98, 2.24, 1.57, 1.00, 0.75, 2.46 2.98, 2.24, 1.57, 1.18, 1.00, 0.75, 2.46

Maximum Gross Vehicle Weight (application and axle ratio dependent)

8,600 lb (3900 kg)

18,000 lb (8165 kg)

Maximum Gross Combined Vehicle Weight (application and axle ratio dependent)

15,500 lb (7030 kg)

22,000 lb (9979 kg)

7-Position Quadrant

P,R,N,OD,D,2,1

P,R,N,OD,D,2,1

Case

Die cast aluminum, removable bell-housing

Die cast aluminum

Shift Pattern

(2) Two-way on/off solenoids

(2) Two-way on/off solenoids (3) Two-way on/off solenoids for 5/6 speed

Shift Quality

Pressure control solenoid 3-2 control solenoid (some models)

Pressure control solenoid

Torque Converter Clutch

Pulse width modulated solenoid control

Pulse width modulated solenoid control

Converter Size

Various

310mm

Fluid Type

DEXRON VI

DEXRON VI

Transmission Weight

Typical Bell, 2-piece case – 2WD: 200 lb (91 kg), 4WD: 196 lb (88 kg)

Wet: 254 lb (115 kg)

Fluid Capacity (approx.)

8.8 qt – 11.4 qt (8.3L – 10.7L)

13.5 qt (12.8L)

Pressure Taps Available

Line Pressure

Line Pressure

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Powertrain Control Solutions

GSM Push Button Shifter The GSM Push Button Shifter is an electronically controlled shifter that offers precise, split-second shifting capability with the push of a button. Its slim touch pad control module and compact, sealed actuator give you virtually unlimited mounting options for tight spaces or grueling environments. The GSM replaces the shift lever for nearly any automatic transmission. The GSM control module can be surface or flush-mounted and is small enough to fit in consoles, dashes, door s, or even armrests. Each button is recessed to avoid inadvertent touches and brightly backlit for darker environments. An easy to read display shows you what gear you’re in. Standard control modules utilize a PRND configuration along with ‘+’ and ‘-‘ buttons for a tap up/tap down feature. Custom modules are also available. The GSM compact actuator box can be mounted next to or near the transmission and connects to the transmission using a flexible shift cable further expanding the mounting envelope. Wiring is simple requiring only power, ground, a brake input, and vehicle speed to operate safely and precisely. The GSM has been designed and is well suited for a variety of markets including automotive, military, commercial, and agricultural.

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Part Number

Application

Part Number

Application

GSM-5000

Ford C4

GSM-5040

GM 1962-1973 Powerglide

GSM-5005

Ford C6

GSM-5045

GM TH300

GSM-5010

Ford AOD

GSM-5050

GM TH400

GSM-5015

Ford AODE

GSM-5055

GM 700R4

GSM-5020

Ford 4R70/75

GSM-5060

GM 4L60/65/70E

GSM-5025

Ford E4OD

GSM-5065

GM 4L80/85E

GSM-5030

Ford 4R100

GSM-5070

Chysler 904/Torqueflite and AMC

GSM-5035

Ford 5R110

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Shifters

Paddle Shifters The PCS Paddle Shifter is designed to provide paddle shifting capability to your hot rod with the look and feel of an OEM system*. Easily installing behind any aftermarket 5, 6, or 9 bolt steering wheel, the Paddle Shifter does not require any external wiring or messy splicing into your vehicle’s wiring system. The paddle unit is powered by simply attaching to the horn button wire, eliminating any external wiring on the column. The Paddle Shifter communicates with the transmission control unit via a wireless receiver module. This receiver module plugs into your PCS transmission control unit harness with one simple, pre-installed plug. The paddle shifter optional display allows the driver to view all of the items listed below. • • • • • • •

Current Gear Vehicle Speed Coolant Temp TCC Lockup % Engine RPM Transmission Slip Turbine RPM

• • • • • • •

5/6 Bolt Paddle Shifter

Throttle Position Manifold Pressure Transmission Temp Line Pressure TCC Slip % Driveshaft RPM Lever Position

9 Bolt Paddle Shifter

Part #

Description

PS-2001

Paddle Shifter w/display for 5 and 6 bolt wheel

PS-2000

Paddle Shifter w/out display for 5 or 6 bolt wheel

PS-2006

Paddle Shifter w/ display for 9 bolt wheel

PS-2005

Paddle Shifter w/out display for 9 bolt wheel

* Paddle Shifter is not designed to be installed on airbag-equipped steering columns. Note: A universal Paddle Shifter kit is available to use with other non-PCS transmission control units.

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Powertrain Control Solutions

D200 Dash Logger The innovative trends at Powertrain Control Solutions continue with our D200. This fully programmable monitoring, data logging, and analysis system can bring together the information on a vehicle from several input sources. Drag race, circle track, road race, and even street cars benefit from the D200 which can combine any set of inputs into one unit. Want to bring together the information from your Lambda meter, aftermarket ECU, and transmission controller, or do you need a stand-alone data acquisition system? Either way, the D200 is your answer. These powerful attributes coupled with a large and easily viewable, even in direct sunlight, LCD touchscreen break new ground. LCD & Touchscreen Features Thorough research and customer have led the D200 along an evolutionary path. Development started with a small screen and navigation buttons but customers wanted something bigger and easier to use with a greater set of features. The D200 has evolved into a , high contrast, large (6 inch), transflective screen that is easily seen day or night, with programmable contrast and backlighting. Our durable, high sensitivity, resistive touchscreen is used in rigorous commercial applications worldwide and can be easily activated with a stylus or finger. Monitor Screens The D200 offers several fully programmable monitor screens capable of displaying any combination of inputs. This allows the to select the most appropriate view for the situation, such as a large tachometer for the track, or a screen with over 20 items for diagnosing a problem. Configuration of individual gauges is as simple as touching the gauge on the screen and selecting the input you wish to associate with it. The D200 also allows the to select the scale and units for the displayed data. Programmable alarms allow the to set high and low points for a particular input. If the input exceeds the specifications, the D200 will alert the driver by flashing the gauge or item. Shift light functionality can be accomplished by having the D200 flash the screen at a desired RPM.

D200 Software

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Data Logging Inputs and Outputs The D200 has 8 anaputs, 2 speed inputs, and 2 PWM outputs. The anaputs can be used for engine sensors, a data log start switch, or any other voltage you wish to monitor and log. All D200 inputs can also be labeled by the for a customized display. The versatile PWM outputs can perform a variety of tasks from an external shift light to boost control. The D200 communicates with external devices using RS-232 or CAN 2.0b. RS-232 is typically used for communicating with most aftermarket ECU’s. The Controller Area Network, or CAN, interface is a communication protocol used for high speed communication in a vehicle environment that utilizes a two-wire harness connecting each device in tandem. CAN is used to communicate with all other PCS devices keeping wiring harness requirements to a bare minimum. Datalog Software

Data Logging & Playback The D200 is the heart of the PCS logging system. When combined with PCS data logging software, the is able to analyze all the information including multiple videos and make the correct adjustments to win at any level of racing. The D200 is equipped with 2MB of on-board data log memory. Additional memory (up to 16MB) is available at the time of purchase. To optimize the memory usage, the can select different logging rates for each device from 5HZ up to 1000HZ. The start of the log is triggered with the touchscreen or a button wired to an input. Multiple logs can be stored on the unit, allowing an entire race weekend’s logs to be ed on Monday instead of between runs. Logs are stored by date and time and are also viewable through a data log explorer on the D200 screen itself so any run can be played back on the D200 to gather information about the run without needing a laptop. The laptop communicates using USB, making quick work of ing large data logs.

Part #

Description

DIS-2022

D200 Dash Logger

DIS-3000

D200 Extreme Environment withSealed Aluminum Case

DIS-0511

D200 Multi-stage Boost Control Kit with 0-100 PSI Stainless Pressure Sensor

DIS-0500

D200 Multi-Stage Boost Control with solenoid

DIS-0501

D200 High Speed Logging Option (1000Hz)

DIS-4001

D200 Desktop Programming Kit

DIS-4100

Serial ECU connection Kit for (AEM, TEC2,TEC3, Autronic, Sakura, OLD Fast, and more)

DIS-4101

FAST Dash/Datalogger Classic ECU Comm. Cable

DIS-4110

Serial/CAN Y cable for TEC GT

DIS-4120

CAN B un-terminated wire kit with TEE and resistor for Motec and CAN based ECU’s

DIS-5000

D200 Suction Cup Mount

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Powertrain Control Solutions

D200 Kits Powertrain Control Solutions has taken our highly successful D200 Touchscreen Dash Logger and made it even better for the sportsman and professional drag racer. We’ve taken from racers and chassis builders alike to put together pre-packaged, completely pre-set kits for both door cars and dragsters. We looked at what types of data you wanted to look at, how you wanted to see it, and developed the gauge screen to reflect that. We chose the best quality sensors to give you that data and even looked at how the wiring harnesses should fit in a door car vs. a dragster. Your input was invaluable to us to put together a system that allows you to install the sensors, plug in the pre-terminated harness, and power up the D200 to start logging without any setup procedures whatsoever. The D200 Drag Race Kit will be a critical component to your success at the racetrack.

Sportsman Drag Race Kit Sensors to Measure and Datalog • Throttle Position • Battery Voltage • Oil Pressure • Fuel Pressure • Coolant Temperature Sensor • Engine RPM • Driveshaft Speed • 3-Axis Accelerometer and Gyro

Wiring Harness Choose between engineered to fit, pre-terminated Door Car or Dragster harnesses

Professional Drag Race Kit Sensors to Measure and Datalog • Throttle Position Sensor Kit • Battery Voltage • Oil Pressure Sensor • Fuel Pressure Sensor • Nitrous Pressure Sensor • Brake Pressure Sensor • Coolant Temperature Sensor • Oil Temperature Sensor

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• • • •

Engine RPM Driveshaft/Clutch/Converter Speed 3-Axis Accelerometer and Gyro 8-Channel EGT Module

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Boost Control

Boost Controller The PCS Boost Controller design incorporates compact packaging with advanced control options. The DBC-2000 combines two of the most common target boost strategies into one extremely versatile approach. There are ten, 8 x 8 point, 3D tables that can be configured for any input or CAN parameter. Each table has a programmable trim table and a programmable ramp rate. Each 3D table can be staged based on time, an input, or a CAN message. This provides 640 target points to achieve virtually any desired target profile. The unique packaging of the boost controller combines the controller, two solenoids, and a pressure sensor into one compact module for a clean installation. Programming the controller is performed using the hand held programmer or PC software via the on-board Description USB connector. The hand held programmer can remain Part # Boost Controller connected to the boost controller to serve as a gauge DBC-2000 or be removed from the vehicle once programming is complete. The DBC-2000 has two auxiliary input/output channels and one dedicated speed input channel. The two I/O channels are software configurable as an anaput, analog output, or ground PWM output. When configured as an input, each channel can be used as an axis for a 3D target table, to trigger a stage change, or to trim a table. When configured as an output each channel can be used as a simulated pressure output for an external data logger, a PWM to turn on a relay or warning light, and much more. The dedicated speed input can be used for RPM, vehicle speed, or any other speed input. The boost controller also receives inputs over CAN. The data received over CAN can be used similar to the anaput channels for determining boost and stage. CAN inputs can be received from any CAN transmitting device including ECU’s, transmission controllers, and more. In addition to receiving CAN data, the DBC-2000 transmits all operating parameters including target boost, actual boost, etc. over CAN. There are also two programmable messages to transmit any internal parameter in a defined format for compatibility with any ECU, data logger, or any other module.

Hand Held Programmer

The DBC-2000 features on-board data logging to log all vital parameters to the controller. Data can be viewed on the hand held programmer or ed via USB to a PC for analysis in the data log software.

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Powertrain Control Solutions

Data Logging Modules Three-Axis Accelerometer and Gyro Module The PCS 3-Axis Accelerometer and Gyro allows monitoring of linear and angular acceleration rates for determining tire and suspension setup, track conditions, and general vehicle dynamics. The Accelerometer outputs all three axes via CAN bus to the D200 Dash Logger where it can be displayed and logged. The axis resolution is programmable so the module can be optimized for the particular application.

Exhaust Gas Temperature Module

ACC-3000

Exhaust Gas Temperature, or EGT, is a fundamental tool in tuning, diagnosing problems, and ensuring the proper operating range of an internal combustion engine. This simple, but effective tool can diagnose potential engine problems before failure and ensure proper cylinder equalization when tuning or running an engine at the edge of its operating capabilities.

Part #

Description

ACC-3000

3-Axis Accelerometer & Gyro

Part #

Description

EGT-2000

8-Channel EGT Module, connects via CAN bus to PCS devices

EGT-5000

Single Channel EGT Module, converts temperature to 0-5 volt analog voltage

Part #

Description

EGT-4025

Thermocouple 1/4” tube 12” with Mini Connector

EGT-4026

Thermocouple 1/4” tube 18” with Mini Connector

EGT-4027

Thermocouple 1/4” tube 24” with Mini Connector

EGT-4028

Thermocouple 1/4” tube 36” with Mini Connector

EGT-4024

Thermocouple 1/4” tube 48” with Mini Connector

EGT-4029

Thermocouple 1/4” tube 60” with Mini Connector

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EGT-2000

EGT-4025

Modules & Sensors

Data Logging Sensors Pressure Sensors Part #

Description

SNS-1002

3-Bar MAP Sensor

SNS-1003

0-100 PSI Pressure Sensor

SNS-1004

0-250 PSI Pressure Sensor

SNS-1005

0-1000 PSI Pressure Sensor

SNS-1006

0-2500 PSI Pressure Sensor

TCM-6000

Temperature Sensors Part #

Description

SNS-3000

Intake Air Temperature Sensor

SNS-3001

Coolant/Fluid Temperature Sensor

SNS-1003

Throttle Position Sensors Part #

Description

SNS-6000

Remote Mount Throttle Position Sensor Kit

SNS-0002

External Arm Style TPS

SNS-2009

Linear Sensors Part #

Description

SNS-2009

Linear Sensor 200mm Stroke

Speed Sensors/Kits SNS-1002

Part #

Description

SNS-5000

3/8”-24 Threaded Body Hall Effect Sensor

SNS-5005

5/16-24 Threaded Body Hall Effect Sensor

SNS-5010

Two Magnet Kit

SNS-5001

Sensor Kit for Mark Williams 35 spline yoke (2.1875” dia.)

SNS-5002

Sensor Kit for Moser/Mark Williams 28 spline yoke (1.875 dia.)

SNS-5003

Sensor Kit for Stange 28 spline yoke (1.8125” dia.)

SNS-5004

Sensor Kit for Strange 28 spline yoke (1.8125” dia.) w/ Ultra Case

SNS-5007

Sensor Kit for Stange 35 spline yoke (2.125” dia.)

SNS-5006

Sensor Kit for Moser 35 Spline yoke (2.195” dia.)

SNS-5500

Clutch Speed Sensor Kit 3/8-24 Sensor

SNS-5501

Clutch Speed Sensor Kit 5/16-24 Sensor

SNS-3200

GPS Sensor Part #

Description

SNS-3200

5Hz GPS Sensor for D200

SNS-5002

CAN Part #

Description

CON-5500

CAN Master Connection Kit

CON-5501

CAN Add-on Connection Kit

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Powertrain Control Solutions

Transmission Reference Finding the right transmission for your hot rod, muscle car, or truck can be confusing and frustrating. Some transmissions have more than one version and the differences can be substantial. For this reason we’ve put together these pages to help you determine exactly which transmission you have to make the installation and operation simple and seamless.

GM 5L40/50E 5L40/50E is found in 2004–2006 Cadillac CTS, SRX and STS; 20062009 Pontiac Solstice, 2007-2009 Saturn Sky and 2008–2009 Pontiac G8. The round black transmission connector enters enger’s side of the case near the back of the transmission.

Connectors

GM 4L80/85E Used 1991 and up in GM trucks. The gray transmission connector and the 2 black speed sensor connectors enter driver side of the case. The 4L80E has removable tailhousing and can be used for 2 or 4 wheel drive. Pan Bolts: 17 Tail Housing Bolts: 6

Connectors

91 - 92 Solenoid Connector

24

93+ Solenoid Connector

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Transmission Reference

GM 4L60E 1993-1996 Found in 1993-1996 GM service trucks, vans, SUVs and most RWD cars. Does not have a T.V. cable. The gray transmission connector enters enger’s side of the case and the black speed sensor connector goes to the tailshaft. Can be used for 2 or 4 wheel drive. Pan Bolts: 16 Tail Housing Bolts: 4

Connectors

GM 4L60/4L65/4L70E 1996 to Current Found in 1996 and up GM service trucks, vans, SUVs, and most RWD Cars. The gray transmission connector enters enger’s side of the case and the black speed sensor connector goes to the tailshaft. 1996 and up 4L60/65/70E transmissions are distinguished by the removable bell housing. Can be used for 2 or 4 wheel drive. 2010 and newer 4L70E can be distinguished by looking at the pin layout inside the transmission connector plug on the enger side of the transmission. Compare the layout of the electrical pins to the pictures below to determine year of your 4L70E transmission. Pan Bolts: 16 Tail Housing Bolts: 6 4L70 ONLY

Connectors

2009 and Earlier

2010 and Later

FORD 5R55E 5R44E/5R55E is found in most 1997-2002 Ford Ranger, Mazda B-Series, and Ford Explorer; and 1998 and newer Mercury Mountaineer.

Connectors

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Powertrain Control Solutions

Transmission Reference Cont’d GM 6L80/90 Introduced in 2006, the 6L80/90 can be found in the late model Chevrolet Corvette, Silverado 1500 Series, Pontiac G8, Cadillac XLR-V, STS, Escalade, CTS-V, GMC Yukon Denali and Hummer H2.

Connectors:

FORD 5R55S/W 5R55S/W are found in most 2002 and newer Ford Ranger and Explorer; 2002–2005 Ford Thunderbird; and 2005–Current Ford Mustang. The transmission is connected by a gray and red transmission connector, a black and yellow range connector, and 3 black and yellow 2 pin speed sensor connectors

Connectors:

FORD AODE/4R70W/4R75 Found in most 1994–1997 Ford Thunderbird and Mercury Cougar; 1993– 2004 Ford Crown Victoria and Mercury Grand Marquis; 1996–2001 Ford Explorer; 1997–2004 Ford Expedition; 1997–2001 Mercury Mountaineer; 1991 and up Ford F-Series; and 1994–2004 Ford Mustang The transmission is connected by a white transmission connector, a black and yellow range connector. Ford changed the speed sensor connector and added a input shaft speed connector with the 4R75 on some vehicles starting in 2005. See picture above to identify the speed sensor type. Pan Bolts: 14

Connectors: 4R75 Speed S d Sensor S Connectors C t

26

4R70 Speed Sensor C Connector 4 R70 S dS ctor

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Transmission Reference

FORD 4R100 Found in 1998-2002 Ford F150,F250,F350,F 450, Expedition, Excursion, and other full size Ford trucks. The transmission is connected by a black and red transmission connector, a black and yellow range connector, and 2 black and red 2 pin speed sensor connectors. Pan Bolts: 20

Connectors:

CHRYSLER 545RFE Found in 2001 and newer Jeep Grand Cherokee; 2003 and newer Dodge Ram, Dakota, and Durango; and 2006 and newer Jeep Commander. The transmission is connected by a black and gray transmission connector, a black and yellow line pressure connector, and 2 black and yellow 2 pin speed sensor connectors. Pan Bolts: 15

Connectors:

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Powertrain Control Solutions

Manufacturing Capabilities Manufacturing PCS’s manufacturing division, Wintronics, manufactures all of PCS’s products and also provides contract manufacturing to other clients. Wintronics offers a complete partnership experience beyond the typical contract manufacturing relationship. Services including initial design assistance, design reviews for ease of manufacturing, and rapid prototype capability can transform a product from an idea to full production quickly and efficiently. Wintronics has experience in high volume, military qualified products and understands all the requirements those products must undergo to satisfy the most stringent specifications. Their continually trained and experienced staff, in combination with the scope of their assembly equipment, results in an extensive capability to provide a full range of through hole to mixed technology to fine pitch, double-sided, SMT PCB assembly. They can provide a critical design review before time and money are spent at the lab. Also, Wintronics can design custom end-ofline test equipment to ensure your product is 100% tested and burned-in before it is shipped to your customer.

Products and Services • Engineering Evaluation and Consultation • PCB Design, Layout, and Documentation • Design for Manufacturability and for test • Material Management: Consignment and Turnkey • PCBA Manufacturing • Compliance to ANSI/IPC-A-610 Class II, III

• • • • • • •

Design for Manufacturing (DFM) Design for Test (DFT) Concurrent Engineering (CE) Turnkey Material Management MRP II/JIT Box Build Quality Assurance Program Compliance

• ISO 9001 Quality System • Functional PCBA and box assembly test • Electro-mechanical, ‘Box Build’ • Box Assembly burn-in • Order Fulfillment • Wire Harness Manufacturing

About Wintronics is a full service, ISO 9001 certified, electronic and electro-mechanical contract manufacturer ing customers in both commercial and industrial markets. The Wintronics’ goal is to earn the customer’s respect as an extension of their process, their performance standards, their company. Located in Sharon, PA, Wintronics occupies an ESD compliant facility, strategically located just a few miles off Interstate 80 and within an hour’s drive of Pittsburgh, Cleveland, or Youngstown, OH airports.

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Capabilities

Engineering Capabilities Engineering In addition to developing and ing the PCS product line 100% in-house, PCS engineers help clients around the world solve challenging vehicle integration issues. We have extensive experience in driveline design, transmission design, and embedded control systems. We have the tools to assist with virtually every stage of vehicle design and development including FMEA, mechanical design, CAN architecture, EMI certification, and PPAP. Our engineers are available 24 hours, 7 days a week to provide on-site engineering .

Mechanical Design Our engineers use SolidWorks® to create your 3D design into reality. Along with our ZPrinter® 450 rapid prototype machine, we also have a Milltronics VM20 CNC milling machine dedicated solely for research and design projects. With the ability to print 3D functional prototypes in hours, our ZPrinter® 450 can save time and money when developing a new product. Prototypes can be used as functional examples for proposals, design reviews, and can also find any design errors before spending thousands on production tooling.

Circuit Schematic Design and Layout Our engineers use Mentor Graphics PADS® to transform your idea to an electrical design. We will perform a complete electrical analysis of the system and make suggestions if improvements can be made. Our experience has taught us how to design a robust system and avoid common pitfalls. The best circuit schematic is only as good as the layout. Careful implementation is critical at this step. Our engineers will not only consider functional and EMI factors, but also perform a thorough design for manufacturing (DFM) review to insure the board can be built using the most reliable and cost effective process.

Wire Harness Design An often overlooked component of a system is the wire harness. A properly designed wire harness not only provides superior reliability and performance but also minimizes costs in labor to manufacture and install, weight, and other considerations to improve the overall system implementation. PCS not only provides wire harness routing, but also performs an engineering review of the harness to ensure proper wire gauge, terminals and connectors for the application.

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PROUD MEMBER OF:

LIMITED WARRANTY STATEMENT. Powertrain Control Solutions, LLC. Warrants all merchandise against defects in factory workmanship and materials for a period of 12 months after purchase. This warranty applies to the first retail purchaser and covers only those products exposed to normal use or service. Provisions of this warranty shall not apply to a Powertrain Control Solutions, LLC. Product used for a purpose for which it is not designed, or which has been altered in any way that would be detrimental to the performance or life of the product, or misapplication, misuse, negligence or accident. On any part or product found to be defective after examination by Powertrain Control Solutions, LLC., Powertrain Control Solutions, LLC. will only repair or replace the merchandise through the original selling dealer or on a direct basis. Powertrain Control Solutions, LLC. assumes no responsibility for diagnosis, removal and/or installation labor, loss of vehicle use, loss of time, inconvenience or any other consequential expenses. The warranties herein are in lieu of any other expressed or implied warranties, including any implied warranty of merchantability or fitness, and any other obligation on the part of Powertrain Control Solutions, LLC., or selling dealer.

Powertrain Control Solutions, LLC 10511 Old Ridge Rd. Ashland, VA 23005

Catalog 0213