First time to post to the Forum. Before any thing else I would like say thank you for all the information on this great website. I have stayed up into the early morning hours for the last several weeks reading the Post/Topics listed here.--Absolutely fantastic information !!! Priceless!


My truck is an 02 D/A with 56k miles,Hypertech III, K&N intake, stock alli, 305/70R16. The tires have been on the truck from day one, the hypertech (at70 HP) & the K&N for the last 40K miles. Oil changed every 5K, 1st OEM fuel filter changed at 20K miles (looked bad)--changed every 8K since. Trans fluid & spin on changed at 48K miles. Approx 12Kmiles pulling a 3500lbs trailer. Rat racing occassionly with the HT at 90hp, but for the most part everyday type driving.


Last month noticed rough Idle/noise problem,a lope and shift business when coming to and pulling away from a traffic light. Took to the dealer on Aug 31st with the complaints and asked to have injectors, FPR and injector pump checked. Dealer called back the same day to inform me that the fuel pressure would command to 160 with techII. and FPR OK at this time.Performed injector balance test and found #4 injector reading at 12.3 mm, replaced #4 injector under warranty.(97720661) part number


Retest after replacing found #2 and #6 injectors reading at 10.5 mm. SM recommended a complete injector flush for $150 to see if it would clear up the problem, ok'd the flush--didn't do anything except make the truck idle worse than before. Dealer & GM's conclusion? replace only the 4 injectors on the left side with the newer style injectors (97729095) Of course they are on backorder and won't be available for 5 weeks, shipping date is Sept 29th. Dealer said to pick up the truck and wait for the injectors (won't cause any problems) "Right"!


Picked up the truck the next morning, the truck Idles worse and is noisier than it's ever been, sorry Dodge fans but this D-max sounds worse than a stoked Cummins. The crankcase does not have any fuel in it at this point and I check it daily, but I can smell raw fuel being dumped out the exhaust and it sounds like a lifter is going to come out through the hood........


This long explaination is in a effort to list the history over the last couple of weeks...........


Now here's the problem and question?


2 days after picking the truck up from the dealer I had to make a 200 mile road trip. Because of the injector problems I was hesitant, but didn't have any choice other than driving the truck. After approx 50 miles traveling at 75mhp I felt the Torgue converter unlock and watched the RPM's jump a few hundred. I backed off to 65mph until I could pull over at the next exit and check the trans fluid level, that ended up being approx 12 miles and the trans temp went slightly over the 200 degree line. Fluid level OK, got back in the truck and when I pulled the shift lever down to the the drive position the truck wouldn't move in any gear or reverse.All the letters on the shift display blinked off & on, cycled the ignition switch several times and tried it again. After about 10 attempts the trans did shift into drive and lurched violently forward. SES light came on (code P0700 trans control fault) Turned around and drove the truck home.


After reading some of the post here on DP I replaced the NSBU switch and cleared the code. Didn't help, the alli still won't lock the TC in 5th gear and if the trans temp gets up to normal operating range it won't go into reverse. After sitting all night and cooling down reverse works fine until it gets hot again, at that point it starts flashing on the display again until the trans cools down.


The real question?


Does this sound like a problem with the TC and transmission ?? a problem with an electrical connector between the ECM & TCM having problems with temps----or---can it be related to the current injector problems, or maybe someth

Ron





Wow that's a lot to swallow.


First off the transmission. Call Joe Webb at Suncoast Converters http://www.suncoastconverters.com/ . Your out of warranty, it's on your dime, get it fixed once and right. Something is going on. When you have a P0700 that says the TCM has DTC codes stored and that is the first place to start.





Injectors do a search or someone else will bring it forward,GM has a replace ALL 8 injector policy for 200k or seven years on your truck.There is a copy here on these pages.


Keep us informed on what happens and good luck.


Mac

Mac,


Thanks for the reply, and I do know that's alot to swallow- just wanted to hear the other side of the fence, Sorry--for the long air. Guess frustration speaks volumes ? I realize I asked a S-load of questions that don't necessarily have a yes or no answer. Actually anything close to a suggestion will be very much appreciated, Thanks for the recommendation at Suncoast, I'll call Joe in the am.


Hard to tell what's BS and what's not coming from the dealer or GM, knew those that have been there with the d-max already might shed some light. For you guys that take the time to do things right the first time without the GM politics ( tell the real story) thanks in advance.


I'll post the details.............


Ron

Ron


Here is the injector information. Thanks again Sid!





http://dieselplace.com/forum/forum_posts.asp?TID=5737&PN=1





Mac

There also was a problem with a wire harness getting chaffed around the drivers front side of the engine. The harness has wires associated with the Allison. Just a pot shot but take a look around the area of the little red box for jump starting. The wire bundle lays up close to sharp edges.

Mac, Hoot and Sid


Gentleman, thank you very much ! I'm on it as soon as I get off today.http://www.dieselplace.com/forum/smileys/Approve.gif http://www.dieselplace.com/forum/smileys/Cool.gif


I haven't had any of the DTC's listed on the GM bulletin yet, but I may have before it goes back to the dealer


Ron

Update--still need help


I called Joe Webb at Suncoast and he recommended a trans shop close to my area. Took the truck in on Monday Sept 20th. Suncoast III and triple lock installed, now $4,000 and a week later same problem. Trans won't hold lock up when it gets to operating temp. All the excuses from this trans shop are starting to wear me a little thin. Any ideas WTF is causing the "no lock up problem" ??


Apparently these guys don't have a clue,


any thoughts?

Wondering





How are you detecting TC lock up? Does it lock up in Tow Haul in second ?


The only thing "easy" to try is change solenoid C which controls lock up.Cheap and Available thru Allison.I do hate to just throw money at a problem although.


Doesn't the Tranny shop have access to a Tech II? Still getting and DTC's?


With Joe Webbs help I would think they could trouble shoot.





Mac


Edited by: Mackin

I talked to the owner of the trans shop just a bit ago.. Tim?


We are working through the situation. Appears that possibly could have a TCM failure.. too early to tell though

Possibly a wire problem due to the work performed at the dealer when the injectors were put in. I would have run a movie on the truck before I ever touched the Ally.


mike

A special thanks to Eric (Dmaxallitech) Joe Webb (Suncoast) Mac (Mackin), Tim Moye Jr. ( T & M transmission, Lutz Florida ) Hoot, Sid and Mike L. http://www.dieselplace.com/forum/smileys/smiley20.gif


It really amazes me at the dedication you guys have with your profession. Business done the way it should be--plain old fashion professional courtesy. That seems so few and far between in today's times.


Picked up my truck yesterday after having the SCIII and T/lock installed, too early to tell what's up yet because the alli is still in the learning process. Appears the problem was a warped aluminum valve body that was dumping fluid around the torque covertor when the trans got up to operating temp. From what I understand there is no gasket between the mating aluminum surface (?)The trans shop ground the valve body (?) back to a level flat surface to fix the problem. Said it was a one in a million and that they have never seen this problem. Anyone ever heard of this before?


Step 2 -now back to the injector problems, dealer says the parts are supposed to be in today-----Hmmm, we'll see?


Thanks again


Ron

<DIV>


There's no gasket but a steel plate between the halves. Most likely it was torque improperly on the reassembly.


I doubt they grind'ed anything or could get it done without the proper surface grinding equipment. But, I wasn't there.


Regardless if they corrected it and it is functioning normal, get the adaptive shifts learned and enjoy.


...that's the bottom line.





Mac http://www.dieselplace.com/forum/smileys/smiley4.gif</DIV>

Thanks Mac,


I don't know what really took place? But it was the same problem before they installed the suncoast kit in the O.E. transmission. Seems they can't explain what happened to the O.E. to start with or how the valve body got warped. Maybe a BS story to cover what they missed on the first diag. Still a little skeptical.


I looked at all the clutches and steels that came out and they looked to be in good shape from the pic's I've seen here on the forum. Not sure if I needed the upgrade at all, Hell they looked almost new to me, no scars, burns, rubs or wear----but glad I had it done. I'm sure it was just a matter of time anyway, kinda like payin for it---a matter of time.


I should know if it's right in the next few weeks. I'll hook it up hard and see what happens? Driving it last night it seems to still run a little above the 200 mark on the temp gauge. It was 85 degrees last night here in Tampa. Is this normal for a newly installed suncoast?


like you said .... the bottom line......Time to play !!http://www.dieselplace.com/forum/smileys/smiley4.gif

that is a one in a million for sure..


I know that the Dodge and Ford trans had/has issues with leaking at the valve body, but never seen it on an Allison. Glad its fixed, would have never even guessed seperator plate/valve body issue