View Aftermarket Catalog - Powertrain Control Solutions

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Product Catalog
www.powertraincontrolsolutions.com | 804.227.3023
Powertrain Control Solutions
TABLE OF CONTENTS
Transmission Controller Application Chart
1
Transmission Controller Overview
2-3
Simple Shift
4
Simple Shift Tuner & Software
5
TCM-2000
6
TCM-2000 Software & Android App
7
TCM-2600 & TCM-2400
8
TCM-2200/10 & TCM-2100
9
TCM-2005 & TCM-2500
10
XCM-2000 & OEM Diagnostics
11
Factory New Transmissions
12-13
Valve Bodies
14
Driveline Validation & Integration
15
GSM Push Button Shifter
16
Paddle Shifters
17
D200 Dashlogger
18-19
Data Logging Modules & Sensors
20-21
Transmission Reference
22-23
Manufacturing Capabilities
24
Engineering Capabilities
25
ABOUT PCS
OEM OR AFTERMARKET
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.
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.
We believe that long term growth and profitability comes from a strong
foundation of reliable, well supported 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
TCM-2000
TCM-2005
TCM-2100
TCM-2200
TCM-2210
TCM-2300
TCM-2400
TCM-2500
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TCM-2600
TRANSMISSION CONTROLLER APPLICATION
GM
4L60/65/70E
4L80/85E
5L40/50
6L45/50
6L80/90
4T40/45E
4T60/65E
4T80E
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6T30/40/45
6T70/75
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Ford
AODE
AXODE
AX4S
4EAT
4R44
4R70W
E4OD
4R100
4R75
CD4E
5R55 S/W/N
5R55E
4F27E
5R110
6R80
6R140
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Chrysler
41TE
42LE
42RLE
545RFE
68RFE
722.6/NAG 1
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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
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ZF 6HP
Volkswagen DSG
804.227.3023
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1
TRANSMISSION CONTROLLER OVERVIEW
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
Weight
Dimensions (L x W x H inches)
Case Material & Finish
2.94 lb
0.87 lb
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 CPC
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 total
1 with 1kΩ 5V pull-up
Inputs
Frequency (Range 0 – 10 kHz)
Programmable Trigger Levels and Filtering for
Frequency Inputs
Analog Voltage (0-5VDC)
Programmable Input Parameters
Yes
Yes
Yes
Failure Diagnostics for each Analog Input
Yes
Yes
Yes
Digital (programmable active high or low)
16
11
6
Overvoltage Protection for Each Input
Yes
Yes
Yes
9
9
7
Outputs
PWM
Digital
3
2
1
3.5 Amp
3.5 Amp
3.5 Amp
Short Circuit, Overcurrent & Thermal Protection
Yes
Yes
Yes
User 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
PWM & Digital Maximum Current
Output Channel Current Monitoring
2
0.89 lb
6.0 x 5.2 x 1.7
-2200
TCM-2200
M-221
TCM-2210
TCM2300
TCM-2400
TCM-2500
TCM-2600
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OEM
O
OEM
Aftermarket
OEM
OEM
OEM
0.64 lb
0.64 lb
0.87 lb
0.70 lb
1.72 lb
0.82 lb
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
8-18 VDC standard (24 VDC models available as an option)
8-36 VDC
On: 100 mA
Quiescent: 9 mA
On: 100 mA
Quiescent: 9 mA
On: 100 mA
Quiescent: 9 mA
On: 100 mA
Quiescent: 9 mA
On: 100 mA
Quiescent: 9 mA
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 CPC
36-pin Mil-spec
Delphi 56-pin
N/A
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
3
2 Channels
2 Channels
2 Channels
No
Yes
Yes
2 total
2 total
2 total
2
6 total
2
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
8
9
6
8
16
16
Yes
Yes
Yes
Yes
Yes
Yes
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7
7
7
9
7
1
1
1
1
3 digital + 2 relay
1
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 PWM Channels
12 PWM Channels
4 PWM Channels
804.227.3023
3
Transmission Control
Simple Shift Controller
*Laptop not required
*La
Product Description
Quick Facts
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.
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
Application
Input
Frequency (Range 0-10kHz): 3
Analog Voltage (0-5 VDC):
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
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
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.
Part #
Description
TCM-5310
GM 4L60/65E 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-5335
GM 4L80/85E 1993+ Simple Shift EFI Kit including TCU and
Harness
TCM-5336
TCM-2300 Dimensions
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GM 4L80/85E 1993+ Simple Shift Carb Kit including TCU,
Harness, and TPS Kit
Continues on page 5.
Part #
Description
Part #
Description
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
TCM-5361
Ford AODE 1993-1997 Simple Shift Carb Kit including
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
* 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
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.
Hand Held Tuner
The hand held tuner can remain connected to the Simple Shift
and serve as a gauge or be removed from the vehicle once
programming is complete. The hand held tuner provides all of
the functionality of the PC software in a convenient package.
Simple Shift Software
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.
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
1 (804) 227-3023
5
TCM-2000 Controller
Product Description
Quick Facts
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 supporting 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.
Intended Use: Aftermarket
Weight: 0.89 lbs
Extruded Aluminum Blue Anodized
(24 VDC models available as option)
1 x CAN 2.0b, 1 x RS-232
Input
Output
PWM: 9
Digital: 3
Output Channel Current Monitoring: No
Application
The TCM-2000 supports most conventional automatic transmissions on the
market. Its user friendly yet powerful software interface allows the user to
have full control over transmission operation.
Ordering
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.
Part #
Description
TCM-2000
Universal Transmission Controller All
Application
All
Year
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
Continues on page 7.
TCM-2000 Dimensions
6
Part #
Description
Application
Year
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 supported (See page 1). Contact PCS for part number and ordering information.
*TCM-4118 is required for 1991-1992 GM 4L80E
TCM-2000 PC Software & Android App
PC Software
Our user-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 user 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
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.
804.227.3023
7
TCM-2600 Controller
Quick Facts
TCM-2600 Dimensions
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.
Intended Use: OEM
Weight: 0.82 lbs
Ingress Protection: IP69K
2 x CAN 2.0b, 1 x RS-232, 1 x J1850
Input
Analog Voltage (0-5 VDC): 2
Output
PWM: 7
Digital: 1
4 PWM Channels
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.
TCM-2400 Controller
Quick Facts
Intended Use: OEM
Weight: 0.70 lbs
Case Material & Finish: Aluminum
Ingress Protection: N/A
Communication Interface: 2 x CAN 2.0b
TCM-2400 Dimensions
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 CAN-based 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.
8
Input
Analog Voltage (0-5 VDC): 2
Output
PWM: 7
Digital: 1
8 PWM Channels
TCM-2200/10 Controller
Quick Facts
Product Description
TCM-2200/10 Dimensions
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 premium. 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
designing a bracket for a specific application.
Application
The TCM-2200/10 is designed for harsh environments such as military vehicles, airport ground support
vehicles, and industrial equipment. Transmission coverage includes most domestic transmissions.
Intended Use: OEM
Weight: 0.64 lbs
Aluminum Black Anodized or CARC
Ingress Protection: IP69K
2 x CAN 2.0b, 1 x RS-232, 1 x GM ALDL
Input
Digital (programmable active high or low):
8 (9 optionally)
Output
PWM: 7
Digital: 1
4 PWM Channels (0 - 2 Amp)
TCM-2100 Controller
Quick Facts
Intended Use: OEM
Weight: 0.87 lbs
Case Material & Finish: Extruded Aluminum
1 x CAN 2.0b, 1 x RS-232, 1 x GM ALDL
TCM-2100 Dimensions
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 fail-safe condition if certain damaging, error states
are encountered.
804.227.3023
Input
Output
PWM: 7
Digital: 1
1 Dedicated high-side measured output
9
TCM-2005 Controller
Quick Facts
TCM-2005 Dimensions
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.
Intended Use: OEM
Weight: 2.94 lbs
1 x CAN 2.0b, 1 x RS-232
Input
Analog Voltage(0-5 VDC):
4 total - 2 with 1kΩ 5V pull-ups
Output
PWM: 9
Digital: 2
Output Channel Current Monitoring: No
TCM-2500 Controller
Quick Facts
Intended Use: OEM
Weight: 1.72 lbs
White Polycarbonate with Clear Lid
Voltage Range: 8-36 VDC
2 x CAN 2.0b, 1 x USB, 1 x J1850
TCM-2500 Dimensions
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.
10
Input
6 total - 2 with 1kΩ 5V pull-ups
Output
PWM: 9
Digital: 3 Digital + 2 Relay
12 PWM Channels
Transfer Case Control
XCM-2000 Controller
Quick Facts
XCM-2000 Dimensions
Product
roduct Description
Intended Use: OEM
Weight: 0.64 lbs
Communication Interface: 1 x CAN 2.0b
The PCS transfer case module is a stand-alone module that controls most modern electronic shift
transfer cases. Shifting is commanded using CAN, which is configurable for J1939 or a proprietary
scheme. Diagnostic messages are also transmitted to alert the driver if there are any issues with
the transfer case. The control module has programmable safety set points for shifting into 4WD Low
including max speed, gear, and brake status. The module is designed for rugged use and is sealed to
IP68 ingress protection standards allowing it to be mounted anywhere on the vehicle, fully exposed
to harsh environments.
OEM Diagnostics
PCS offers several tools for OEM in-field support. These tools enable the technician to read and clear trouble codes, view sensor data, and capture a data log. The
data logs can be reviewed on-site using the PC software or sent back to PCS or the vehicle manufacturer for further analysis. These tools do not allow access to the
calibration on the transmission controller to ensure the factory calibration is not modified, potentially compromising the life of the transmission.
Available products include Windows based PC software, a 6-inch touchscreen LCD, and a 3-inch color LCD screen. Communication is established using RS-232,
GM ALDL, or CAN.
These tools are also well suited for an end-of-line test on the vehicle assembly line to check for trouble codes and verify vital transmission inputs including throttle
position, vehicle speed, and engine RPM.
GEAR DISPLAY
Our billet aluminum gear display uses a digital 16-segment alphanumeric display to show P, R, N, D, and gear positions 1 through 9. It comes
in two sizes for ease of integration into your hot rods dash and is available in either polished or black anodized finishes. This display also has
automatic night-time dimming and easily connects to any of our transmission controllers via CAN.
Part #
Description
TCM-3700
Gear Display Black 2” OD, 1.2” Display
TCM-3701
Gear Display Polished 2” OD, 1.2” Display
TCM-3702
Gear Display Black 1.75” OD, 0.8” Display
TCM-3703
Gear Display Polished 1.75” OD, 0.8” Display
804.227.3023
11
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 user 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, GM 6L50/80/90 and GTP 4L80/85E transmissions.
These are only available to qualified OEM’s.
GM 4L60/65/70E
GTP 4L80/85E
GM 6L50
GM 6L80
GM 6L90
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
Six-speed RWD/AWD,
electronically controlled
automatic overdrive
transmission w/ torque
converter clutch, Clutch-toclutch architecture, w/ Integral
Electro/Hydraulic Controls
Module
Six-speed RWD/4WD/AWD,
electronically controlled
automatic overdrive transmission
w/ torque converter clutch.
Clutch-to-clutch architecture,
w/ Integral Electro/Hydraulic
Controls Module
Six-speed RWD/4WD/AWD,
electronically controlled automatic
overdrive transmission w/ torque
converter clutch. Clutch-to-clutch
architecure, w/ Integral Electro/
Hydraulic Controls Module
Engine Range
2.2L – 6.2L Gasoline/Diesel
4.8L – 6.0L Gasoline,
6.5L – 6.6L Diesel
2.0L - 4.6L - Gasoline,
2.9L - Diesel
4.4L SC, 6.0L, 6.2L - Gasoline
6.2L - Gasoline, 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)
332 lb-ft (450 Nm)
487 lb-ft (660 Nm)
531 lb-ft (720 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)
479 lb-ft (650 Nm)
664 lb-ft (900 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
4.065, 2.371, 1.551, 1.157,
0.853, 0.674, -3.200
4.027, 2.364, 1.532, 1.152,
0.852, 0.667, -3.064
4.027, 2.364, 1.532, 1.152, 0.852,
0.667, -3.064
Maximum Gross Vehicle
Weight
(application and axle ratio
dependent)
8,600 lb (3900 Kg)
18,000 lb (8165 Kg)
6613 lb (3000 Kg)
8600 lb (3900 Kg)
15,000 lb (6803 Kg)
Maximum Gross Combined
Vehicle Weight (application
and axle ratio dependent)
15,500 lb (7030 Kg)
22,000 lb (9979 Kg)
12,505 lb (5672 Kg)
14,000 lb (6350 Kg)
21,000 lb (9525 Kg)
7-Position Quadrant
P, R, N, OD, D, 2, 1
P, R, N, OD, D, 2, 1
P, R, N, D, (M)
P, R, N, D, (M)
P, R, N, D, (M)
Die cast aluminum
(3-piece: bell & main
w/ extension)
Die cast aluminum
w/ extension)
Case
Die cast aluminum,
removable bell-housing
Die cast aluminum
Die cast aluminum
w/ extension)
Shift Pattern
(2) Two-way on/off solenoids
(2) Two-way on/off solenoids
(3) Two-way on/off solenoids for 5/6
speed
(2) Three-way on/off solenoids
Shift Quality
Pressure control solenoid
3-2 control solenoid (some
models)
Pressure control solenoid
(5) Variable bleed solenoids
Torque Converter Clutch
Pulse width modulated
solenoid control
Pulse width modulated solenoid
control
Variable bleed solenoid
Converter Size
Various
310 mm
240/245/258 mm
258, 300 mm
300 mm
Fluid Type
DEXRON VI
DEXRON VI
DEXRON VI
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)
Wet: 187-198 lb (85-89 Kg)
Wet: 225 lb (102 Kg)
Wet: 240 lb (109 Kg)
Fluid Capacity (approx.)
8.8 – 11.4 qt
(8.3 – 10.7 Liters)
13.5 qt
(12.8 Liters)
10.1 – 11.4 qt
(9.6 - 10.82 Liters)
10.2 – 12.8 qt
(9.7 – 12.1 Liters)
12.3 – 13.3 qt
(11.6 – 12.54 Liters)
Pressure Taps Available
Line Pressure
Line Pressure
Line Pressure
Line Pressure
Line Pressure
12
D
F
A
TRANSFER CASES
C
B
4L70 4WD
Transfer Case
Factory new transfer cases (manual or electric shift),
extension housings and adapters are available for a
complete driveline solution.
E
in
*Units: mm
A
B
C
D
D
E
F
G
H
Trans Model
Bell
Housing
Main
Case
Case
Extension
Length
to
Flange
Length to
Shaft
Engine
Block to
Converter
Lug
Length to
Extension
Housing
Engine
Block to
Mount
Center Line
to
Bottom Pan
4L60/70 2WD
6.941
176.30
15.421
391.70
8.909
226.30
N/A
30.975
786.75
0.853
21.67
31.272
794.30
24.331
618.00
7.820
198.60
4L60/70 4WD
6.941
176.30
15.421
391.70
4.433
112.60
N/A
26.941
684.30
0.853
21.67
26.795
680.60
24.353
618.56
7.820
198.60
4L80
No separate
bell housing
26.01
660.65
5.495
139.57
29.00 (4WD)
736.71
32.1745 (2WD)
817.23
0.893
22.68
31.505
800.23
30.672
771.19
7.80
198.00
6L50
6.181
157.00
16.752
425.50
2.283
58.00
27.559
700.00
26.437
671.50
0.413
10.50
25.216
640.50
25.279
642.10
9.177
233.10
6L80 Fixed Yoke
6.74
171.20
16.468
418.30
3.49
88.66
27.815
706.51
29.089
738.87
0.853
21.67
26.699
678.16
N/A
9.196
233.60
6L80 Slip Yoke
6.74
171.20
16.468
418.30
5.87
149.10
N/A
29.962
761.06
0.853
21.67
30.850
783.60
25.595
650.10
9.196
233.60
6L80 4WD
6.74
171.20
16.468
418.30
3.587
91.10
N/A
26.968
684.98
0.853
21.67
26.795
680.60
25.409
645.38
9.196
233.60
6L90 2WD
(Duramax)
7.07
179.63
17.840
453.15
5.629
143.00
N/A
31.439
798.56
0.909
23.10
30.542
775.78
27.480
698.00
9.196
233.60
6L90 4WD
6.74
171.20
17.84
453.15
N/A
28.559
725.42
28.559
725.42
0.853
21.67
N/A
N/A
9.196
233.60
*NOTE: Dimensions are for typical applications. Dimensions will vary based on converter, bell housing and application. For reference only.
NEW TRANSMISSION REFERENCE
4L60/70
4L80
6L80 Slip Yoke
6L80 4WD
6L50
6L90 2WD
804.227.3023
6L80 Fixed Yoke
6L90 4WD
13
Transmissions
6-Speed 4L80 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.
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.
Stock Gear Set
Gear
Ratio
1
2.48
2
New Gear Set
5-Spd Step
6-Spd Step
Ratio
6-Spd Step
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
2.98
2.46
Gear Set Comparison
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, TCM2000, and external harness
VBM-5300
Simple Shift Kit including valve body kit, Simple
Shift, and external harness
Cooler Line Locations
The PCS 6-speed valve body is only compatible with the 1997 and newer
center lube 4L80/85 transmissions. To determine if your transmission
is compatible, verify the cooler lines connect to the transmission in the
locations shown in the picture to the left.
14
Transmissions
Driveline Integration & Validation
PCS provides complete driveline integration services for
qualified vehicle manufacturers. PCS can assist during
the entire development cycle including component design,
selection, validation, production procurement, and final
assembly. PCS services include, but are not limited to the
items below.
Transmission Simulation and Selection
SAE4 GM 4L60/70 Bellhousing
Computer simulation of vehicle and transmission
performance based vehicle specific parameters including
GVW, engine, and final drive ratio. Several transmission
options will be evaluated and compared. Factors also
considered are cost, availability (new or remanufactured),
suitability for vehicle mission, and other implementation
factors. For four-wheel-drive applications, the transfer case
can be included in the analysis.
Engine to Transmission Interface
CAD design and analysis includes alignment, torque
converter engagement, production feasibility, and costs.
Custom bell housings can be designed to simplify installation
and reduce production costs. PCS offers bell housings for
popular engine/transmission combinations including SAE4
and VM Motori 3.0L to GM 4L60/70.
GM 4L60/70 4WD w/ transfer case for 3.0L VM Motori engine
Vehicle Fitment
CAD design and analysis of vehicle specific transmission
mount loading capability, transmission field serviceability,
driveline angle, transmission angle, maximum vehicle
operation angle, driveshaft and axles, shift mechanism,
cooling system, neutral safety, reverse indication, and
parking brake.
Calibration, Validation, and Durability Testing
Transmission calibration and validation is offered to insure
the transmission is properly integrated into the vehicle. While
continuously monitoring transmission load, slip, cooling,
and other variables, durability testing can be performed to
verify the transmission will withstand the mission for the
expected life of the vehicle.
804.227.3023
15
Shifters
GSM Push Button Shifter
The GSM Push Button Shifter is an electronically
controlled shifter that replaces the shift lever and
offers precise, split-second shifting capability with the
push of a button. The GSM was designed and is well
suited for a variety of markets including automotive,
military and agricultural and works with nearly any
automatic transmission.
Its slim touch pad control module and compact,
sealed actuator give you virtually unlimited mounting
options for tight spaces and grueling environments.
The GSM control module can be surface or flushmounted and is small enough to fit consoles, dashes,
door panels or even armrests. An easy to read display
shows the vehicle’s current gear and each button is
recessed to avoid inadvertent touches and brightly
backlit for all environments.
The GSM monitors vehicle speed and brake switch
status to ensure the vehicle is slowed to a safe speed
and the brake is pressed to prevent inadvertent shift in
or out of Park, or into Reverse while moving forward.
The GSM has built-in contacts for neutral safety for
simple wiring to the start circuit and reverse lights can
be controlled from the GSM’s reverse circuit contacts.
Part #
Description
Gear Select Module Kit
GSM-5000
Gear Select Module kit including cable drive and driver interface
panel
Vehicle Speed Interfaces
GSM-2050
GM Speed Signal Generator
GSM-2060
Ford Speed Signal Generator
GSM-2080
GSM GM Speed Sensor Pass-Through Adapter
WRE-3500
GM Bulkhead Pass-Through w/ CAN and Option Connector
Breakouts
Install Kits
GSM-2010
GSM Install Kit for GM 4L60/65/70/80/85 w/ PRNDL
GSM-2011
GSM Install Kit for Ford AODE/4R70W
GSM-2012
GSM Install Kit for GM TH-200/200-4R/250/350/400/700-R4,
4L60/65/60/85 w/out PRNDL
GSM-2013
GSM Install Kit for Ford 1965-1982 C-4
GSM-2014
GSM Install Kit for GM 1962-1973 Powerglide
GSM-2015
GSM Install Kit for Ford AOD
GSM-2016
GSM Install Kit for Chrysler 1966+ 727 or 904 Torqueflite and AMC
1972+ Torque Command Transmission
Installation kits are available for most common
transmissions and should be ordered with your GSM.
An electronic vehicle speed signal is required and
mechanical to electric speed signal generators are
available for GM and Ford cable driven speedometers.
GSM Dimensions
16
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.
Paddle shifters are compatible with PCS transmission controllers or GM
Mechatronic transmissions such as the GM 6L80.
5/6 Bolt Paddle Shifter
Paddle shifters purchased with a PCS transmission controller or GSM are
eligible for a significant bundled discount. Contact your PCS dealer for more
information.
Paddle Shifter Dimensions
9 Bolt Paddle Shifter
Optional display allows the driver to view all of the items listed below:
• Current Gear
• Throttle Position
• Vehicle Speed
• Line Pressure
• TCC Slip %
• Transmission Slip
• Manifold Pressure
• Coolant Temp
• Transmission Temp
Part #
Description
PS-2001
Paddle Shifter w/ display for 5 or 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
PS-2011
Paddle Shifter w/ display for 5 or 6 bolt wheel for GM Mechatronic transmission
PS-2010
Paddle Shifter w/out display for 5 or 6 bolt wheel for GM Mechatronic transmission
PS-2016
Paddle Shifter w/ display for 9 bolt wheel for GM Mechatronic transmission
PS-2015
Paddle Shifter w/out display for 9 bolt wheel for GM Mechatronic transmission
• Driveshaft RPM
• Turbine RPM
• Lever Position
* 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.
804.227.3023
17
Data Logging
D200 Dashlogger
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.
Data Logging & Playback
LCD & Touchscreen Features
Thorough research and customer feedback 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.
The D200 is the heart of the PCS logging system. When
combined with PCS data logging software, the user 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 user 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 downloaded 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
downloading large data logs.
D200 Dimensions
18
Inputs and Outputs
The D200 has 8 analog inputs, 2 speed inputs, and 2 PWM outputs.
The analog inputs 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 user 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.
D200 Software
Monitor Screens
The D200 offers several fully programmable monitor screens capable
of displaying any combination of inputs. This allows the user 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 user to select the scale and units
for the displayed data. Programmable alarms allow the user 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.
Datalog Software
D200 Kits
PCS offers a Sportsman and Professional Drag Race Kit that packages the D200 with common sensors. The Sportsman kit includes
the D200, accelerometer, two pressure sensors, two temperature sensors, and one speed sensor. The Professional kit includes all
the items of the Sportsman kit plus an 8-channel EGT module including 4 probes, an additional pressure sensor, and an additional
speed sensor. Sensors are specified by the customer when the kit is ordered.
Part #
Description
DIS-5100
D200 Dash Logger
DIS-3000
D200 Extreme Environment with Sealed 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
DIS-9200
D200 Sportsman Kit
DIS-9300
D200 Pro Kit
804.227.3023
19
Modules & Sensors
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.
Part #
Description
ACC-3000
3-Axis Accelerometer & Gyro
ACC-3000
Exhaust Gas Temperature Module
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
EGT-5100
EGT-2000 8-Channel EGT Module Kit Including Harness
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-4027
EGT-4028
EGT-4024
EGT-4029
EGT-2000
EGT-4025
20
Modules & Sensors
Data Logging Sensors
Pressure Sensors
Part #
Description
SNS-1002
3-Bar MAP Sensor
SNS-1003
0-100 PSI Pressure Sensor
SNS-1004
SNS-1005
SNS-1007
SNS-1002
Temperature Sensors
Part #
Description
SNS-3000
Intake Air Temperature Sensor
SNS-3001
Coolant/Fluid Temperature Sensor
Throttle Position Sensors
Part #
Description
TCM-6000
Remote Mount Throttle Position Sensor Kit
SNS-0002
External Arm Style TPS
SNS-1003
Linear Sensors
Part #
Description
SNS-2009
Linear Sensor 200mm Stroke
SNS-2009
Speed Sensors/Kits
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 (2.187” dia.)
SNS-5002
Sensor Kit for Moser/Mark Williams 28 spline yoke (1.875 dia.)
SNS-5003
Sensor Kit for Stange 28 spline yoke (1.812” dia.)
SNS-5004
Sensor Kit for Strange 28 spline yoke (1.812” 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
TCM-6000
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
804.227.3023
21
GM Transmissions
GM 4L60E 1993-1996
GM 5L40/50E
The 5L40/50E is found in 2004-2006 Cadillac CTS, SRX and STS; 2006-2009
Pontiac Solstice; 2007-2009 Saturn; & 2008-2009 Pontiac G8. The round
black transmission connector enters the passenger’s side of the case near the
back of the transmission.
The GM 4L60E is found in 1993-1996 GM service trucks, vans, SUV’s and most
RWD cars. It does not have a T.V. cable. The gray transmission connector enters
the passenger side of the case. The black speed sensor connector goes into the
tail shaft. It can be used for 2 or 4 wheel drive applications.
Pan Bolts: 16
Tail Housing Bolts: 4
GM 4L60/65/70E 1996+
GM 4L80/85E
The GM4L80/85E is used in 1991+ GM trucks. The gray transmission
connector and the 2 black speed sensor connectors enter driver side of the
case. The 4L80E has a removable tail housing and can be used for 2 or 4
wheel drive applications.
Solenoid Connectors
1991-1992
Pan Bolts: 17
The GM 4L60/65/70E is found in 1996+ GM service trucks, vans, SUVs, and
most RWD cars. The gray transmission connector goes to the tailshaft. 1996+
4L60/65/70E transmissions are distinguished by the removable bell housing.
It can be used for 2 or 4 wheel drive applications. 2010+ 4L70E can be
distinguished by looking at the pin layout inside the transmission connector plug
on the passenger side of the transmission. Compare the layout of the electrical
pins to the pictures below:
Pan Bolts: 16
4L70 ONLY
1993+
GM 6L50
GM 6L80/90
The 6L80/90 was introduced in 2006. It can be found in 2006+ Cadillac STS-V,
2007+ Cadillac STS, 2007-2009 Cadillac SRX, 2008+ Cadillac CTS, 2009+
Chevrolet Lumina, 2009+ Chevrolet Caprice, and 2009+ Chevrolet Camaro.
The 6L80/90 was introduced in 2006. It 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 the Hummer H2.
22
Ford & Chrysler Transmissions
FORD 5R55S/W
FORD 5R55E
The 5R55S/W is found in most 2002+ Ford Ranger and Explorer; 2002-2005
Ford Thunderbird; and 2005+ 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.
The 5R44/55E is found in most 1997-2002 Ford Ranger, Mazda B-Series, and
FOrd Explorer; and 1998+ Mercury Mountaineer.
EARLY FORD AODE/4R70W
LATE FORD 4R70W/4R75
The AODE/4R70W/4R75 is found in most 1994-1997 Ford Thunderbird
and Mercury Cougar; 1993-2004 Ford Crown Victoria and Mercury Grand
Marquis; 1996-2001 For Explorer; 1997-2004 Ford Expedition; 1997-2001
Mercury Mountaineer; 1991+ Ford F-Series; and 1994-2004 Ford Mustang.
The transmission is connected by a white transmission connector and a red
and black range connector. Ford changed the speed sensor connector and
added an input shaft speed connector with the 4R75 on some vehicles starting
in 2005. Compare speed sensors to pictures below.
Pan Bolts: 14
The AODE/4R70W/4R75 is found in most 1994-1997 Ford Thunderbird and
Mercury Cougar; 1993-2004 Ford Crown Victoria and Mercury Grand Marquis;
1996-2001 For Explorer; 1997-2004 Ford Expedition; 1997-2001 Mercury
Mountaineer; 1991+ Ford F-Series; and 1994-2004 Ford Mustang. The
transmission is connected by a white transmission connector and a black and
yellow range connector. Ford changed the speed sensor connector and added
an input shaft speed connector with the 4R75 on some vehicles starting in 2005.
Compare speed sensors to pictures below.
Pan Bolts: 14
Speed Sensors
4R70
4R75
4
CHRYSLER 545RFE
FORD 4R100
The 4R100 is found in 1998-2002 Ford F-150, F-250, F-350, 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
The 545RFE is found in 2001+ Jeep Grand Cherokee; 2003+ Dodge Ram,
Dakota and Durango; and 2006+ 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.
804.227.3023
Pan Bolts: 15
23
Capabilities
Manufacturing Capabilities
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-of-line 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
ISO 9001 Quality System
Functional PCBA and box assembly test
Electro-mechanical, ‘Box Build’
Box Assembly burn-in
•
•
•
•
•
•
•
•
•
Order Fulfillment
Wire Harness Manufacturing
Design for Manufacturing (DFM)
Design for Test (DFT)
Concurrent Engineering (CE)
Turnkey Material Management
MRP II/JIT
Box Build
Quality Assurance Program
Compliance
About Wintronics
Wintronics is a full service, ISO 9001 certified, electronic and electro-mechanical contract manufacturer
supporting 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.
24
Capabilities
Engineering Capabilities
In addition to developing and supporting 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 support.
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.
804.227.3023
25
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 0214

View Aftermarket Catalog - Powertrain Control Solutions

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