Another AT545 to A2000 Tranny Swap - Page 3

Diverdude0075 · 01-15-2021, 10:35 AM

I found the bulb number that goes to my dash. Eiko PC74. I bought a pack of ten at oreillys for $8-9.

I noticed I have no bulbs missing where’s there’s a place for one but I have several blanked off areas to the far left and right of my dash. Here are a few pics.

I’m guessing I am either missing the check trans or it is already there and I haven’t paid attention. It’s funny how small things like this can be tedious and take a lot of time. I enjoy the puzzle! To be continued...

Edit: I remembered Dave said to shine a light into the front of the dash and look for it. I held it up to the sun and saw many of what the lit indicators were but not all. I finally took his advice and actually found “Check Trans.” I’m slow on the uptake sometimes 😬. It was on the bottom left.

sportyrick · 01-15-2021, 12:12 PM

If yours is like my 3060 the bulb is switched 12V constant and the interface grounds it to activate.

Diverdude0075 · 01-15-2021, 02:24 PM

This is what I’ve determined so far on the six wires going to the Allison plug near the ecm (not going to the ecm). There a 3 wire weatherpak coming from ecm.

The two part challenge is 1. determine what is coming from Allison. And 2. Determining where it goes into the Bluebird bus. Is the dash stuff International or Bluebird wiring?

sportyrick · 01-15-2021, 04:24 PM

I talked to Allison when I was doing my conversion and they said: "they supply the transmission and computer, the manufacturer does the rest" I think from the computer TO the interface module and on is the manufacturers. I noticed when I was doing my conversion that was exactly what was happening. Those wires are possibly: 2 yellow back up lights, pinks are neutral start, green as described, odd pink possibly 12+?? So you run the start wire from your ign switch down to the IM and then back up to starter. You run your back up light power to the IM and then back up to your back up lights. There are relays in your IM to make this happen.

Diverdude0075 · 01-18-2021, 08:27 PM

Thanks Sportyrick. Good to know. I’m getting close.

I’m still hopeful for all or a portion of the dash components and intermediate harness I’m missing.

I did reach a milestone today. The bus moved on its own power! She moved in 1st and reverse which is to be expected. I have not updated the ecm yet.
Either my current ecm has to be reprogrammed or I need to use a newer ecm. I have a 2001 coming (same year as transmission).

This is an important milestone because:

1. No leaks! I made all new coolant lines following guidance in Redbyrd and had no issues! I closely measured how much I put in and came to 15.5 quarts total. I expect to have to top it off a few more times but in small amounts. My torque converter had been drained, and the transmission and cooler as well. I did not have the transmission rebuilt though.

2. The new flex plate worked perfectly. I ordered a new one from International so wasn’t too worried. I read in other threads that the flex plate is based on engine and not transmission.

3. My aforementioned battery cables have been properly repaired and the bus started first try, easily. I cut out bad portions, put new lugs on, used heat shrink, and the bus is really happy. I also upgraded the GPR. The old one wasn’t working.
Three quarter inch heat shrink, with interior adhesive, fit both 3/0 and 4/0 cables well.

4. The transmission was bought online from someone I didn’t know. They turned out to be nice. It’s nice to know the transmission works. It still has to be put through it’s paces. Also, I at least have it hooked up well enough to operate. I can work out the bugs. Side note: the pump runs off the rotation of the torque converter from what I understand.

5. I put a new NSS on, link in Redbyrd. It was an exact match to what I had.

6. Linkage worked perfectly. I put selector on dash to 1st gear, then also on transmission then made the connection. Good to have confirmation this is all proper.

7. The driveline works well. I had to shorten it one inch and two ujoints were replaced. All three sections were taken to be balanced.

I’m down to electrical now and waiting to hopefully acquire what I need. Thanks for reading and big thanks to Dave and Christopher for all their input and previous documentation.

Diverdude0075 · 01-29-2021, 04:29 PM

Hello All,

I thought I would provide a brief update. I bought the ECM that was originally paired with my Allison 2000 in the donor bus, 2001 model.

It came this past Tuesday and today I finally had time to swap it into the bus. She sounds like she idles smoother, and started the first try and drove well. She only drove in first gear

with a top speed of 31 MPH.

The speedo still isn't working

I noticed RPMs maxed out at around 2200, down from the 2600 before. Could it be set this low, or just this low due to being in limp mode.

From conversing with Dave I think I'll connect the 125 Green wire from the transmission harness to the Brown 92 wire somewhere in the dash. I'm not looking forward to searching for it...Perhaps it could make a difference? I also believe I was told that now that it's gone to limp mode I need International or their software to fix it. I would like to have all the dash components installed before taking it to them.

I'm still on my quest to find the rest of the dash components as well. From the big plug coming from the transmission harness, through the dash via another big round plug, to the various components I'm missing.

Those include the econ button and light, the aforementioned connection to Brown 92 (which goes to the trans light on the dash), and the big diagnostic port.

Thanks for reading,
Josh

Diverdude0075 · 04-04-2021, 10:05 AM

Hey Everyone,

I've been silent for a bit. Traveling for work, other hobbies, etc. have caused delays. Today I'm heading to the storage unit to make one connection on the bus. Brown wire 92 in the dash to green wire 125 from the transmission harness. Let's see what this does!

This link on page 13 of an International wiring diagram seems to be consistent with the research already shared. Fingers crossed that this gets the transmission fully functional.

http://bodybuilder.navistar.com/Gene...df/S08285A.PDF

I also noticed a slight leak on one of the new transmission lines so I'll fix that.

I'm moving my mom soon and would love to be able to use the bus and save $$ from not having to rent a moving truck!

I'll post how it went later today.

Diverdude0075 · 04-04-2021, 11:43 AM

Ok, found brown wire 92a. See pics.

It’s looks like it connects to another wire then goes to the gear selector.

Do I just piggyback a wire to 92a and run to the green 125?

It seems easy. Am I thinking of this correctly?

Here are some pics:

Dieselwrenchturner · 07-09-2021, 11:54 AM

hello I was wondering what ever happened because I am close to your same spot in my swap and having issues.

Diverdude0075 · 07-09-2021, 01:15 PM

Quote:

Originally Posted by Dieselwrenchturner

hello I was wondering what ever happened because I am close to your same spot in my swap and having issues.

Hi, I’m still in limp mode. Life got in the way. I had to move, and move my mom…

From what I can tell I need to connect the check trans light up and there’s a 12v wire that gets connected. I may get to some of it this weekend.

I’m still missing the harness where is goes through the firewall. It feeds the econ mode switch and light, j1939 diag port, and something else. From previous reading though I don’t those are necessary.

Lastly, I’ll buy the programmer and software or take it to international to see which codes may exist and check settings. I’m using the donor ecm so that should be all set for the a2000.

If you figure something out please circle back! I will update here as well.

Oldyeller · 07-09-2021, 02:16 PM

Quote:

Originally Posted by Diverdude0075

Hi, I’m still in limp mode. Life got in the way. I had to move, and move my mom…

From what I can tell I need to connect the check trans light up and there’s a 12v wire that gets connected. I may get to some of it this weekend.

I’m still missing the harness where is goes through the firewall. It feeds the econ mode switch and light, j1939 diag port, and something else. From previous reading though I don’t those are necessary.

Lastly, I’ll buy the programmer and software or take it to international to see which codes may exist and check settings. I’m using the donor ecm so that should be all set for the a2000.

If you figure something out please circle back! I will update here as well.

I have an '04 IC CE 200 with the T444e and Allison 2000. Regarding codes I just pulled mine using the STI Diagnostic Switch (button actually) under the dash. I assume it's not as good as the EST (Electronic Service Tool) but it's free and you can do it yourself at home. The process described in the form EGED-130-1 Hard Start/No Start Diagnostic Manual. I found it by searching Google.

Diverdude0075 · 07-12-2021, 07:53 AM

I will have to check out getting codes. I'm still missing a few wires so want to get those connected/figured out.

Minor Update:
I sold the AT545 yesterday for $340. I was happy to get rid of it. The buyer is doing a really cool project and wanted it.

I'm hoping to get back to the bus this weekend and do some figuring out. I'm still missing the big silver plug through the firewall, and where it comes off of the TCM at the passenger side valve cover.

cadillackid · 07-12-2021, 09:15 AM

the J1939 wires should be a twisted pair in the harness from your TCM and be green / yellow, thats assuming they followed the standard thats in the books, and I think rolesville mentioned..

at the valve voer my connector was tucked down in, I never knew it was there till I went digging and found it dropped down and taped around the plastic wire loom..

thats the all importabt piece to make the transmission work.. and ovbviously power to the TCM.. the inside cab stuff for mode and check trans light are items that are nice-to-have but shouldnt keep the trans from operating

cadillackid · 07-12-2021, 09:15 AM

amazing to get $340 for a 545 !!! thats a great Score!!!!

Diverdude0075 · 07-19-2021, 12:11 PM

Quote:

Originally Posted by cadillackid

amazing to get $340 for a 545 !!! thats a great Score!!!!

Yeah, it sat on FB market for a while. Worth it! I just wanted it gone anyway!!

Chris, I have a question you can probably easily answer. When I look at the TCM pin out it looks like there are two yellow wires that get 12+ from the ignition. Those aren’t in my tcm harness.

Earlier in this thread I posted a pic of what I have, written on a pad of paper. The six wires are labeled. One is a green 125 that I know is for check trans. Can you determine or do you know which of the remaining five gets ignition 12+?

Thanks,
Josh

cadillackid · 07-19-2021, 12:23 PM

id have to look.. im not as familiar with 3rd gen stuff.. my allison TCM is a single 80 pin connector.. I know there are power pins designated on the TCM pinout in mine which arent connected.. I have one BAT (all time 12 volts) and one IGN (12 volts when the key is on) and a couple grounds going to mine and thats it for power in my harness.

Diverdude0075 · 07-24-2021, 01:43 PM

Worked on the bus a few hours to try getting out of limp mode… I have two yellow wires coming off the tcm that I connected ignition power to. Didn’t help. I also connected the green 125 off my tcm harness to brown 92a. Check trans light won’t come on. After messing with it for 3-4 hours I’m disgusted…

I need to research the scan tool that I need to buy.

Chris, is there a particular scan tool you recommend? I think I remember reading something but would rather not reread several pages plus maybe there is something newer/better/cheaper out now?

sportyrick · 07-24-2021, 03:23 PM

driverdude I just sent you a PM.

cadillackid · 07-24-2021, 07:53 PM

ultimately the transmission diagnostic you need is allison DOC. there are "unofficial" copies of it obtainable and the hardware device is a Nexiq USBlink2 (or a clone).

you do need to have the J1939 wired all the way through as the Nexiq or clone will use the 9 pin round Connector to try and talk to the TCM.

my setup is a little different because I used a 4th gen setup which has CAN 1 and CAN 2 so I can program my secondary port for OBD2 and use about any scan tool on the market. the 3rd gen controls dont allow us that luxury unfortunately.

Diverdude0075 · 07-31-2021, 12:27 PM

Hit 60 mph!!! Speedo works now! Bus has a ton more power!

Connecting the pink wire 13E from the TCM harness to ignition 12+ did the trick! I am so excited right now! At 60 mph my rpms were at 2000. Before, with the AT545, rpms were at 2200-2300 at around 53 mph.

I used the donor ECM so the settings should already be good. My check trans light still isn’t coming on. I’ve got green 125 from the TCM connected to tan 92a. I will try changing out the bulb next time I’m in there.

I’m still going to install the nine pin connector. I can move forward on some other stuff on the bus now I know it will operate properly!

Thanks everyone!!!

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