PCS Full Line Catalog

Product CatalogProduct Catalogwww.powertraincontrolsolutions.com | 804.227.3023

TABLE OF CONTENTS

All PCS manufactured modules are proudly made in the USA.

www.powertraincontrolsolutions.com

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 profi tability comes from a strong foundation of reliable, well supported products rather than marketing fl ash. 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.

ABOUT PCS

PCS is an engineering/manufacturing fi rm 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 benefi ts 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.

OEM OR AFTERMARKET

Transmission Controller Application Chart 1Transmission Controller Overview 2-3Simple Shift 4Simple Shift Tuner & Software 5TCM-2000 6TCM-2000 Software & Android App 7TCM-2600 & TCM-2400 8TCM-2200/10 & TCM-2100 9TCM-2005 & TCM-2500 10XCM-2000 & OEM Diagnostics 11Factory New Transmissions 12-13Valve Bodies 14Driveline Validation & Integration 15GSM Push Button Shifter 16Paddle Shifters 17D200 Dashlogger 18-19Data Logging Modules & Sensors 20-21Transmission Reference 22-23Manufacturing Capabilities 24Engineering Capabilities 25

Powertrain Control SolutionsPowertrain Control Solutions

TCM-2000 TCM-2005 TCM-2100 TCM-2200 TCM-2210 TCM-2300 TCM-2400 TCM-2500 TCM-2600

GM

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 • •Volkswagen DSG • •

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WAll 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

PhysicalWeight 0.89 lb 2.94 lb 0.87 lb

Dimensions (L x W x H inches) 6.0 x 5.2 x 1.7 7.2 x 7.3 x 2.5 4.9 x 6.1 x 1.5

Case Material & Finish Extruded Aluminum Blue Anodized

AluminumBlack Anodized

Extruded Aluminum

Operating ConditionsVoltage Range 8-18 VDC standard (24 VDC models available as an option)

Current (device only, not including outputs) On: 100 mAQuiescent: 0 mA

On: 100 mA Quiescent: 0 mA

On: 100 mAQuiescent: 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

Reverse/Transient Protections Yes Yes Yes

Ingress Protection IP62 IP67 IP50

Harness Interface 63-pin CPC 37-pin Mil spec6-pin Mil spec

Delphi 56-pin

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

CommunicationInterface 1 x CAN 2.0b,

1 x RS-2321 x CAN 2.0b,

1 x RS-2321 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 hand-held interface Yes Yes Yes

In-Field Flash Upgradable Yes Yes Yes

InputsFrequency (Range 0 – 10 kHz) 4 4 3

Programmable Trigger Levels and Filtering for Frequency Inputs Yes Yes 2 Channels

Analog Voltage (0-5VDC) 6 total2 with 1kΩ 5V pull-ups

4 total2 with 1kΩ 5V pull-ups

2 total1 with 1kΩ 5V pull-up

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

OutputsPWM 9 9 7

Digital 3 2 1

PWM & Digital Maximum Current 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

Output Channel Current Monitoring No No 1 Dedicated high-sidemeasured output

2 www.powertraincontrolsolutions.com

Powertrain Control Solutions

TCM-2200 TCM-2210 TCM2300 TCM-2400 TCM-2500 TCM-2600

OEM 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

AluminumBlack Anodized or

CARC

AluminumBlack Anodized or

CARC

Aluminum Black Anodized

Aluminum White Polycarbonate with Clear Lid

AluminumBlack Anodized

8-18 VDC standard (24 VDC models available as an option) 8-36 VDC







-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 certifi ed for MIL-STD 461. Certifi cation for other standards available as a cost option.

All modules are designed for robust EMI immunity. PCS offers certifi cation 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 2 x CAN 2.0b, 1 x USB, 1 x J1850

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




3 3 3 4 4 3

2 Channels 2 Channels 2 Channels No Yes Yes




2 6 total2 with 1kΩ 5V pull-ups

2



8 9 6 8 16 16


7 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


Ground Only Ground Only Ground Only Ground Only Yes Yes


4 PWM Channels0 - 2 Amp

4 PWM Channels0 - 2 Amp

1 Dedicated high-sidemeasured output 8 PWM Channels 12 PWM Channels 4 PWM Channels

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Simple Shift ControllerTransmission Control

Product DescriptionSimple Shift is the latest breakthrough in electronic overdrive transmission control. No laptops or expensive technicians are required to completely control shift points, shift fi rmness, 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 fi ngertips. Included are complete diagnostic capabilities communicated via simple fl ashing LED’s that can tell you what gear you’re in, and whether or not your torque converter is locked up.

ApplicationSimple 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.

OrderingSimple 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 fi rst time. All Simple Shift kits come with a complete wiring harness tailored to your specifi c transmission, not a universal harness that fi ts 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 GM 4L80/85E 1993+ Simple Shift Carb Kit including TCU, Harness, and TPS Kit

Continues on page 5.

*Laptop not required

TCM-2300 Dimensions

Intended Use: AftermarketWeight: 0.87 lbsCase Material & Finish: Aluminum Black AnodizedVoltage Range: 8-18 VDC standardOperating Temperature: -50 to 125°CStorage Temperature: -55 to 125°CIngress Protection: IP50Communication Interface: 1 x CAN 2.0b, 1 x RS-232,1 x GM ALDL

InputFrequency (Range 0-10kHz): 3Analog Voltage (0-5 VDC): 2 total - 1 with 1kΩ 5V pull-upDigital (programmable active high or low): 6

OutputPWM: 7Digital: 1Output Channel Current Monitoring: 1 Dedicated high-side measured output

Quick Facts

*La

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Simple Shift Tuner & Software

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

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 TCU, Harness, and TPS Kit 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


Hand Held TunerThe 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 is designed with knobs to calibrate shift points, shift fi rmness and torque converter lockup. However, there may be a customer who would prefer to use a more visual device for calibrating or desire to fi ne tune the TCM. For those customers, PCS offers PC software or a hand held tuner.

Simple Shift SoftwareThe 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 # DescriptionTCM-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



Product DescriptionThe 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 fi rmness, 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 simplifi es the connection to a PCS Paddle Shifter or GSM-2100 Gear Select Module so you can eliminate the shift lever in your car.

ApplicationThe 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.

OrderingTo 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 Application YearTCM-2000 Universal Transmission Controller All AllTCM-4108 FORD 4R100 Harness 4R100 1998-CurrentTCM-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

Intended Use: AftermarketWeight: 0.89 lbsCase Material & Finish: Extruded Aluminum Blue AnodizedVoltage Range: 8-18 VDC standard (24 VDC models available as option)Operating Temperature: -40 to 125°CStorage Temperature: -40 to 125°CIngress Protection: IP62Communication Interface: 1 x CAN 2.0b, 1 x RS-232


OutputPWM: 9Digital: 3Output Channel Current Monitoring: No

Quick Facts

TCM-2000 ControllerTransmission Control

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

Part # Description Application YearTCM-4115 FORD AODE/4R70 Harness (Late Model) AODE, 4R70 1998-2007TCM-4112 FORD E4OD Harness (Early Model) E4OD 1989-1994TCM-4109 FORD E4OD Harness (Late Model) E4OD 1995-1997TCM-4100 GM 4L80E Harness 4L80/85E* 1991 - CurrentTCM-4118 GM 4L80/85E Adapter for TCM-4100 4L80E 1991-1992

TCM-4134 GM 4T4X Harness 4T40/ 45E 1997-2007TCM-4101 GM 4T60E Harness 4T60E AllTCM-4120 GM 4T65E Harness 4T65E AllTCM-4104 GM 4T80E Harness (Late Model) 4T80E 2000 - Current

TCM-4102 GM 4T80E Harness (Early Model) 4T80E 1996-1999TCM-4000 Universal Transmission Harness 5’ All AllTCM-4156 GM 4L60/65/70E 4L60/65/70E 1993-2008TCM-4166 GM 4L70E 4L70E 2009+

7804.227.3023

PC SoftwareOur 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 AppPCS 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 fi rmness, torque converter lockup, and more.

TCM-2000 PC Software & Android App



Product DescriptionThe 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 confi gurable for discrete inputs such as TPS and RPM to accommodate virtually every installation confi guration. The new internal harness uses the typical 20-pin 4L70 transmission connector with a different pin out.

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

Intended Use: OEMWeight: 0.82 lbsCase Material & Finish: Aluminum Black AnodizedVoltage Range: 8-36 VDC standardOperating Temperature: -50 to 125°CStorage Temperature: -55 to 125°CIngress Protection: IP69KCommunication Interface: 2 x CAN 2.0b, 1 x RS-232, 1 x J1850

InputFrequency (Range 0-10kHz): 3Analog Voltage (0-5 VDC): 2Digital (programmable active high or low): 16

OutputPWM: 7Digital: 1Output Channel Current Monitoring: 4 PWM Channels

Quick Facts

TCM-2400 Dimensions

Product DescriptionThe 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 diffi cult 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.

ApplicationThe 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-2600 Dimensions

Intended Use: OEMWeight: 0.70 lbsCase Material & Finish: AluminumVoltage Range: 8-18 VDC standard (24 VDC models available as option)Operating Temperature: -50 to 135°CStorage Temperature: -55 to 150°CIngress Protection: N/ACommunication Interface: 2 x CAN 2.0b

InputFrequency (Range 0-10kHz): 4Analog Voltage (0-5 VDC): 2Digital (programmable active high or low): 8

OutputPWM: 7Digital: 1Output Channel Current Monitoring: 8 PWM Channels

Quick Facts

TCM-2600 Controller

TCM-2400 Controller

Transmission Control

9804.227.3023

Intended Use: OEMWeight: 0.87 lbsCase Material & Finish: Extruded AluminumVoltage Range: 8-18 VDC standard (24 VDC models available as option)Operating Temperature: -50 to 125°CStorage Temperature: -55 to 125°CIngress Protection: IP50Communication Interface: 1 x CAN 2.0b, 1 x RS-232, 1 x GM ALDL


OutputPWM: 7Digital: 1Output Channel Current Monitoring: 1 Dedicated high-side measured output

Quick Facts

Product DescriptionThe 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.

ApplicationThe 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.

TCM-2100 Dimensions

TCM-2200/10 Controller

TCM-2100 Controller


Quick FactsIntended Use: OEMWeight: 0.64 lbsCase Material & Finish: Aluminum Black Anodized or CARCVoltage Range: 8-18 VDC standard (24 VDC models available as option)Operating Temperature: -50 to 125°CStorage Temperature: -55 to 125°CIngress Protection: IP69KCommunication Interface: 2 x CAN 2.0b, 1 x RS-232, 1 x GM ALDL

InputFrequency (Range 0-10kHz): 3Analog Voltage (0-5 VDC): 2 total - 1 with 1kΩ 5V pull-upDigital (programmable active high or low): 8 (9 optionally)

OutputPWM: 7Digital: 1Output Channel Current Monitoring: 4 PWM Channels (0 - 2 Amp)

Product DescriptionThe 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 specifi c application.

ApplicationThe 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.

TCM-2200/10 Dimensions


Product DescriptionTransmission 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.

ApplicationThe 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 confi gurable from one transmission to another.


Product DescriptionDesigned 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.

ApplicationThe 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 FactsIntended Use: OEMWeight: 2.94 lbsCase Material & Finish: Aluminum Black AnodizedVoltage Range: 8-18 VDC standard(24 VDC models available as option)Operating Temperature: -40 to 125°CStorage Temperature: -40 to 125°CIngress Protection: IP67Communication Interface: 1 x CAN 2.0b, 1 x RS-232

InputFrequency (Range 0-10kHz): 4Analog Voltage(0-5 VDC): 4 total - 2 with 1kΩ 5V pull-upsDigital (programmable active high or low): 11

OutputPWM: 9Digital: 2Output Channel Current Monitoring: No

TCM-2005 Dimensions

TCM-2500 Dimensions

Intended Use: OEMWeight: 1.72 lbsCase Material & Finish: White Polycarbonate with Clear LidVoltage Range: 8-36 VDCOperating Temperature: -40 to 85°CStorage Temperature: -40 to 85°CIngress Protection: IP50Communication Interface: 2 x CAN 2.0b, 1 x USB, 1 x J1850

InputFrequency (Range 0-10kHz): 4Analog Voltage (0-5 VDC): 6 total - 2 with 1kΩ 5V pull-upsDigital (programmable active high or low): 16

OutputPWM: 9Digital: 3 Digital + 2 RelayOutput Channel Current Monitoring: 12 PWM Channels

Quick Facts

TCM-2005 Controller

TCM-2500 Controller


11804.227.3023

OEM Diagnostics

XCM-2000 ControllerTransfer Case Control

PCS offers several tools for OEM in-fi eld 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 modifi ed, 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.

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

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 fi nishes. This display also has automatic night-time dimming and easily connects to any of our transmission controllers via CAN.

GEAR DISPLAY

Quick FactsIntended Use: OEMWeight: 0.64 lbsCase Material & Finish: Aluminum Black Anodized Voltage Range: 8-18 VDC standard (24 VDC models available as option)Operating Temperature: -50 to 125°CStorage Temperature: -55 to 125°CIngress Protection: IP68Communication Interface: 1 x CAN 2.0bProduct Description

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 confi gurable 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.

XCM-2000 Dimensionsroduct Description



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, fi ve, 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-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 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 Torque4L60E: 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, -2.072.48, 1.86, 1.48, 1.00, 0.75, -2.072.98, 1.57, 1.00, 0.75, -2.462.98, 2.24, 1.57, 1.00, 0.75, -2.462.98, 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)

Case Die cast aluminum, removable bell-housing Die cast aluminum

Die cast aluminum (3-piece: bell & main w/ extension)

Die cast aluminum(3-piece: bell & main w/ extension)

Die cast aluminum(3-piece: bell & main 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 (2) Three-way on/off solenoids (2) Three-way on/off solenoids

Shift QualityPressure control solenoid3-2 control solenoid (some models)

Pressure control solenoid (5) Variable bleed solenoids (5) Variable bleed solenoids (5) Variable bleed solenoids

Torque Converter Clutch Pulse width modulated solenoid control

Pulse width modulated solenoid control Variable bleed solenoid Variable bleed solenoid 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 WeightTypical 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

Through the past several years of supplying transmission controllers, PCS has often encountered a scenario where a new vehicle manufacturer has diffi cultly 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 diffi cult 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 qualifi ed OEM’s.

Factory New TransmissionsTransmissions

13804.227.3023

DF

BA C

E

TRANSFER CASES

4L70 4WD Transfer Case

Factory new transfer cases (manual or electric shift), extension housings and adapters are available for a complete driveline solution.

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 ExtensionHousing

Engine Block to Mount

Center Line to

Bottom Pan

4L60/70 2WD 6.941176.30

15.421391.70

8.909226.30 N/A 30.975

786.750.85321.67

31.272794.30

24.331618.00

7.820198.60

4L60/70 4WD 6.941176.30

15.421391.70

4.433112.60 N/A 26.941

684.300.85321.67

26.795680.60

24.353618.56

7.820198.60

4L80 No separate bell housing

26.01660.65

5.495139.57

29.00 (4WD)736.71

32.1745 (2WD)817.23

0.89322.68

31.505800.23

30.672771.19

7.80198.00

6L50 6.181157.00

16.752425.50

2.28358.00

27.559700.00

26.437671.50

0.41310.50

25.216640.50

25.279642.10

9.177233.10

6L80 Fixed Yoke 6.74171.20

16.468418.30

3.4988.66

27.815706.51

29.089738.87

0.85321.67

26.699678.16 N/A 9.196

233.60

6L80 Slip Yoke 6.74171.20

16.468418.30

5.87149.10 N/A 29.962

761.060.85321.67

30.850783.60

25.595650.10

9.196233.60

6L80 4WD 6.74171.20

16.468418.30

3.58791.10 N/A 26.968

684.980.85321.67

26.795680.60

25.409645.38

9.196233.60

6L90 2WD (Duramax)

7.07179.63

17.840453.15

5.629143.00 N/A 31.439

798.560.90923.10

30.542775.78

27.480698.00

9.196233.60

6L90 4WD 6.74171.20

17.84453.15 N/A 28.559

725.4228.559725.42

0.85321.67 N/A N/A 9.196

233.60

inmm*Units:

*NOTE: Dimensions are for typical applications. Dimensions will vary based on converter, bell housing and application. For reference only.

6L80 Slip Yoke

6L80 Fixed Yoke

6L90 2WD

6L504L60/70

NEW TRANSMISSION REFERENCE

6L80 4WD 6L90 4WD

4L80



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 fl uid fl ow diagrams of the stock 4L80E. The PCS engineers studied every pressure, every orifi ce, 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 fi fth 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 modifi cation to an existing gear set. When combined with an optimized gear set, the 6-speed transmission maintains the engine in its most effi cient operating range, thus improving performance and fuel effi ciency. 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 specifi cations that meet or exceed factory specifi cations.

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 New Gear SetGear Ratio 5-Spd Step 6-Spd Step Ratio 6-Spd Step

1 2.48 2.982 1.86 1.33 1.33 2.24 1.333 1.48 1.26 1.26 1.57 1.434 1.11 - 1.33 1.18 1.335 1.00 1.48 1.11 1.00 1.186 0.75 1.33 1.33 0.75 1.33R 2.07 2.46

Gear Set Comparison

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.

Cooler Line Locations

6-Speed 4L80 Valve BodyTransmissions

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Driveline Integration & Validation

PCS provides complete driveline integration services for qualifi ed vehicle manufacturers. PCS can assist during the entire development cycle including component design, selection, validation, production procurement, and fi nal assembly. PCS services include, but are not limited to the items below.

Transmission Simulation and SelectionComputer simulation of vehicle and transmission performance based vehicle specifi c parameters including GVW, engine, and fi nal 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 InterfaceCAD 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.

Vehicle FitmentCAD design and analysis of vehicle specifi c transmission mount loading capability, transmission fi eld 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 TestingTransmission 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.

SAE4 GM 4L60/70 Bellhousing

GM 4L60/70 4WD w/ transfer case for 3.0L VM Motori engine

Transmissions



GSM Push Button ShifterShifters

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 fl ush-mounted and is small enough to fi t 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.

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.

Part # DescriptionGear Select Module Kit

GSM-5000 Gear Select Module kit including cable drive and driver interface panel

Vehicle Speed InterfacesGSM-2050 GM Speed Signal GeneratorGSM-2060 Ford Speed Signal GeneratorGSM-2080 GSM GM Speed Sensor Pass-Through AdapterWRE-3500 GM Bulkhead Pass-Through w/ CAN and Option Connector

Breakouts

Install KitsGSM-2010 GSM Install Kit for GM 4L60/65/70/80/85 w/ PRNDLGSM-2011 GSM Install Kit for Ford AODE/4R70WGSM-2012 GSM Install Kit for GM TH-200/200-4R/250/350/400/700-R4,

4L60/65/60/85 w/out PRNDLGSM-2013 GSM Install Kit for Ford 1965-1982 C-4GSM-2014 GSM Install Kit for GM 1962-1973 PowerglideGSM-2015 GSM Install Kit for Ford AODGSM-2016 GSM Install Kit for Chrysler 1966+ 727 or 904 Torquefl ite and AMC

1972+ Torque Command Transmission

GSM Dimensions

17804.227.3023

9 Bolt Paddle Shifter

5/6 Bolt Paddle Shifter

Part # DescriptionPS-2001 Paddle Shifter w/ display for 5 or 6 bolt wheel

PS-2000 Paddle Shifter w/out display for 5 or 6 bolt wheelPS-2006 Paddle Shifter w/ display for 9 bolt wheelPS-2005 Paddle Shifter w/out display for 9 bolt wheelPS-2011 Paddle Shifter w/ display for 5 or 6 bolt wheel for GM Mechatronic transmissionPS-2010 Paddle Shifter w/out display for 5 or 6 bolt wheel for GM Mechatronic transmissionPS-2016 Paddle Shifter w/ display for 9 bolt wheel for GM Mechatronic transmissionPS-2015 Paddle Shifter w/out display for 9 bolt wheel for GM Mechatronic transmission

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.

Paddle shifters purchased with a PCS transmission controller or GSM are eligible for a signifi cant bundled discount. Contact your PCS dealer for more information.

* 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.

Paddle ShiftersShifters

Paddle Shifter Dimensions

Optional display allows the driver to view all of the items listed below:

• Current Gear • Throttle Position• Vehicle Speed

• Manifold Pressure• Coolant Temp• Transmission Temp

• Driveshaft RPM• Turbine RPM• Lever Position

• Line Pressure • TCC Slip % • Transmission Slip


www.powertraincontrolsolutions.comwww.powertraincontrolsolutions.com

D200 DashloggerData Logging

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), transfl ective 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 fi nger.

Data Logging & PlaybackThe 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

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 benefi t 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.

804.227.3023804.227.3023

Monitor ScreensThe 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. Confi guration 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 specifi cations, the D200 will alert the driver by fl ashing the gauge or item. Shift light functionality can be accomplished by having the D200 fl ash the screen at a desired RPM.

Inputs and OutputsThe 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.

Part # DescriptionDIS-5100 D200 Dash Logger

DIS-3000 D200 Extreme Environment with Sealed Aluminum CaseDIS-0511 D200 Multi-stage Boost Control Kit with 0-100 PSI Stainless Pressure SensorDIS-0500 D200 Multi-Stage Boost Control with solenoidDIS-0501 D200 High Speed Logging Option (1000Hz)DIS-4001 D200 Desktop Programming KitDIS-4100 Serial ECU connection Kit for (AEM, TEC2,TEC3, Autronic, Sakura, OLD Fast, and more)DIS-4101 FAST Dash/Datalogger Classic ECU Comm. CableDIS-4110 Serial/CAN Y cable for TEC GTDIS-4120 CAN B un-terminated wire kit with TEE and resistor for Motec and CAN based ECU’sDIS-5000 D200 Suction Cup MountDIS-9200 D200 Sportsman KitDIS-9300 D200 Pro Kit

Datalog Software

19

D200 Software

D200 KitsPCS 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 specifi ed by the customer when the kit is ordered.



Three-Axis Accelerometer and Gyro ModuleThe 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 ModuleExhaust 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 # DescriptionEGT-4025 Thermocouple 1/4” tube 12” with Mini Connector

EGT-4027 Thermocouple 1/4” tube 24” with Mini ConnectorEGT-4028 Thermocouple 1/4” tube 36” with Mini ConnectorEGT-4024 Thermocouple 1/4” tube 48” with Mini ConnectorEGT-4029 Thermocouple 1/4” tube 60” with Mini Connector

Part # DescriptionACC-3000 3-Axis Accelerometer & Gyro

Part # DescriptionEGT-5100 EGT-2000 8-Channel EGT Module Kit Including Harness

EGT-5000 Single Channel EGT Module, converts temperature to 0-5 volt analog voltage

Data Logging ModulesModules & Sensors

EGT-4025

EGT-2000

ACC-3000

21804.227.3023

Part # DescriptionSNS-3200 5Hz GPS Sensor for D200

GPS Sensor

Part # DescriptionCON-5500 CAN Master Connection Kit

CON-5501 CAN Add-on Connection Kit

CAN

Part # DescriptionTCM-6000 Remote Mount Throttle Position Sensor Kit

SNS-0002 External Arm Style TPS

Throttle Position Sensors

Part # DescriptionSNS-2009 Linear Sensor 200mm Stroke

Linear Sensors

Part # DescriptionSNS-3000 Intake Air Temperature Sensor

SNS-3001 Coolant/Fluid Temperature Sensor

Temperature Sensors

Part # DescriptionSNS-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 SensorSNS-5501 Clutch Speed Sensor Kit 5/16-24 Sensor

Speed Sensors/Kits

Part # DescriptionSNS-1002 3-Bar MAP Sensor

SNS-1003 0-100 PSI Pressure SensorSNS-1004 0-250 PSI Pressure SensorSNS-1005 0-1000 PSI Pressure Sensor

SNS-1007 0-3000 PSI Pressure Sensor

Pressure Sensors

Modules & Sensors

Data Logging Sensors

TCM-6000

SNS-3200

SNS-2009

SNS-1003

SNS-1002

SNS-5002



GM TransmissionsTransmission Reference

GM 5L40/50EThe 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.

GM 4L60E 1993-1996The 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: 16Tail Housing Bolts: 4

GM 4L60/65/70E 1996+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:


4L70 ONLY

GM 4L80/85EThe 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.


1991-1992 1993+

Solenoid Connectors

GM 6L80/90The 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.

GM 6L50The 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.

23804.227.3023

Transmission Reference

Ford & Chrysler Transmissions

FORD 5R55EThe 5R44/55E is found in most 1997-2002 Ford Ranger, Mazda B-Series, and FOrd Explorer; and 1998+ Mercury Mountaineer.

FORD 5R55S/WThe 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.

CHRYSLER 545RFEThe 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.

Pan Bolts: 15

4R70 4R75

EARLY FORD AODE/4R70WThe 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

4R7544

LATE FORD 4R70W/4R75The 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: 14Speed Sensors

FORD 4R100The 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


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 effi ciently. Wintronics has experience in high volume, military qualifi ed products and understands all the requirements those products must undergo to satisfy the most stringent specifi cations. 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 fi ne 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.

About WintronicsWintronics is a full service, ISO 9001 certifi ed, 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.

• Order Fulfi llment• 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

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


Manufacturing CapabilitiesCapabilities

25804.227.3023

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 certifi cation, and PPAP. Our engineers are available 24 hours, 7 days a week to provide on-site engineering support.

Mechanical DesignOur 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 fi nd any design errors before spending thousands on production tooling.

Circuit Schematic Design and LayoutOur 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 DesignAn 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.

Capabilities

Engineering Capabilities

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Powertrain Control Solutions, LLC10511 Old Ridge Rd. Ashland, VA 23005 Catalog 0214

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 fi rst 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 fi tness, and any other obligation on the part of Powertrain Control Solutions, LLC., or selling dealer.

Documents

PCS Full Line Catalog