Eaton Fuller Hybrid Transmission Fault Code 63: Gear Motor Circuit Fault

Fault code for Eaton Hybrid Drive Systems models (MY09) EH-8E406A-U/P, EH-8E406A-UP, EH-8E406A-UPG, EH-8E406A-CD, EH-8E406A-CDG, EH-8E406A-CDR, EH-8E406A-T, EH-6E706B-CD, EH-6E706B-P and EH-6E706B-UPG. Read below to learn how to test, clear and fix fault code errors for your Freightliner, Mack, Peterbilt, Kenworth, Volvo, International, and heavy-duty truck and equipment. The Hybrid Transmission is equipped with an X-Y Shifter that selects a transmission gear. The X-Y Shifter motors are controlled with current supplied by the TECU to move the Shift Finger either side-to-side (rail selection) or fore-and-aft (gear engagement and disengagement). Fault Code 63 indicates a failure of the circuit controlling the Gear Motor and the fore-and-aft movement of the X-Y Shift Finger.

Fault Code 63: Gear Motor Circuit Fault Detection

The system can identify an issue with the X-Y Shifter Gear Motor circuit, the TECU gear motor controller or the power and ground connections to the TECU under the following conditions:

  • FMI 1 and 12 can be detected when the X-Y Gear Motor is energized
  • FMI 5 and 6 can be detected when the X-Y Gear Motor is not energized

Note: When troubleshooting an Inactive code refer to the Product Diagnostic Mode (PDM)

Conditions to Set Fault Code Active

  • FMI 1 – Data Valid but Below Normal: Transmission fails to complete a shift and the measured current draw of the Gear Motor is below expected values.
  • FMI 5 – Current Below Normal or Open Circuit: TECU detects an open circuit or a short-to-ground condition on the Gear Motor circuit for 0.5 seconds at power up or prior to a shift.
  • FMI 6 – Current Above Normal or Shorted Circuit: TECU detects a short-to-power on the Gear Motor circuit for 0.5 seconds at power-up or prior to a shift.
  • FMI 12 – Bad Intelligent Device: Transmission fails to complete a shift and the TECU detects intermittent fluctuations in supply voltage due to poor connections, shorted Gear Motor circuit or a hardware failure of the TECU.

Fallback When Fault Code 63 is set the following conditions occur:

  • “F” flashes in the gear display.
  • Service light flashes (if equipped).
  • Engine may not crank.
  • Transmission may not engage a gear from neutral.
  • Transmission does not shift while the vehicle is moving.
  • Until the fault becomes Inactive, driver may have to shut off engine with transmission in gear.

Conditions to Set Fault Code Inactive

FMI 1, 12: This fault is set Inactive when the shift is completed.
FMI 5, 6: This fault is set Inactive when the open or short circuit condition is not detected for 0.5 seconds.

This fault code can be caused by any of the following:

FMI 1, 5

  • Transmission Harness
    • This fault is set Inactive when the shift is completed.
    • Terminals bent, spread, corroded or loose
    • Wiring shorted to ground, shorted to power or open
  • X-Y Shifter Gear Motor
    • Terminals bent, spread, corroded or loose
    • Wiring shorted to ground, shorted to power or open
    • Rail Motor shorted to ground, partial short to ground, shorted to power or open
    • Rail Motor internal failure
  • TECU
    • Internal failure

FMI 6

  • Transmission Harness
    • Wiring shortened to power
  • TECU
    • Internal failure

FMI 12

  • OEM Power Supply
    • Poor power or ground supply to TECU (may be in conjunction with Fault Codes 33 or 34)
    • Battery failure
    • Terminals bent, spread, corroded or loose
    • Wiring shorted to ground, shorted to power or open
  • OEM Batteries
    • Internal failure
  • OEM 30-amp Battery Fuse
    • Terminals bent, spread, corroded or loose
    • Fuse missing or improperly seated
  • TECU
    • Internal failure

Fault Code 63: Gear Motor Circuit Fault Test

Component Identification:

Gear motor circuit fault component identification Eaton Fuller transmission

1. X-Y Shifter
2. 2-Way Gear Motor Connector (blue)
3. 2-Way Gear Motor Connector Body (blue)
4. 4-Way Diagnostic Connector
5. 38-Way Transmission Harness Connector
6. 38-Way Vehicle Harness Connector
7. Transmission Electronic Control Unit (TECU)

NOTE: Refer to the Eaton Hybrid Component and Connector Location for Connector Locations in MY09 Systems.

TECU location for gear motor circuit fault troubleshooting

STEP 1. Check for Active or Inactive fault codes.

  1. Key on with engine off.
  2. Connect ServiceRanger.
  3. Retrieve Snapshot and VPA data by creating a Service Activity Report within ServiceRanger.
  4. Update transmission software to latest available level.
    Caution: To avoid damaging the TECU, use an Eaton-approved communications adapter and ensure all satellite systems are disabled before updating software.
  5. Retrieve and record the transmission fault codes and FMIs, and their occurrences and timestamps.
    • If either Fault Code 33 or 34 are Active, troubleshoot it first per Fault Code Isolation Procedure.
    • If Fault Code 61 is Active and Fault Code 33 or Fault Code 34 are Inactive or not set, go to Step 4.
    • If Fault Code 61 is Inactive and Fault Code 33 or Fault Code 34 are Inactive or not set, go to Step 2.

STEP 2. Verify condition of power and ground supply.

  1. Perform the Electrical Pretest Gen1 ECA. Record the reading(s) from the Load Test in Step 3 of the Electrical Pretest.
    • If the Electrical Pretest fails, repair per Electrical Pretest instructions. Retest vehicle operation.
    • If the Electrical Pretest passes, go to Step 3.

STEP 3. Use Product Diagnostic (PD) Mode to locate intermittent failures.

  1. Set parking brakes and chock wheels.
  2. Place transmission in PD (Product Diagnostic) Mode.
  3. Wiggle wiring and connections between the 38- Way Vehicle Harness Connector at the TECU and vehicle battery supply. Look for signs of rubbing or chafing.
  4. Wiggle wiring and connections between 38-Way Transmission Harness Connector at the TECU and the black (X-Rail Motor) 2-Way Transmission Harness Connector.
  5. Wiggle wiring and connections between 38-Way Connector at the TECU and the blue (Y-Gear Motor) 2- Way Transmission Harness Connector.
  6. Exit PD Mode by powering down.
    Important: Allow 2–3 minutes for the TECU to per-form a complete power-down sequence before proceeding.

    • If any faults set Active while wiggling the Vehicle Harness, refer to OEM guidelines for repair or replacement of the OEM wiring. Go to Step 13.
    • If any fault sets Active while wiggling the Transmission Harness, replace the Transmission Harness. Go to Step 13.
    • If no faults set Active while wiggling either harness, go to Step 4.

STEP 4. Verify which FMI set.

  1.  Determine which FMI set for Fault Code 63.
    • If FMI 1 or 12 set, go to Step 5.
    • If FMI 5 set and is Active, go to Step 5.
    • If FMI 5 set and is Inactive, go to Step 11.
    • If FMI 6 set, replace TECU. Go to Step 13.

STEP 5. Verify proper resistance through the Transmission Harness and Gear Motor.

  1. Key off.
  2. Disconnect 38-Way Transmission Harness Connector from the TECU.
  3. Verify that the 38-Way Connector is free from corrosion; terminals are not bent, spread, or loose terminals; and there is no damage to the connector body.
  4. Measure resistance between 38-Way Connector Pin 36 and Pin 38. Record reading(s).38 way connector
  5. Measure the resistance between 38-Way Connector Pin 36 and ground. Record reading(s).measure-gear-motor-resistance Eaton Fuller transmission
  6. Compare reading(s) to specified range:
    • If reading(s) is in range, go to Step 6.
    • If reading(s) is out of range, go to Step 8.

STEP 6. Verify which FMI set.

  1. Determine which FMI set for Fault Code 63.
    • If FMI 1 set, replace X-Y Shifter and Transmission Harness. Go to Step 13.
    • If FMI 5 set, go to Step 7.
    • If FMI 12 set, go to Step 8.

STEP 7. Verify internal circuit resistance of the TECU.

  1. Reconnect 38-Way Transmission Harness to the TECU.
  2. Disconnect blue 2-Way Gear Motor Connector from the Transmission Harness.
  3. Remove connector cover of the 4-Way Diagnostic Connector.
  4. Measure resistance between the 2-Way Connector Pin A and the 4-Way Connector Pin C. Record reading(s).38 way transmission harness to TECU
  5. Reverse meter leads and take the same measurement between the 2-Way Connector Pin A and the 4-Way Connector Pin C. Record reading(s).Eaton Fuller 38 way transmission harness to TECU
  6. Compare reading(s) to specified range in recordings.
    • If reading(s) is in range, replace the X-Y Shifter. Go to Step 13.
    • If reading(s) is out of range, replace the TECU. Go to Step 13.

STEP 8. Verify the resistance of the X-Y Gear Motor and verify motor is not shorted to ground.

  1. Key off.
  2. Disconnect blue 2-Way Gear Motor Connector from the Transmission Harness.
  3. Verify 2-Way Connector is free from any corrosion; the terminals are not bent, spread or loose, and there is no damage to the connector body.
  4.  Measure resistance between the 2-Way Connector Pin A and Pin B. Record reading(s).2-Way Gear Motor Connector
  5. Measure resistance between the 2-Way Connector Pin A and ground. Record reading.2 way connector
  6. Compare reading(s) to specified range.
    • If reading(s) is in range, go to Step 9.
    • If reading(s) is out of range, replace the X-Y Shifter. Go to Step 13.

STEP 9. Verify which FMI set.

  1. Determine which FMI set for Fault Code 63.
    • If FMI 1 set, replace Transmission Harness. Go to Step 13.
    • If FMI 5 set, replace Transmission Harness. Go to Step 13.
    • If FMI 12 set, go to Step 10.

STEP 10. Load Test the vehicle power supply to the TECU.

  1. Key off.
  2. Verify TECU battery power and ground supply from the Vehicle Harness is connected properly and not corroded, damaged, or loose.
  3. Disconnect 38-Way Vehicle Harness Connector at the TECU.
  4. Verify that the 38-Way Connector is free from corrosion, there are no bent, spread, or loose terminals, and there is no damage to the connector body.
  5. Load test the vehicle power supply harness with an external load source. Use a sealed beam headlamp or blower motor attached to Pin 36 (power) and Pin 38 (ground). Load Test for 5 minutes to verify the harness will carry a load with the 30-amp fuse installed.TECU
  6. Wiggle the harness during the Load Test from the vehicle batteries to the TECU.
    • If issues are found with the Vehicle Harness or connectors, refer to OEM guidelines for repair or replacement of OEM wiring and continue Load Test.
    • If the Vehicle Harness does not carry a load, refer to OEM guidelines for repair or replacement of OEM wiring. Go to Step 13.
    • If no issues are found with the Vehicle Harness or connectors and the power supply carries a load, replace the TECU. Go to Step 13.

STEP 11. Verify proper resistance through the Transmission Harness and Gear Motor.

  1. Key off.
  2. Disconnect 38-Way Transmission Harness Connector from the TECU.
  3. Verify that the 38-Way Connector is free from corrosion, there are no bent, spread, or loose terminals, and there is no damage to the connector body.
  4. Measure resistance between 38-Way Connector Pin 36 and Pin 38. Record reading.Proper resistance through the Transmission Harness and Gear Motor Eaton Fuller transmission
  5. Measure resistance between 38-Way Connector Pin 36 and ground. Record reading.Measure resistance gear motor Eaton Fuller transmission
  6. Compare reading(s) to specified range in table:
    • If reading(s) is in range, replace the X-Y Shifter. Go to Step 13.
    • If reading(s) is out of range, go to Step 12.

STEP 12. Verify the internal resistance of the X-Y Shifter Gear Motor and verify motor is not shorted to ground.

  1. Key off.
  2. Disconnect blue 2-Way Gear Motor Connector from the Transmission Harness.
  3. Verify that the 2-Way Connector is free from corrosion, there are no bent, spread, or loose terminals, and there is no damage to the connector body.
  4. Measure resistance between the 2-Way Connector Pin A and Pin B. Record reading in the table.Shifter Gear Motor ground test Eaton Fuller transmission
  5. Measure resistance between 2-Way Connector Pin A and ground. Record reading.Measure gear motor resistance Eaton Fuller transmission
  6. Compare resistances to specified range in table.
    • If both resistances are in range, replace the Transmission Harness. Go to Step 13.
    • If either resistance is out of range, replace the X- Y Shifter. Go to Step 13.

STEP 13. Verify repair.

  1. Key off.
  2. Reconnect all connectors and the negative battery cable.
  3. 3. Key on with engine off.
  4. Clear codes, see  Clear Inactive Faults.
  5. Drive the vehicle and attempt to reset the code or duplicate issue.
  6. Check for codes, see View Active and Inactive Faults.
    • If no codes, test is complete.
    • If fault Code 63 appears, find error in testing, go to Step 1.
    • If a code other than 63 appears, see Fault Code Index List.

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