Well, good news. I finally got off my butt and figured out how to trick the PCU into not throwing codes and turning on the check engine light, now that the stock transmission is no longer present. So far with four test drives, no DTC's are being set. This will work for both auto and manual transmission swaps.
With this bit of wiring trickery, the PCU "thinks" the stock transmission is still there and that the transmission and transfer case are both in Neutral.
This does not appear to affect engine performance or drivability. The PCU is not smart enough to wonder why the engine is under load and throttling up and down while the transmission and transfer case are in Neutral.
Error Codes Seen:
After the transmission swap to the ZF 8HP75 I had five DTC's stored in the PCU:
P0710 Transmission Fluid Temperature
P0753 Solenoid A
P0758 Solenoid B
P0773 Solenoid E & F
P1780 P/N Position Switch Malfunction
Solenoid Error Codes:
The solenoid error codes can be easily addressed by putting a 12 Ohm power resistor on the lines for the three solenoids. A power resistor should be used in case the PCU tries to turn on one of the solenoids, but I am pretty sure that it will not given the state the PCU thinks the transmission is in. But, to be safe I used power resistors and mounted them on an aluminum plate for heat sinking, just in case. If I get really motivated I could hook up thermocouples to each of them and see if they ever get hot, but, not a big priority for me.
The power resistors I used are readily available at Digikey for $5.15 each. Three are required.
Bourns PWR220T-20-12R0F Power Resistor
View attachment 4066471
The three solenoid lines are on Connector A on the PCU harness. There are four connectors that plug into the PCU (A, B, C, and D). They are also named E4, E5, E6, and E7.
View attachment 4066482
The pin numbers are 8, 9, and 10 on Connector A.
View attachment 4066483
I connected the power resistors to extended wires for the three pins on the harness connector and also soldered on ground wires that combined into one larger wire. I then mounted them on a 1/4" thick piece of aluminum sheet. It does not matter what side of the power resistor you attach the wire from the ECU or which is ground. I used the same color/stripe wire that is in the ECU harness. I have a bunch of Toyota wire in my stash from Toyota Sienna minivan harnesses at PnP.
You want to cut the wires at the PCU connector with enough length so that you can connect the wire extensions. You will attach the wire extensions to the wire that goes into the PCU connector, not the side that goes into the harness bundle. That side is left cut and open in the harness, as, it does not go anywhere since the stock transmission is gone.
For the ground side of the power resistors I combined all three into 1 larger wire and ran that to the ground lug in the passenger footwell.
View attachment 4066485
Sous le tableau de bord, côté passager, au niveau des pieds, deux goujons filetés M6 traversent la tôle. L'entraxe de ces goujons est de 70 mm. J'ai percé deux trous espacés de 70 mm dans la plaque d'aluminium, puis j'y ai fixé les trois résistances de puissance à l'aide de vis M3 insérées dans des trous taraudés de 6,35 mm (1/4"). J'ai préalablement ajouté des rondelles sur les goujons pour surélever légèrement la plaque du dissipateur thermique, avant de la fixer avec deux écrous.
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Cela résout les problèmes liés aux codes d'erreur des solénoïdes. Le calculateur détecte la résistance correcte et, s'il alimente un ou plusieurs solénoïdes, la plaque en aluminium se chargera de dissiper la chaleur.
Ensuite, je parlerai de la solution/astuce concernant la température du liquide de transmission.