Buick Encore Owners & Service Manuals

Buick Encore: Diagnostic information and procedures

DTC P0502 OR P0503: Vehicle speed sensor (VSS)

DIAGNOSTIC CODE INDEX

DIAGNOSTIC CODE INDEX

DTC P0502 OR P0503: VEHICLE SPEED SENSOR (VSS)

Diagnostic Instructions

  • Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure.
  • Review Strategy Based Diagnosis for an overview of the diagnostic approach.
  • Diagnostic Procedure Instructions provides an overview of each diagnostic category.

DTC Descriptors

DTC P0502

Vehicle Speed Sensor (VSS) Circuit Low Voltage

DTC P0503

Vehicle Speed Sensor (VSS) Circuit Intermittent

Diagnostic Fault Information

Diagnostic Fault Information

Typical Scan Tool Data

Vehicle Speed Sensor

Typical Scan Tool Data

Typical Scan Tool Data

Circuit/System Description

The vehicle speed sensor (VSS) is a 3 wire sensor. The engine control module (ECM) provides a 5 volt reference circuit, low reference circuit and a signal circuit to the VSS. The VSS is a Hall Effect type sensor that produces a square wave output signal to the ECM. As vehicle speed increases, the output frequency of the VSS signal increases. The ECM converts the square wave output signal into vehicle speed shown as km/h (MPH).

The ECM supplies the VSS signal to other control modules on the vehicle through the serial data communications line.

Conditions for Running the DTC

P0502

  • DTC P0503 is not set.
  • Ignition voltage is between 9-16 V.
  • Throttle position is 15% or greater.
  • Engine speed is between 1,500-6,500 RPM.

P0503

  • Ignition voltage is between 9-16 V.
  • Engine speed is between 200-7,500 RPM for 5 s or greater.
  • Transmission Output Shaft Speed signal is 200 RPM or greater for 2 s or greater.

Conditions for Setting the DTC

P0502

Transmission Output Shaft Speed signal is less than 60 RPM for 4.5 s.

P0503

Change in Transmission Output Shaft Speed signal is 350 RPM or greater for 3.3 s.

Action Taken When the DTC Sets

P0502 and P0503 are Type B DTCs.

Conditions for Clearing the DTC

P0502 and P0503 are Type B DTCs.

Diagnostic Aids

The battery must be fully charged. Refer to Battery Inspection/Test .

Reference Information

Schematic Reference

Manual Transmission Schematics (Encore, MR5), Manual Transmission Schematics (Encore, MR5)

Connector End View Reference

WIRING SYSTEMS AND POWER MANAGEMENT - COMPONENT CONNECTOR END VIEWS - INDEX - ENCORE WIRING SYSTEMS AND POWER MANAGEMENT - COMPONENT CONNECTOR END VIEWS - INDEX - Encore

Description and Operation

Transmission System Description and Operation

Electrical Information Reference

  • Circuit Testing
  • Connector Repairs
  • Testing for Intermittent Conditions and Poor Connections
  • Wiring Repairs

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions (LUV) , Powertrain Diagnostic Trouble Code (DTC) Type Definitions (2H0)

Scan Tool Reference

K20 Engine Control Module: Scan Tool Information (LUV or 2H0)

Special Tools

J-38522-A Vehicle Signal Generator

For equivalent regional tools, refer to Special Tools.

Circuit/System Verification

CAUTION: Support the lower control arms in the normal horizontal position in order to avoid damage to the drive axles. Do not operate the vehicle in gear with the wheels hanging down at full travel.

  1. Raise and support the drive wheels in a horizontal position.
  2. Start and idle the engine.
  3. Place the transmission in second gear and release the clutch pedal.
  4. Verify the scan tool Vehicle Speed Sensor parameter increases as the drive wheel speed increases.
  • If the Vehicle Speed Sensor parameter does not increase

Refer to Circuit/System Testing

  • If the Vehicle Speed Sensor parameter does increase
  1. Operate the vehicle within the conditions for running the DTC to verify the DTC does not set. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records.

If the DTC sets

Refer to Circuit/System Testing.

If the DTC does not set

  1. All OK.

Circuit/System Testing

  1. Ignition OFF and all vehicle systems OFF. Disconnect the harness connector at the B115 Vehicle Speed Sensor. It may take up to 2 minutes for all vehicle systems to power down.
  2. Test for less than 10 ohms between the low reference circuit terminal 2 and ground.

If 10 ohms or greater

  1. Disconnect the X3 harness connector at the K20 Engine Control Module.
  2. Test for less than 2 ohms in the circuit end to end.
  • If 2 ohms or greater, repair the open/high resistance in the circuit.
  • If less than 2 ohms, replace the K20 Engine Control Module.

If less than 10 ohms

  1. Ignition ON.
  2. Test for 4.8-5.2 V between the 5 V reference circuit terminal 1 and ground.

If less than 4.8 V

  1. Ignition OFF, disconnect the X3 harness connector at the K20 Engine Control Module.
  2. Test for infinite resistance between the 5 V reference circuit and ground.
  • If less than infinite resistance, repair the short to ground on the circuit.
  • If infinite resistance
  1. Test for less than 2 ohms in the 5 V reference circuit end to end.
  • If 2 ohms or greater, repair the open/high resistance in the circuit.
  • If less than 2 ohms, replace the K20 Engine Control Module.

If greater than 5.2 V

  1. Ignition OFF, disconnect the X3 harness connector at the K20 Engine Control Module, Ignition ON.
  2. Test for less than 1 V between the 5 V reference circuit and ground.
  • If 1 V or greater, repair the short to voltage on the circuit.
  • If less than 1 V, replace the K20 Engine Control Module.

If between 4.8-5.2 V

  1. Ignition OFF, connect the test leads of the J-38522-A vehicle signal generator as follows:
  • Red test lead to the signal circuit terminal 3 at the B115 Vehicle Speed Sensor wire harness connector.
  • Black test lead to ground at the transmission case.
  • Double black power and ground lead wire to B+ and ground.
  1. Set and adjust the J-38522-A vehicle signal generator to the following switch positions:
  • Signal switch to 5 V.
  • Frequency switch to 600 Hz.
  • Duty cycle switch to 50% or normal position.
  1. Ignition ON.
  2. Verify the scan tool Vehicle Speed Sensor parameter displays between 41-51 km/h (25-31 mph).
  • If the vehicle speed sensor parameter is not within the specified range
  1. Ignition OFF, disconnect the X3 harness connector at the K20 Engine Control Module.
  2. Test for infinite resistance between the signal circuit terminal 3 and ground.
  • If less than infinite resistance, repair the short to ground on the circuit.
  • If infinite resistance
  1. Test for less than 2 ohms in the signal circuit end to end.
  • If 2 ohms or greater, repair the open/high resistance in the circuit.
  • If less than 2 ohms, replace the K20 Engine Control Module.

If the vehicle speed sensor parameter is within the specified range

  1. Replace the B115 Vehicle Speed Sensor.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair.

  • Control Module References for ECM replacement, programming and setup.

DTC P0806-P0808: Clutch pedal position (CPP) Sensor

Diagnostic Instructions

  • Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure.
  • Review Strategy Based Diagnosis for an overview of the diagnostic approach.
  • Diagnostic Procedure Instructions provides an overview of each diagnostic category.

DTC Descriptors

DTC P0806

Clutch Pedal Position (CPP) Sensor Performance

DTC P0807

Clutch Pedal Position (CPP) Sensor Circuit Low Voltage

DTC P0808

Clutch Pedal Position (CPP) Sensor Circuit High Voltage

Diagnostic Fault Information

Diagnostic Fault Information

Typical Scan Tool Data

CPP Sensor Voltage

CPP Sensor Voltage

CPP Sensor Percentage

CPP Sensor Percentage

CPP Sensor Percentage

Circuit/System Description

The clutch pedal position (CPP) sensor is a three wire sensor, connected to a 5 V reference circuit, a low reference circuit, and a signal circuit. The engine control module supplies 5 V to the CPP sensor, and also provides a sensor ground path on the low reference circuit. The CPP sensor sends a voltage signal to the ECM on the signal circuit. The voltage on the signal circuit will vary from a voltage near 4 V when the clutch pedal is released, to a voltage near 1 V when the clutch pedal is applied.

Conditions for Running the DTC

P0806

  • DTC P0335, P0336, P0502, P0503, P0807, or P0808 is not set.
  • The engine is running with transmission in gear.
  • The vehicle speed is greater than 1.9 kmh (1.2 mph).

P0807 and P0808

  • The ignition is ON.
  • The system voltage is more than 10 V.

Conditions for Setting the DTC

P0806

The CPP sensor is stuck in range.

P0807

The CPP sensor voltage is less than 0.2 V for more than 1 s.

P0808

The CPP sensor voltage is more than 4.8 V for more than 1 s.

Action Taken When the DTC Sets

DTC P0806 - P0808 are Type A DTCs.

Conditions for Clearing the DTC

DTC P0806 - P0808 are Type A DTCs.

Reference Information

Schematic Reference

Manual Transmission Schematics (Encore, MR5), Manual Transmission Schematics (Encore, MR5)

Connector End View Reference

WIRING SYSTEMS AND POWER MANAGEMENT - COMPONENT CONNECTOR END VIEWS - INDEX - ENCORE WIRING SYSTEMS AND POWER MANAGEMENT - COMPONENT CONNECTOR END VIEWS - INDEX - Encore

Description and Operation

Transmission System Description and Operation

Electrical Information Reference

  • Circuit Testing
  • Connector Repairs
  • Testing for Intermittent Conditions and Poor Connections
  • Wiring Repairs

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions (LUV) , Powertrain Diagnostic Trouble Code (DTC) Type Definitions (2H0)

Scan Tool Reference

K20 Engine Control Module: Scan Tool Information (LUV or 2H0) for scan tool information

Circuit/System Verification

  1. Ignition ON.
  2. Verify DTC P0651 or P080A is not set

If DTC P0651 or P080A is set

Refer to Diagnostic Trouble Code (DTC) List - Vehicle .

If DTC P0651 or P080A is not set

  1. Verify the scan tool CPP Sensor percent parameter varies from 0% when the clutch pedal is released, to 100% when the clutch pedal is in the apply position.

If the percentage does not vary from 0% to 100%

Refer to Circuit/System Testing.

If the percentage varies from 0% to 100%

  1. Operate the vehicle within the conditions for running the DTC to verify the DTC does not set. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data.

If the DTC sets

Refer to Circuit/System Testing.

If the DTC does not set

  1. All OK.

Circuit/System Testing

  1. Ignition OFF and all vehicle systems OFF. Disconnect the harness connector at the B25B Clutch Pedal Position Sensor. It may take up to 2 min for all vehicle systems to power down.
  2. Test for less than 5 ohms between the low reference circuit terminal C and ground.

If 5 ohms or greater

  1. Disconnect the X3 harness connector at the K20 Engine Control Module.
  2. Test for less than 2 ohms in the circuit end to end.
  • If 2 ohms or greater, repair the open/high resistance in the circuit.
  • If less than 2 ohms, replace the K20 Engine Control Module.

If less than 5 ohms

  1. Ignition ON.
  2. Test for 4.8-5.2 V between the 5 V reference circuit terminal A and ground.

If less than 4.8 V

  1. Ignition OFF, disconnect the X3 harness connector at the K20 Engine Control Module.
  2. Test for infinite resistance between the 5 V reference circuit and ground.
  • If less than infinite resistance, repair the short to ground on the circuit.
  • If infinite resistance
  1. Test for less than 2 ohms in the 5 V reference circuit end to end.
  • If 2 ohms or greater, repair the open/high resistance in the circuit.
  • If less than 2 ohms, replace the K20 Engine Control Module.

If greater than 5.2 V

  1. Ignition OFF, disconnect the X3 harness connector at the K20 Engine Control Module, Ignition ON.
  2. Test for less than 1 V between the 5 V reference circuit and ground.
  • If 1 V or greater, repair the short to voltage on the circuit.
  • If less than 1 V, replace the K20 Engine Control Module.

If between 4.8-5.2 V

  1. Verify the scan tool CPP Sensor voltage parameter is less than 0.1 V.
  • If 0.1 V or greater
  1. Ignition OFF, disconnect the X3 harness connector at the K20 Engine Control Module, Ignition ON.
  2. Test for less than 1 V between the signal circuit terminal B and ground.
  • If 1 V or greater, repair the short to voltage on the circuit.
  • If less than 1 V, replace the K20 Engine Control Module.

If less than 0.1 V

  1. Install a 3 A fused jumper wire between the signal circuit terminal B and the 5 V reference circuit terminal A.
  2. Verify the scan tool CPP Sensor voltage parameter is greater than 4.9 V.

If 4.9 V or less

  1. Ignition OFF, remove the jumper wire, disconnect the X3 harness connector at the K20 Engine Control Module.
  2. Test for infinite resistance between the signal circuit terminal B and ground.
  • If less than infinite resistance, repair the short to ground on the circuit.
  • If infinite resistance
  1. Test for less than 2 ohms in the signal circuit end to end.
  • If 2 ohms or greater, repair the open/high resistance in the circuit.
  • If less than 2 ohms , replace the K20 Engine Control Module.

If greater than 4.9 V

  1. Test or replace the B25B Clutch Pedal Position Sensor.

Component Testing

Static Test

  1. Ignition OFF, disconnect the harness connector of the B25B Clutch Pedal Position Sensor.
  2. Measure the resistance between the signal terminal B and the low reference terminal C at the B25B Clutch Pedal Position Sensor. Depress the clutch pedal through the entire range. The resistance should vary from low to high and vice versa without any spikes or dropouts.

If the resistance is erratic with spikes or dropouts

Replace the B25B Clutch Pedal Position Sensor.

If the resistance is not erratic without spikes or dropouts

  1. All OK.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair.

  • Clutch Pedal Position Sensor Replacement
  • Control Module References for ECM replacement, programming and setup.

DTC P080A: Clutch pedal position (CPP) Not learned

Diagnostic Instructions

  • Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure.
  • Review Strategy Based Diagnosis for an overview of the diagnostic approach.
  • Diagnostic Procedure Instructions provides an overview of each diagnostic category.

DTC Descriptor

DTC P080A

Clutch Pedal Position (CPP) Not Learned

Circuit/System Description

The clutch pedal position (CPP) is a 3-wire sensor, connected to a 5 V reference circuit, a low reference circuit, and a signal circuit. The engine control module supplies 5 V to the CPP sensor, and also provides a sensor ground path on the low reference circuit. The CPP sensor sends a voltage signal to the ECM on the signal circuit. The voltage on the signal circuit will vary from a voltage near 5 V when the clutch pedal is released to a voltage less than or equal to 1.5 V when the clutch pedal is applied.

Conditions for Running the DTC

Clutch pedal fully applied.

Conditions for Setting the DTC

Clutch pedal position not learned.

Action Taken When the DTC Sets

P080A is a Type A DTC.

Conditions for Clearing the DTC

P080A is a Type A DTC.

Reference Information

Schematic Reference

Manual Transmission Schematics (Encore, MR5), Manual Transmission Schematics (Encore, MR5)

Connector End View Reference

WIRING SYSTEMS AND POWER MANAGEMENT - COMPONENT CONNECTOR END VIEWS - INDEX - ENCORE WIRING SYSTEMS AND POWER MANAGEMENT - COMPONENT CONNECTOR END VIEWS - INDEX - Encore

Description and Operation

Transmission System Description and Operation

Electrical Information Reference

  • Circuit Testing
  • Connector Repairs
  • Testing for Intermittent Conditions and Poor Connections
  • Wiring Repairs

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions (LUV) , Powertrain Diagnostic Trouble Code (DTC) Type Definitions (2H0)

Scan Tool Reference

K20 Engine Control Module: Scan Tool Information (LUV or 2H0)

Circuit/System Verification

Perform the clutch pedal position sensor learn procedure.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair.

  • Clutch Pedal Position Sensor Learn
  • Control Module References for replacement, programming and setup.

DTC P0812: REVERSE POSITION SWITCH CIRCUIT

Diagnostic Instructions

  • Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure.
  • Review Strategy Based Diagnosis for an overview of the diagnostic approach.
  • Diagnostic Procedure Instructions provides an overview of each diagnostic category.

DTC Descriptor

DTC P0812

Reverse Position Switch Circuit

Diagnostic Fault Information

Reverse Position Switch

Diagnostic Fault Information

Typical Scan Tool Data

Reverse Position Switch

Typical Scan Tool Data

Circuit/System Description

The Backup Lamp (Reverse Position) switch is a two wire switch mounted on the transmission assembly. The Backup Lamp switch is connected to a 12 V signal circuit from the engine control module (ECM). The ground circuit is connected to chassis ground. The Backup Lamp switch is a normally open switch. The voltage on the Backup Lamp switch signal circuit to the ECM is HIGH when the switch is open and the transmission is in Neutral or another forward gear. The voltage on the Backup Lamp switch signal circuit to the ECM is LOW when the switch is closed and the transmission is in the reverse position. When the transmission is placed in the reverse position, the ECM sends a serial data message to the Body Control Module (BCM). The message indicates that the gear selector is in the reverse position. The BCM applies battery voltage to the backup lamps.

When the gear selector is moved out of the reverse position, a message is sent by the ECM via serial data requesting the BCM to remove battery voltage from the backup lamp control circuit.

Conditions for Running the DTC

P0812

  • The system voltage is greater than 9 V.
  • The ignition is in the RUN position.

Conditions for Setting the DTC

P0812

The Backup Lamp switch signal circuit is high with the transmission in reverse

Action Taken When the DTC Sets

DTC P0812 is a Type B DTC.

Conditions for Clearing the DTC

DTC P0812 is a Type B DTC.

Reference Information

Schematic Reference

Exterior Lights Schematics (Encore) , Exterior Lights Schematics (Encore)

Connector End View Reference

WIRING SYSTEMS AND POWER MANAGEMENT - COMPONENT CONNECTOR END VIEWS - INDEX - ENCORE WIRING SYSTEMS AND POWER MANAGEMENT - COMPONENT CONNECTOR END VIEWS - INDEX - Encore

Electrical Information Reference

  • Circuit Testing
  • Connector Repairs
  • Testing for Intermittent Conditions and Poor Connections
  • Wiring Repairs

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions (LUV) , Powertrain Diagnostic Trouble Code (DTC) Type Definitions (2H0)

Scan Tool Reference

K20 Engine Control Module: Scan Tool Information (LUV or 2H0) for scan tool information

Circuit/System Verification

  1. Ignition ON, verify the scan tool Reverse Position Switch parameter changes between On when the transmission is in reverse and Off when the transmission is in neutral.
  • If the Reverse Position Switch parameter does not change states

Refer to Circuit/System Testing below.

  • If the Reverse Position Switch parameter does change states
  1. Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data.
  2. Verify the DTC does not set.

If the DTC sets

Refer to Circuit/System Testing.

If the DTC does not set

  1. All OK.

Circuit/System Testing

NOTE: You must perform the Circuit/System Verification first.

  1. Ignition OFF, disconnect the harness connector at the B16 Backup Lamp Switch.
  2. Test for less than 5 ohms between the ground circuit terminal 2 and ground.

If 5 ohms or greater

  1. Test for less than 2 ohms in the ground circuit end to end.
  • If 2 ohms or greater, repair the open/high resistance in the circuit.
  • If less than 2 ohms, repair the open/high resistance in the ground connection.

If less than 5 ohms

  1. Ignition ON.
  2. Verify the scan tool Reverse Switch parameter is Off.

If the parameter is On

  1. Ignition OFF, disconnect the X3 harness connector at the K20 Engine Control Module.
  2. Test for infinite resistance between the signal circuit terminal 1 and ground.
  • If less than infinite resistance, repair the short to ground on the circuit.
  • If infinite resistance, replace the K20 Engine Control Module.

If the parameter is Off

  1. Ignition ON, install a 3 A fused jumper wire between the signal circuit terminal 1 and the ground circuit terminal 2.
  2. Verify the scan tool Reverse Switch parameter is On.

If the parameter is Off

  1. Ignition Off, remove the jumper wire, disconnect the X3 harness connector at the K20 Engine Control Module.
  2. Test for less than 2 ohms in the signal circuit end to end.
  • If 2 ohms or greater, repair the open/high resistance in the circuit.
  • If less than 2 ohms, replace the K20 Engine Control Module.

If the parameter is On

  1. Test or replace the B16 Backup Lamp Switch.

Component Testing

Static Test

  1. Ignition OFF, disconnect the electrical harness connector of the B16 Backup Lamp switch.
  2. With the transmission in Reverse and the Backup Lamp switch closed, measure for less than 2 ohms between the signal circuit terminal 1 and the ground circuit terminal 2 on the B16 Backup Lamp switch.

If 2 ohms or greater

Replace the B16 Backup Lamp Switch.

If less than 2 ohms

  1. All OK.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair.

  • Backup Lamp Switch Replacement
  • Control Module References for ECM replacement, programming and setup.

Clutch pedal position sensor learn

NOTE:

The clutch pedal position (CPP) sensor learn procedure is required when the following service procedures have been performed regardless of whether DTC P080A is set:

  • An engine control module (ECM) replacement
  • A CPP sensor replacement
  • Any repairs which affect the CPP sensor relationship
  1. Install a scan tool.
  2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P080A, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC that set.
  3. With a scan tool, select Clutch Pedal Position Learn under Module Setup in Manual Transmission, and perform the following instructions displayed on the scan tool screen.

NOTE: The CPP sensor learn procedure cannot be performed more than once per ignition cycle. The clutch pedal needs to be fully depressed and held steady throughout this procedure in order to perform a correct learning.

  1. The scan tool will display under CPP Learn Status: Not Learned, In Process, Complete, Fail - Low Volt, Fail - High Volt, or Fail Moving. The scan tool will display under CPP Learn Status Complete if the process was successful.
  2. If the scan tool indicates that DTC P080A ran and passed this ignition the CPP sensor learn procedure is complete. If the scan tool indicates DTC P080A failed or did not run this ignition, refer to DTC P080A, .

    If any other DTC is set, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC.

  3. Turn OFF the ignition for 30 s after the learn procedure has successfully completed in order to store the CPP sensor variation values in ECM history.

SYMPTOMS - MANUAL TRANSMISSION

Symptoms - Manual Transmission

SYMPTOMS - MANUAL TRANSMISSION

SYMPTOMS - MANUAL TRANSMISSION

SYMPTOMS - MANUAL TRANSMISSION

SYMPTOMS - MANUAL TRANSMISSION

TRANSMISSION SHIFTS HARD

Diagnostic Aids

An intermittent hard shift may be caused by an intermittent clutch condition.

Test Description

The numbers below refer to the step numbers on the diagnostic table.

3

A static shift test is performed by shifting into all of the gear positions with the engine not operating.

While performing the test one should note how the shift lever movement is felt. Also while shifting from one gear to the other feel for binding in the shift rails. You should be able to feel the detent plungers operating when coming out of a gear and going into a gear.

6

A dynamic shift test is performed by shifting into the gear positions with the engine operating. Test for the correct mesh of the synchronizers and for the clutch releasing correctly. When shifting into and out of a gear, feel for the shift detent plungers and for the synchronizers sleeve for moving freely.

8

The transmission uses a synthetic transmission fluid that allows proper synchronizer operation. The incorrect fluid may cause hard shifting by varnish build-up, or not enough lubrication for proper synchronizer operation.

Transmission Shifts Hard

Transmission Shifts Hard

Transmission Shifts Hard

TRANSMISSION GEAR CLASH WHEN SHIFTING GEARS

Diagnostic Aids

Gear clashing may be caused by shifting at too high of an engine RPM or by rushing the shift. If gear clashing is occurring in more than one gear, the clutch may not be releasing properly for proper synchronizer operation.

Test Description

The numbers below refer to the step numbers on the diagnostic table.

2

This step tests for the proper releasing of the clutch. If the clutch reserve is not proper, the mainshaft gears may still be turning causing the gear clashing.

5

This step inspects for the proper transaxle fluid. A special fluid is required for the correct lubrication of the synchronizers.

7

A static shift test is performed by shifting into all of the gear positions with the engine not operating.

While performing the test, you should note how the shift lever movement is felt. Also, while shifting from one gear to another, feel for binding in the shift rails. You should be able to feel the detent plungers operating when coming out of a gear and going into a gear. Excessive play in the gear shift lever may prevent the shift forks from fully engaging the synchronizer.

10

A dynamic shift test is performed by shifting into all of the gear positions with the engine operating. Test for the correct mesh of the synchronizers, and for the clutch releasing correctly. Move the shift lever and feel for the synchronizer sleeve to just release from the gear, then let up on the clutch pedal. Depress the clutch pedal and move the shift lever to engage that gear again. If it shifts back into the gear without clashing, the clutch is releasing correctly and the synchronizer is working. If clashing occurs, test on another gear. If all gears clash, the clutch is not releasing correctly.

Transmission Gear Clash When Shifting Gears

Transmission Gear Clash When Shifting Gears

Transmission Gear Clash When Shifting Gears

Transmission Gear Clash When Shifting Gears

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