23 · Diagnostics

The gears do not engage

Make: Fiat
Model: Panda Factory Service Manual
Year: 2003–2012
Section: Gear shift › The gears do not engage

‹ Prev Manual-automatic shift Next › The gears do not engage in "auto" operation

Fault diagnosisThe gears do not engage

THE GEARS DO NOT ENGAGE

1.2 8v

First and/or Reverse after a stop.

0	CONTROL UNIT ERRORS CHECK	All OK	Problems met	Operation
		Results of the tests
	Check that there are no control unit errors. In particular: Clutch sensor error Lever switch error (any one of the 4 switches or the ECO/Normal switch) Microprocessor 2 error Even gear engagement error Odd gear engagement error Clutch solenoid current error Electromagnetic brake error (Selection solenoid) Control unit earth error Load relay error	Continue to Step 5	Presence of one or more of the errors included in the list	Continue to Step 1
1	CHECKS ON FAULTS DETECTED	All OK	Problems met	Operation
	Check the faults according to the See Test 2127I What to do for error in Selespeed control unit	Continue to Step 3	Faulty connections (Clutch sensor, Odd or even gear engagement, Clutch solenoid Current error, Electromagnetic brake error, Control unit earth error and/or Load relay error)	Repair/replace the wiring Continue to Step 3
			The state displayed is not correct (Lever switch error - Lever check)	Check the connections, continuity of the wiring and the gear lever Continue to Step 3
			There is no change of state and/or the word 'ECO is not displayed (Lever switch error - check ECO button)	Check the button and wiring Continue to Step 3
			Replace the Robotized Gearbox control unit (Microprocessor error 2)	Continue to Step 3
			The active diagnosis is not successful and there are no faults detected at the wiring (Odd or even gear engagement and/or Clutch solenoid valve current error)	Continue to Step 2
2	AFTER THE SOLENOID VALVE ACTIVE DIAGNOSIS	All OK	Problems met	Operation
	If this step has been reached for the active diagnosis of the clutch solenoid valve, replace it Op. 2127C56and check the operation by carrying out a C.M. If this step has been reached for the active diagnosis of the engagement solenoid valve, replace it Op. 2127C52and check the operation	Continue to Step 3
3	SOLENOID VALVE REPLACEMENT	All OK	Problems met	Operation
	If there is an electromagnetic brake error and no faults are detected at the connections/wiring, replace Op. 2127C54and check the brake is operating correctly	Continue to Step 4
4	AFTER THE CHECKS ON THE FAULTS DETECTED	All OK	Problems met	Operation
	Check that the fault is no longer present	End of diagnosis	The fault persists	Continue to Step 7
5	GEAR LEVER CHECK	All OK	Problems met	Operation
	Check that the gear lever is working properly following See Test 2127L GEAR LEVER CHECK	Continue to Step 6	The lever states displayed are not correct	Check the wiring and the switches/gear lever Repair/replace the part that is not working
		Continue to Step 6	There is no change of state and/or the 'AUTO button is not displayed	Check the switch and the wiring. Repair/replace the part that is not working
6	OIL LEVEL CHECK	All OK	Problems met	Operation
	Check the oil level as described in See Test 2127B OIL LEVEL CHECK	Continue to Step 8	Level below the Max reference	Top up the oil level Continue to Step 7
		Continue to Step 8	Level above the Max reference	Reduce to the Max level Continue to Step 8
7	CHECK FOR OIL LEAKS	All OK	Problems met	Operation
	Check that there are no oil leaks as described in See Test 2127C CHECK FOR OIL LEAKS	Continue to Step 8	Oil leaks detected in the clutch assembly	Carry out the clutch bleeding procedure in active diagnosis using the Examiner Continue to Step 8
		Continue to Step 8	Oil leaks detected in other parts of the hydraulic unit	Replace/repair the parts concerned, and top up the oil level Continue to Step 7
8	OIL PRESSURE CHECK	All OK	Problems met	Operation
	Check the amount of oil present and continue with the topping up Check the oil pressure as described in See Test 2127D OIL PRESSURE CHECK	Continue to Step 10	Pressure < 40 bar	Continue to Step 9
9	ELECTRIC PUMP OPERATION CHECK	All OK	Problems met	Operation
	Check the correct operation of the pump as described in See Test 2127E ELECTRIC PUMP OPERATION CHECK	Continue to Step 10	Voltage below 11 V	Check the battery Continue to Step 9
		Continue to Step 10	It is not possible to make gear changes from the lever	Activate the 'clutch bleed' service from the Examiner Plus or Smart to activate the pump Continue to Step 10
10	CHECK ON BRAKE PEDAL SWITCH	All OK	Problems met	Operation
	Check that the brake pedal switch is working properly as described in See Test 2127F CHECK ON BRAKE PEDAL SWITCH	Continue to Step 11	The brake pedal switch is not working properly	Check the switch on the brake pedal, its fastening, its positioning, the wiring and the engine management control unit. Repair/replace the part that is not working
11	CHECK THAT THE CLUTCH IS NOT DRAGGING	All OK	Problems met	Operation
	Check that the clutch is not dragging following See Test 2127K CLUTCH DRIVE CHECK	End of diagnosis	The clutch drags	Replace the clutch mechanism Op. 1810A28 Continue to Step 12
12	AFTER OPERATION ON CLUTCH KIT	All OK	Problems met	Operation
	Check that the fault is no longer present	End of diagnosis	The fault persists	Contact Technical Service for further information on the problem

With the engine warm.

0	CONTROL UNIT ERRORS CHECK	All OK	Problems met	Operation
		Results of the tests
	Check that there are no control unit errors. In particular: Clutch sensor error Lever switch error (any one of the 4 switches or the ECO/Normal switch) Microprocessor 2 error Even gear engagement error Odd gear engagement error Clutch solenoid current error Electromagnetic brake error (Selection solenoid) Control unit earth error Load relay error	Continue to Step 5	Presence of one or more of the errors included in the list	Continue to Step 1
1	CHECKS ON FAULTS DETECTED	All OK	Problems met	Operation
	Check the faults according to the See Test 2127I What to do for error in Selespeed control unit	Continue to Step 3	Faulty connections (Clutch sensor, Odd or even gear engagement, Clutch solenoid current error, Electromagnetic brake error, Control unit earth error and/or Load relay error)	Repair/replace the wiring Continue to Step 3
			The state displayed is not correct (Lever switch error - Lever check)	Check the connections, continuity of the wiring and the gear lever Continue to Step 3
			There is no change of state and/or the word 'ECO is not displayed (Lever switch error - Check ECO button)	Check the button and wiring Continue to Step 3
			Replace the Robotized Gearbox control unit (Microprocessor error 2)	Continue to Step 3
			The active diagnosis is not successful and there are no faults detected at the wiring (Odd or even gear engagement, Clutch solenoid valve current error)	Continue to Step 2
2	AFTER THE SOLENOID VALVE ACTIVE DIAGNOSIS	All OK	Problems met	Operation
	If this step has been reached for the active diagnosis of the clutch solenoid valve, replace it Op. 2127C56and check the operation by carrying out a C.M. If this step has been reached for the active diagnosis of the engagement solenoid valve, replace it Op. 2127C52and check the operation	Continue to Step 3
3	SOLENOID VALVE REPLACEMENT	All OK	Problems met	Operation
	If there is an electromagnetic brake error and no faults are detected at the connections/wiring, replace Op. 2127C54and check brake is operating correctly.	Continue to Step 4
4	AFTER THE CHECKS ON THE FAULTS DETECTED	All OK	Problems met	Operation
	Check that the fault is no longer present	End of diagnosis	The fault persists	Continue to Step 5
5	GEAR LEVER CHECK	All OK	Problems met	Operation
	Check that the gear lever is working properly following See Test 2127L GEAR LEVER CHECK	Continue to Step 6	The lever states displayed are not correct	Check the wiring and the switches/gear lever Repair/replace the part that is not working
		Continue to Step 6	There is no change of state and/or the 'AUTO button is not displayed	Check the switch and the wiring. Repair/replace the part that is not working
6	OIL LEVEL CHECK	All OK	Problems met	Operation
	Check the oil level as described in See Test 2127B OIL LEVEL CHECK	Continue to Step 8	Level below the Max reference	Top up the oil level Continue to Step 7
		Continue to Step 8	Level above the Max reference	Reduce to the Max level Continue to Step 8
7	CHECK FOR OIL LEAKS	All OK	Problems met	Operation
	Check that there are no oil leaks as described in See Test 2127C CHECK FOR OIL LEAKS	Continue to Step 8	Oil leaks detected in the clutch assembly	Carry out the clutch bleeding procedure in active diagnosis using the Examiner Continue to Step 8
		Continue to Step 8	Oil leaks detected in other parts of the hydraulic unit	Replace/repair the parts concerned, and top up the oil level Continue to Step 7
8	OIL PRESSURE CHECK	All OK	Problems met	Operation
	Check the amount of oil present and continue with the topping up Check the oil pressure as described in See Test 2127D OIL PRESSURE CHECK	Continue to Step 10	Pressure < 40 bar	Continue to Step 9
9	ELECTRIC PUMP OPERATION CHECK	All OK	Problems met	Operation
	Check the correct operation of the pump as described in Test 2127E	Continue to Step 10	Voltage below 11 V	Check the battery Continue to Step 9
		Continue to Step 10	It is not possible to make gear changes from the lever	Activate the 'clutch bleed' service from the Examiner Plus or Smart to activate the pump Continue to Step 10
10	CHECK THAT THE CLUTCH IS NOT DRAGGING	All OK	Problems met	Operation
	Check that the clutch is not dragging following See Test 2127K CLUTCH DRIVE CHECK	Continue to Step 11	The clutch drags	Replace the clutch mechanism Op. 1810A28
11	CHECK ON BRAKE PEDAL SWITCH	All OK	Problems met	Operation
	Check that the brake pedal switch is working properly as described in See Test 2127F CHECK ON BRAKE PEDAL SWITCH	End of diagnosis	The brake pedal switch is not working properly	Check the switch on the brake pedal, its fastening, its positioning, the wiring and the engine management control unit. Repair/replace the part that is not working Move on to step 12
12	AFTER THE BRAKE PEDAL SWITCH CHECK	All OK	Problems met	Operation
	Check that the fault is no longer present	End of diagnosis	The fault persists	Contact Technical Service for further information on the problem

Reverse gear cannot be engaged sometimes

0	CONTROL UNIT ERRORS CHECK	All OK	Problems met	Operation
		Results of the tests
	Check that there are no control unit errors. In particular: Lever switch error (any one of the 4 switches or the ECO/Normal switch) Electromagnetic brake error (Selection solenoid)	Continue to Step 4	Presence of one or more of the errors included in the list	Continue to Step 1
1	CHECKS ON FAULTS DETECTED	All OK	Problems met	Operation
	Check the faults according to the See Test 2127I What to do for error in Selespeed control unit	Continue to Step 2	Connections faulty (Electromagnetic brake error)	Repair/replace the wiring Continue to Step 2
			The state displayed is not correct (Lever switch error - Lever check)	Check the connections, continuity of the wiring and the gear lever Continue to Step 2
			There is no change of state and/or the word 'ECO is not displayed (Lever switch error - ECO button check)	Check the button and wiring Continue to Step 2
2	SOLENOID VALVE REPLACEMENT	All OK	Problems met	Operation
	If there is an electromagnetic brake error and no faults are detected at the connections/wiring, replace Op. 2127C54and check brake operation	Continue to Step 3
3	AFTER THE CHECKS ON THE FAULTS DETECTED	All OK	Problems met	Operation
	Check that the fault is no longer present	End of diagnosis	The fault persists	Continue to Step 4
4	GEAR LEVER CHECK	All OK	Problems met	Operation
	Check that the gear lever is working properly following See Test 2127L GEAR LEVER CHECK	Continue to Step 5	The lever states displayed are not correct	Check the wiring and the switches/gear lever Repair/replace the part that is not working
		Continue to Step 5	There is no change of state and/or the 'AUTO button is not displayed	Check the switch and the wiring. Repair/replace the part that is not working
5	OIL LEVEL CHECK	All OK	Problems met	Operation
	Check the oil level as described in See Test 2127B OIL LEVEL CHECK	Continue to Step 7	Level below the Max reference	Top up the oil level Continue to Step 6
		Continue to Step 7	Level above the Max reference	Reduce to the Max level Continue to Step 7
6	CHECK FOR OIL LEAKS	All OK	Problems met	Operation
	Check that there are no oil leaks as described in See Test 2127C CHECK FOR OIL LEAKS	Continue to Step 7	Oil leaks detected in the clutch assembly	Carry out the clutch bleeding procedure in active diagnosis using the Examiner Continue to Step 7
		Continue to Step 7	Oil leaks detected in other parts of the hydraulic unit	Replace/repair the parts concerned, and top up the oil level Continue to Step 6
7	OIL PRESSURE CHECK	All OK	Problems met	Operation
	Check the amount of oil present and continue with the topping up Check the oil pressure as described in See Test 2127D OIL PRESSURE CHECK	Continue to Step 9	Pressure < 40 bar	Continue to Step 8
8	ELECTRIC PUMP OPERATION CHECK	All OK	Problems met	Operation
	Check the correct operation of the pump as described in See Test 2127E ELECTRIC PUMP OPERATION CHECK	Continue to Step 9	Voltage below 11 V	Check the battery Continue to Step 8
		Continue to Step 9	It is not possible to make gear changes from the lever	Activate the 'clutch bleed' service from the Examiner Plus or Smart to activate the pump Continue to Step 9
10	CHECK THAT THE CLUTCH IS NOT DRAGGING	All OK	Problems met	Operation
	Check that the clutch is not dragging following See Test 2127K CLUTCH DRIVE CHECK	End of diagnosis	The clutch drags	Replace the clutch mechanism Op. 1810A28 Continue to Step 11
11	AFTER OPERATION ON CLUTCH KIT	All OK	Problems met	Operation
	Check that the fault is no longer present	End of diagnosis	The fault persists	Contact Technical Service for further information on the problem

Whilst driving, nothing above second is engaged irrespective of the mode (manual/automatic).

0	CONTROL UNIT ERRORS CHECK	All OK	Problems met	Operation
		Results of the tests
	Check that there are no control unit errors. In particular: Engagement sensor error Selection sensor error Engine speed error Clutch disc speed error Vehicle speed error No accelerator pedal information error Microprocessor 2 error CAN error	Continue to Step 5	Presence of one or more of the errors included in the list	Continue to Step 1
1	CHECKS ON FAULTS DETECTED	All OK	Problems met	Operation
	Check the faults described in Test 2127I	Continue to Step 2	Faulty connections (Engagement sensor, Selection sensor, Clutch disc speed, Vehicle speed, No acelerator pedal information and/or CAN network errors	Repair/replace the wiring Continue to Step 2
			Faulty connection (Engine speed)	Repair/replace the part concerned Continue to Step 2
			Replace the Robotized Gearbox control unit (Microprocessor 2 error)	Continue to Step 2
			One of the control units does not dialogue (Errors on CAN network)	Repair/replace the control unit concerned Continue to Step 2
2	SENSOR REPLACEMENT	All OK	Problems met	Operation
	If there is a gear engagement sensor error and no faults are detected at the connections/wiring, replace it Op. 2127E42and check that the position reading is correct by carrying out a series of C.M. If there is a gear selector sensor error and no faults are detected at the connections/wiring, replace it Op. 2127E40and check that the position reading is correct by carrying out a series of C.M. If there is a clutch disc speed error and no faults are detected at the connections/wiring, replace it Op. 2127E52and check that the position reading is correct by carrying out a series of C.M. It is advisable to mark the two potentiometers in order to be able to recognize them once they have been removed	Continue to Step 3
3	AFTER THE CHECKS ON THE FAULTS DETECTED	All OK	Problems met	Operation
	Check that the fault is no longer present	End of diagnosis	The fault persists	Continue to Step 4
4	OIL LEVEL CHECK	All OK	Problems met	Operation
	Check the oil level as described in See Test 2127B OIL LEVEL CHECK	End of diagnosis	Level below the Max reference	Top up the oil level Continue to Step 5
		End of diagnosis	Level above the Max reference	Reduce to the Max level Continue to Step 6
5	CHECK FOR OIL LEAKS	All OK	Problems met	Operation
	Check that there are no oil leaks as described in See Test 2127C CHECK FOR OIL LEAKS	Continue to Step 6	Oil leaks detected	Replace/repair the parts concerned, and top up the oil level Continue to Step 5
6	THE FAULT PERSISTS	All OK	Problems met	Operation
	Contact Technical Service for further information on the problem	End of diagnosis

It skips a gear/the requested gear is not engaged.

If no errors are detected, the problem could be due to incorrect use of the vehicle by the customer.

0	CONTROL UNIT ERRORS CHECK	All OK	Problems met	Operation
		Results of the tests
	Check that there are no control unit errors. In particular: Engagement sensor error Selection sensor error	Continue to Step 4	Presence of one or more of the errors included in the list	Continue to Step 1
1	CHECKS ON FAULTS DETECTED	All OK	Problems met	Operation
	Check the faults described in Test 2127I	Continue to Step 2	Faulty connections	Repair/replace the wiring Continue to Step 2
2	SENSOR REPLACEMENT	All OK	Problems met	Operation
	If there is a gear engagement sensor error and no faults are detected at the connections/wiring, replace it Op. 2127E42and check that the position reading is correct by carrying out a series of C.M. If there is a gear selector sensor error and no faults are detected at the connections/wiring, replace it Op. 2127E40and check that the position reading is correct by carrying out a series of C.M. It is advisable to mark the two potentiometers in order to be able to recognize them once they have been removed	Continue to Step 3
3	AFTER THE CHECKS ON THE FAULTS DETECTED	All OK	Problems met	Operation
	Check that the fault is no longer present	End of diagnosis	The fault persists	Continue to Step 4
4	OIL LEVEL CHECK	All OK	Problems met	Operation
	Check the oil level as described in See Test 2127B OIL LEVEL CHECK	Continue to Step 6	Level below the Max reference	Top up the oil level Continue to Step 5
		Continue to Step 6	Level above the Max reference	Reduce to the Max level Continue to Step 6
5	CHECK FOR OIL LEAKS	All OK	Problems met	Operation
	Check that there are no oil leaks as described in See Test 2127C CHECK FOR OIL LEAKS	Continue to Step 6	Oil leaks detected	Replace/repair the parts concerned, and top up the oil level Continue to Step 5
6	PARAMETERS CHECK USING THE EXAMINER	All OK	Problems met	Operation
	Check that the failed engagements counters in the parameters environment (failed engagement counters for: neutral, 1st-5th and reverse) are all at zero.	Continue to Step 9	These counters are at a value different from zero	Make a note of/print out the screen showing the failed engagement counters Continue to Step 7
7	SELF CALIBRATION	All OK	Problems met	Operation
	With the Examiner Plus or Smart, in active diagnosis start end-of-line/Service self-calibration	Continue to Step 8	The self-calibration is not successful	Continue according to the instructions for the diagnostic equipment
8	ROAD TEST	All OK	Problems met	Operation
	Carry out a road test, making sure to make as many gear changes as possible with all the available gears (under different engine speed and load conditions). Check the failed engagement counters in the parameters environment (failed engagement counters in: neutral, 1st-5th and Reverse). Print out/make a note of the new counter values. Compare the new values of the parameters with those noted down previously, checking that there is not a signficant increase for one or several counters	End of diagnosis	There is a significant increase for one or more counters	Replace the gearbox Op. 2110A11
9	THE FAULT PERSISTS	All OK	Problems met	Operation
	The fault may be caused by false contacts on the gear lever: check the state of the connections and wiring for the lever. At all events, contact Technical Service for further information on the problem.	End of diagnosis

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