AMT System Troubleshooting

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Failure analysis about DTC of AMT system
Ordinal DTC Definition Analysis Fault phenomenon Solution

1.Clutch speed sensor 1.Replace clutch

open or short circuit 1. Unable to shift gear position sensor
Friction Plate 2.Malfunction of operator- 2. Only can shift on the 1st 2.Replace operating
1 P0715
angular velocity clutch gear, the 2nd gear and the mechanism of clutch
3.Friction Plate of clutch reverse gear. 3.Replace friction
worn out and skip plate or clutch assy.
1.Odometer sensor open
or short circuit
2. Malfunction of 1. Replace odometer
instrument. If instrument 1. Only can shift on the 1st sensor.
was failure, the signal of gear, the 2nd gear and the 2.Replace instrument
2 P0720 Car velocity
car velocity can’t be reverse gear. 3.Remove and
transmitted. 2. Out-of-gear spontaneously. reinstall odometer
3. Odometer sensor didn’t sensor
gear well with the
Differential.
1.Engine speed sensor
1Replace engine
open or short circuit Out to natural position
speed sensor
Engine angular 2.Malfunction of cable spontaneously 1.8 seconds
3 P0725 2.Check whether the
velocity which connect engine later stepping on the brake
cable connection is
speed sensor to ECU or pedal.
in good condition.
connect ECU to TCU
1. Engine was unable to
restart or gear was unable to
Replace the failure
Stroke Sensor Malfunction of position shift with engine stalling.
4 P1741/P1742 solenoid valve-
clutch/selection sensor-selection. 2. Only can shift on the 1st
selection
gear, the 2nd gear and the
reverse gear.

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Ordinal DTC Definition Analysis Fault Phenomenon Solution

1.Unable to shift gear

1. Clutch position sensor 2.No power output on the 1st gear ,
open or short, or with the 2nd gear or the reverse gear,
Replace clutch position
5 P1743 Clutch Position sensor water inflow. when the speed of the car below
sensor or cable-selespeed
2.Cable-selespeed open or 4Km/h, the engine speed below
short 1800rpm, and throttle opening below
45%.

1. Malfunction of
Hydraulic Circuit Pressure 1. Fuel pump work continually or Replace Hydraulic Circuit
Hydraulic Circuit Pressure
6 P1744 Sensor. didn’t work at all. pressure sensor or cable-
Sensor
2. Cable-selespeed open or 2. Unable to shift gear in AUTO. selespeed
short.

Shift on 1st gear spontaneously

Switch lever was unable to when stepping on brake pedal in
7 P1772 Switch Lever stuck (any) Replace Selespeed assy
work normally. AUTO, unable to shift on the reverse
gear.

8 P1752 Driver Relay Pump Driver relay burn-out Unable to shift gear at all. Replace driver relay

1.Malfunction of cable
1. Only can shift on the 1st gear,
No information about connect accelerator pedal
9 P1770 the 2nd gear and the reverse Replace cable or ECU.
accelerator pedal to ECU
gear.
2.Malfunction of ECU

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Ordinal DTC Definition Analysis Fault Phenomenon Solution

1. Low pressure of
hydraulic circuit as
leakage of hydraulic group. 1. Only can shift on the 1st gear,
1. Replace the leak parts.
High leakage hydraulic 2. Fuel pump didn’t work the 2nd gear and the reverse
10 P1771 2. Replace fuel pump relay.
group as fuel pump relay burn- gear.
3. Replace fuel pump.
out, 2. Unable to shift gear at all.
3.Malfunction of fuel
pump
1. Fuel pump didn’t work
as fuel pump relay burn-
Insufficient 1. Replace fuel pump relay.
11 P1773 out, Unable to shift gear at all.
Capacity/Pressure 2. Replace fuel pump
2. Malfunction of fuel
pump

1. Unable to shift gear as clutch

1. Malfunction of clutch 1. Replace clutch position
didn’t work normally.
Error on friction under- position sensor sensor or cable-selespeed
12 P1810 2. Repair as the procedure of P1743,
system 2. Friction Plate of clutch 2. Replace friction plate or
if the DTC P1743 and P1810
worn out and skip clutch assy.
occurred together.

Automatic switch lever 1. AUTO and Manual Mode were

Repair automatic switch
was unable to self-return unable to switch each other.
13 P0790 Switch lever self-stuck lever or replace return
as the return spring didn’t 2. Unable to shift on the reverse
spring.
work normally. gear.

1. Replace friction plate or

1. Friction Plate of clutch 1. Unable to shift gear as clutch clutch assy.
Error on speed gear case worn out and skip didn’t work normally. 2. Disassemble and
14 P1818
under-system 2. Internal mechanical 2. Lack of one gear position when assemble transmission to
failure of transmission. driving. replace the failure
mechanical parts.

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¾ Case 1：Only can shift on the 1st gear, the 2nd gear and the reverse gear， with
DTC P0715；
Measures：
Step 1:
Check whether clutch speed sensor have bump marks.
1) The input shaft should be replaced, if clutch speed sensor has bump marks and the
input shaft of transmission is loosening with axial and radial runout.

Check whether
Check whether this
this surface have
shaft is loosening
bump marks

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2） Check transmission oil, if found no input shaft runout, but clutch speed sensor
have bump marks: If there were scrap iron and impurities in the oil, replace
transmission oil.

Check whether Check whether

the oil outflow the oil outflow is
have scrap iron going bad and
and impurities have odors

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3）DTC P1818 occurred with P0715 together, both clutch speed sensor and input
shaft of transmission are normal: Disassemble transmission and check whether the
synchronizers are normal, If necessary, replace the failure parts.
All above is OK, go to next step.

Check
whether the
synchronizers
are normal

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Step 2:
Check whether clutch was matched with TCU version: The version CAA04QHO must be
equipped with clutch supplied by “1CU”, the version CAA05QM5 must be equipped
with clutch supplied by “1CW”.
Otherwise, vehicle will be caused some problems, such as, move automatically, didn’t
run when stepping on the accelerate pedal, hard shift etc.
All above is OK, go to next step.

Check TCU version

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Step 3:
Check clutch position reference data with X-431: If the value deviate from the standard
value much, means clutch disc was wearing seriously and should be replaced.
END line/service AUTO-set and friction AUTO-set enabling should be preformed after
replacing.
All above is OK, go to next step.

The standard value

of clutch position
reference can be
found when
Checking the actual If the value deviate
reference. from the standard
value much, check
the clutch.

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Step 4:
Check the operating mechanism of clutch:
1)Replace clutch disengaging bearing if it is wearing;
2)Replace the spline of shaft assy-clutch release if it is wearing;
3)Replace clutch disengaging push rod if it is wearing.
All above is OK, go to next step.

检查离合器分离轴承
Check the spine of
有无异常磨损，分离
shaft assy-clutch
杆有无工作异常
release

Check clutch
disengaging bearing

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Step 5:
Check cable of selespeed:
1)Malfunction of clutch position sensor: If there were water inflow into clutch
position sensor, it will be failure with DTC P1810 and P0715 exist.
Clean and dry the water, then replace a new clutch position sensor.
END line/service AUTO-set and friction AUTO-set enabling should be preformed
after replacing.
2) Other failures: Damage of cable or cable open to the ground.

Check whether connector

of clutch position sensor
was normal.

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 Attachment 1:
END line/service AUTO-set and friction AUTO-set enabling .

① ②

END line/service
AUTO-set and Both END line/service
friction AUTO-set AUTO-set and friction
enabling AUTO-set enabling
should be preformed
for three times,
ignition switch should
turn off for ten second
every AUTO-set
course.

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¾Case 2：Shift down one or more gear automatically while normal driving, with
DTC P1818.
Measures：
Step 1:
Check transmission:
1) Shift down one gear or gear free automatically: Disassemble transmission and
check whether synchronizers are failure, replace the failure parts if necessary.

Check whether
synchronizers and
gears were normal.

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2）Gear free automatically: Disassemble transmission and check whether shifting
forks are failure，replace the failure parts if necessary.

Check whether
shifting forks were
normal.

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3）Wrong signal of vehicle speed: Vehicle speed showed on X-431 was zero while
driving, gear shift down to the 1ST gear or gear free automatically.

a. Malfunction of odometer sensor: Replace it.

检查车速传感器线束
插头有无松动、插接
Check the connector
of不良；线束有无破
odometer sensor
损，开路或短路

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b. Malfunction of instrument cluster: Replace instrument cluster or cable.
The signal of car velocity will be unable to transmit if instrument was failure, as
instrument receives the signal from odometer sensor, then transmit it to TCU
and ECU .

4）Odometer sensor didn’t gear well with the Differential: Remove and reinstall
odometer sensor.
All above is OK, go to next step.

Remove odometer
拆解车速传感器，检
sensor and check
查车速传感器表面有
whether the sensor
无质损或磕碰痕
was normal.

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 Step2:
Check driver door contact switch : Replace the switch if it was failure,.
All above was OK, go to next step.

Turn the lamp in position of

lighting when doors were open,
then press driver door contact
switch. If the lamp still light,
replace the switch.

Step3:
Check engine problems with X-431: Replace knock sensor if it was short to ground.

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¾Case 3：Leakage of selespeed hydraulic oil.
Measures:
Step 1：
Check whether the air hole of tank lid was in good ventilation:
The air hole would be obstructed if the O-ring of oil tank lid didn’t be removed when
installing selespeed on the vehicle, which could cause crack of oil tank as
abnormal pressure in it.

The O-ring of oil tank lid.

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Step2：
Replace operator-clutch if it leakage.
END line/service AUTO-set and friction AUTO-set enabling should be preformed
after replacing.

Leakage because of
eccentric wear of cable
of operator-clutch

Leakage because of
damaged of internal oil
seal of operator-clutch

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Step 3：
Leakage of gear shifting shaft:

Leakage of piston of gear Leakage of solenoid Leakage of gear shifting

shifting shaft, replace the valves, replace the failure shaft, replace selespeed
piston and washer. part. kit assy.

END line/service AUTO-set and friction AUTO-set enabling should be preformed

after replacing.

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 ¾Case 4：Lack of one gear or unable to shift gear at all, with DTC P1810 or
P1743.
Measures：
Step 1：
Regarding DTC P1743: Check clutch position sensor, if there were water in flowed,
clean and dry the water, then replace a new sensor.
END line/service AUTO-set and friction AUTO-set enabling should be preformed
after replacing.

Clutch position sensor is located

under transmission.

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 Step 2：
Regarding DTC P1810: Check clutch position reference data with X-431, if the value
deviate from the standard value much, means clutch disc was wearing
seriously and should be replaced.
END line/service AUTO-set and friction AUTO-set enabling should be preformed
after replacing.

The standard
value of clutch
position reference
can be found If the value
when Checking deviate from the
the actual standard value
reference. much, check the
clutch.

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¾Case 5：The warning lamp of transmission light occasionally when driving, then
gear was unable to shift and engine was unable to restart after stopping until one
minute later, with DTC P1773 or P1744 usually.
Measures:
Step 1:
Check whether cable of selespeed was normal.
All above was OK, go to next step.

检查速选器线束有无破损，线束有
Confirm that the cable is normal, no
无短路、断路，线束插头有无松动、
short or open circuit, the connector
插接不良normal and connect well.
pins are

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Step 2:
If DTC P1755 exist, check whether drive relay starting was connect well. Replace
the relay if it was burn out.
All above was OK, go to next step.

The relay was located under Check whether the

the dashboard left side. relay was normal.

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Step 3:
Check the hydraulic circuit pressure when failure, comparing with normal
pressure , which between 39bar to 52bar usually. If the pressure wasn’t
covered with normal value, replace fuel pump.
END line/service AUTO-set and friction AUTO-set enabling should be preformed
after replacing.

The pressure should be

covered with normal
value.

Fuel pump.
Check hydraulic circuit
pressure.

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¾Case 6：Engine stop suddenly when normal driving, then engine is unable to
restart and gear is unable to shift.
Measures：
Step 1:
Power-lack of battery: Check whether the voltage of battery was normal.
All above was OK, go to next step.

Check the voltage

of battery.

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Step 2:
Check clutch position reference data with X-431: If the value deviate from the
standard value much, means clutch disc was wearing seriously and should
be replaced.
END line/service AUTO-set and friction AUTO-set enabling should be preformed
after replacing.
All above was OK, go to next step.

The standard value

of clutch position
reference can be
found when
Checking the actual
reference.

If the value deviate

from the standard
value much, check
the clutch.

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Step 3:
If DTC P1755 occurred, check whether drive relay starting was connect well. Replace
the relay if it was burn out.
All above was OK, go to next step.

The relay was located under Check whether the

the dashboard left side. relay was normal.

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 Step 4:
Check hydraulic circuit pressure: If the pressure wasn’t covered with normal
value, which is between 39bar to 52bar usually, replace fuel pump.
END line/service AUTO-set and friction AUTO-set enabling should be
preformed after replacing.

The pressure should

be covered with normal
value.

Fuel pump.

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¾Case 7：The warning lamp of transmission light when up-shift to the 5th gear,
unable to shift to the reverse gear.
Measures：
Step 1：
Check whether cable of selespeed was normal. If there were DTC exist, repair as
the description of DTC.
All above was OK, go to next step.

检查速选器线束有无破损，线束有无
Confirm that the cable is normal, no
短路、断路，线束插头有无松动、插
short or open circuit, the connector
接不良
pins are normal and connect well.

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 Step 2：
Perform action-text about the 5-R gears selection solenoid valve with X-431,
replace the solenoid valve if the action-text was failure.

END line/service AUTO-set and friction AUTO-set enabling should be preformed

after replacing.

All above was OK, go to next step.

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 Step 3：
Disassemble transmission and check whether the internal mechanism parts
were normal.

Check whether
synchronizers and
gears were normal.

Check whether the

reverse gear shifting
fork was normal.

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 ¾Case 8：Unable to up-shift when driving, starter of engine fail to work when
start the engine.
Measures ：
Step 1:
Check whether cable of selespeed was normal. If there were DTC occurred, repair
as the description of DTC.
All above was OK, go to next step.

检查速选器线束有无破损，线束有
Confirm that the cable is normal, no
无短路、断路，线束插头有无松动、
short or open circuit, the connector
插接不良
pins are normal and connect well.

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Step 2:
If DTC P1755 exist, check whether drive relay starting was connect well. Replace the
relay if it was burn out.
All above was OK, go to next step.

The relay was located under Check whether the

the left side dashboard. relay was normal.

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 Step 3:
Check hydraulic circuit pressure: If the pressure wasn’t covered with normal
value, which is between 39bar to 52bar usually, replace fuel pump.
END line/service AUTO-set and friction AUTO-set enabling should be preformed
after replacing.

The pressure should be

covered with normal
value.

Fuel pump.

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 ¾Case 9: Lack of one up-shift gear when driving, which was normal when
shifting down and parking, sometimes with DTC P1810.

Measures :
Step 1:
Check clutch position reference data with X-431: If the value deviate from the
standard value much, means clutch disc was wearing seriously and should be
replaced.
END line/service AUTO-set and friction AUTO-set enabling should be preformed
after replacing.

Step 2:
Disassemble transmission and check whether synchronizers and gears were
normal, replace the failure parts if necessary.

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¾Case 10:
1、Run automatically without pressing accelerator pedal when shift on the 1st gear.
2、Vibrate heavily while starting, then all is normal.
Measures ：
Step 1:
Perform END line/service AUTO-set and friction AUTO-set enabling, ignition switch
should be turned off for ten second every AUTO-set course.
NOTE: If ignition switch didn’t turn off for ten seconds, the AUTO-set course will
failure.
All above was OK, go to next step.

Step 2:
Check clutch position reference data with X-431: If the value deviate from the
standard value much, means clutch disc was wearing seriously and should be
replaced.
END line/service AUTO-set and friction AUTO-set enabling should be preformed
after replacing.

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 All above was OK, go to next step.

Step 3:
Replace clutch position sensor.
END line/service AUTO-set and friction AUTO-set enabling should be preformed
after replacing.
All above was OK, go to next step.

Step 4:
Check whether clutch was matched with TCU version: The version CAA04QHO
must be equipped with clutch supplied by “1CU”, the version CAA05QM5
must be equipped with clutch supplied by “1CW”.

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¾Case 11：The warning lamp of transmission light when driving, then gear was
unable to shift.
Measures ：
Wrong signal of clutch speed sensor: Remove the sensor, then reinstall it
adding a 0.2mm thick washer, up-date TCU to the latest version(CAA05QN0).
END line/service AUTO-set and friction AUTO-set enabling should be preformed
after the repair work.

Add a 0.2mm thick

washer here.

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 Thanks

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