1,2 TDI clutch/ gearbox problems

I removed that Gear actuator, and indeed the top arm have plenty of play...
It's weird that its end by showing a rod too short while doing basic settings, but we are all here to learn something ;-)
Will reinstall the first one I've got, or I need a new gear actuator :-(
 
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Hi there, the car works now!
So few input for who's looking to fix their 3Ls:
-RTFM! 12 was for me bad gear actuator and/or bad adjustment (also RTFM! 9) and/or remaining air in the pipes.
-When you indeed change the gear actuator etc, the first basic settings will naturally fail because some air remain in the pipe, but as the gear (and clutch) actuator will make quite few moves during basic settings, the next try will be OK on this side (check the green oil level at that point, unplug the pump and open the pressure accumulator in order to do that).
-After installing a gear actuator, leave gear selector shaft on Neutral, and switch on with the gear lever on 'N'. It make no difference on calibration (visible on Block 15), it's just that the Transmission Computer will not try to change too many gears before you do the basic settings.
-Errors 00844 (F257) & 00845 (F258) did not matter, I just delete them prior to basic settings.
-Be sure to have good voltage in your battery, slow response from calculators happen with too low voltage.
I notice also a poor response in the 2 first minute after reconnecting the battery.
-Prior to all that, using VCDS, the letters about the Transmission calculator was corrupted, with "no communication" errors from the engine calculator (error 01312/01314) or the ABS calculator 01316 (errors also stored in the Instrument calculator).
The only solution was to swap the Transmission calculator, also check relay 109 and 424 and fuse 31.
-On my 100K/160.000kms gear box, the neutral/natural position was not on front of the first gear (that's why the rod was looking too short, and was then OK by less than 1mm with another gear actuator). So of course when you adjust with no tension on the vertical rod, the basic settings will then fail (again, as not on front of first gear). But your adjustment will be accepted if reverse light switch on at test 5 of the 28, what ever was the tension on vertical rod during adjustment in this case. I manage to find the right adjustment by engaging manually the Reverse (with no pressure in the system by opening the accumulator) and then adjust with the top arm at the highest position (without using force, just push gently the vertical rod to the highest position and tight the 13mm nut). I then reconnect the pump and do the basic settings ignoring the "Adjust!" invitation.
- Not all Lupo's Transmission Computer have the Creep point adaptation, mine shows "Group 25 unavailable", in current car, as it was in the previous Lupo. I got confirmation the early models might not have this function. Audi A2 appears a year after so should have it. Creep point adaptation is somehow included here to the step 1, where you set the correct voltage value for the clutch travel sender -G162-.
And better be conservative with a value as low as 1.7V than over 2V. Low value open the clutch earlier, so if you don't have too much slip, it will manage your gearbox better.
- Last, so far, when you see the first gear constantly been ejected (the gear actuator will automatically try to put it back, and so on), and no possibility to select reverse, but have no error on VCDS, and all gears passing OK with engine off; you can start to suspect your gearbox and/or the clutch actuator. It happen to me with a 20.000km FLE from 2004! At least the gear actuator or the electric wiring was not the cause. But I need to do more kilometers to be 100% sure, to confirm this problem is gone. Will also post here once this gearbox will be opened and inspected.
Voila; and good luck!
 
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1200TDI said:
- Not all Lupo's Transmission Computer have the Creep point adaptation, mine shows "Group 25 unavailable", in current car, as it was in the previous Lupo. I got confirmation the early models might not have this function. Audi A2 appears a year after so should have it.
Click to expand...

All 1.2Tdi PD diesels have creep point adaptation. We have a very early Lupo 3L and it certainly has.

RAB
 
RAB said:
All 1.2Tdi PD diesels have creep point adaptation. We have a very early Lupo 3L and it certainly has.

RAB
Click to expand...

Great, but does it have "Siemens Prototyp" stickers on the Transmission Computer? Mine does!
What a minute, isn't weird to say it must be this way for all because our own one does?
 
RAB said:
Your claim is based on one example with a prototype part!

RAB
Click to expand...

Not at all, you assume that. I was asking competent people that bring me that information, seeing this time to time. I don't know why it's like that, maybe VW had a batch of 100, 500, 1000 Transmission Computer prototypes? Go figure. However, with Google search, people facing this "problem" -Group 25 not available- can now understand it is not one (if everything else is OK of course).
 
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A 1.2Tdi PD without creep adaptation would be and is undriveable. My wife's car, for some reason, at one point completely 'lost' its' creep adaptation. You could start the car but as soon as you took your foot off the brake, it stalled. It was restored by a basic setting.

RAB
 
My 1.2TDi is running pretty great at the moment but I seem to get only 3 changes before the pump starts running. The pump and the gear actuator have been overhauled less than a year ago, the clutch slave cylinder is only a few months old and the accumulator is under a year old. Should I just be content with the situation? It does pump the pressure up quite fast so the pump is working nicely. Do(es) the relay(s) that control the hydraulic system need changing? The German guy who did the system overhaul recommended renewing the relay.
 
It won't be the relay (if he means a relay); that is something that will either work or not. The actuator on my A2 currently only gives three with an accumulator that gives 6 or 7 on the Lupo. It'll be a worn actuator or possibly the pressure sensor on the hydraulic unit.

RAB
 
Even if I don't change gears and the car just sits with the ignition on, it'll pump more pressure quite often. Oh well, can't be bothered to spend much more on this... i guess this will have to do.
 
Hi there,

Quick introduction on my case: my Audi A2 1.2TDI started to fail on gear changes, so I tried to do basic settings, which failed with RTFM 12. Did inspection on gear actuator and there some loose on top arm of operating rod and on bottom finger. I removed gear actuator, and saw, that "cup" ( 6E0142089 ) is too worn. Replaced it, repaired bottom gear selector finger ( had to disassemble whole actuator bottom part ). Put all back together, but now I have
error 01605 - Potentiometer 2 for Gear Recognition (G240)
16-10 - Signal Outside Specifications - Intermittent
Probably aligned potentiometer incorrectly. I've aligned both potentiometer pin and finger axis in the middle of their routes. On visual inspection during basic settings I see that actuator does not moves gate selector in the upper position. In the middle and bottom positions gears are activated.
Maybe you can tell me how to align potentiometer of gear recognition?
Thanks in advance
 
Well that potentiometer was not faulting before dismantling.

This is whole part I've dismantled.

Screenshot_1.png

There is bottom gear selector finger with potentiometer. It has some loose one the axis, I've repaired it, now it's set tight as it should.

Screenshot_2.png

I had remove potentiometer to realign rocker piston, probably as I said I've set it wrong, because I couldnt find any information how to connect it.
 
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In addition:

Worn gear selector finger cup also could be the reason for RTFM 12 during basic settings. If rubber bellow (6N0711167B) is damaged and there is insufficient grease, inner space gets corrosion. During gear shifts, there will be too much space to play. There is two ways to deal with it: replace washer (085142473) from 18.6mm to ~20mm or replace whole part (6E0142089).

1.jpg

2.jpg
 
The shaft has a spline and there is only one correct way to put it back together. The correct instructions tell you not to take it apart to change the gasket but to keep it all together with a rubber band and 5mm nuts. You'll have to use trial and error.

RAB
 
I have a spare actuator which is correctly set up. I will remove the pot and place a photo here later that should enable you to assemble your actuator correctly.

RAB
 
Thanks RAB, that would help me a lot.

Yes, I have read instructions on gasket removal instructions to not separate that shaft from potentiometer, but there was too much play so I had to do some repairs there :)

Thanks again RAB.
 
Hi there,

Update on my situation: re-adjusted Potentiometer 2 for Gear Recognition (G240), but still got same error. But then I noticed that G240 is upper potentiometer of gate selection recognition, not gear recognition :D Well, checked the wiring, and after refitting all connectors, error where gone. But still basic settings fails with 12 error. Checked gear actuator during basic settings process and I saw, that some gears could not be activated ( R, 3rd and 4th ). Bit confused with that, as selector finger is able to reach gear activation points. No errors on solenoid valves. When tried to release the pressure from the system and did all gear activation's by hand. Maybe is there way to check those solenoid valves not only by VCDS?

Thanks
 
Make sure that the plugs connecting to the unit are connected correctly. They should have been marked before dis-assembly. The solenoids can be checked with a volt meter by checking the resistance. Should be a few ohms. If a lot larger, suspect the solenoid. Alternatively apply 12vdc directly; the solenoids should have an audible click. Also check the connection between the actuator loom and the connection to the car loom (under the hydraulic station). It could be contaminated with oil, especially if you had a leak.

RAB
 
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