22 · Diagnostics

The gearbox is stuck

Make: Alfa Romeo
Model: GT Factory Service Manual
Year: 2003–2010
Section: Gear shift › The gearbox is stuck

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Fault diagnosisThe gearbox is stuck

THE GEARBOX IS STUCK

1.8 T.SPARK, 2.0 JTS

It remains stuck in one gear and, when the vehicle stops, the engine cuts out and cannot be started up again or it starts again after a few minutes.

Preliminary check: If during engine starting you notice that the starter motor works normally, the problem is caused by other systems (engine management, ABS, fuel pump). Refer to specific charts.

If the starter motor does not turn (after checking its operation and the relevant electrical supply circuit), continue with the next diagnosis chart.

0	OIL LEVEL CHECK	All OK	Problems met	Operation
		Results of the tests
	Check the oil level as described in See Test See Test 2127B OIL LEVEL CHECK	Continue to Step 2	Level below the Max reference	Top up the oil level Continue to Step 1
		Continue to Step 2	Level above the Max reference	Reduce to the Max level Continue to Step 2
1	CHECK FOR OIL LEAKS	All OK	Problems met	Operation
	Check that there are no oil leaks as described in See Test See Test 2127C HYDRAULIC GEAR SELECTION SYSTEM	Continue to Step 2	OIl leaks detected	Replace/repair the parts concerned, and top up the oil level Continue to Step 1
2	OIL PRESSURE CHECK	All OK	Problems met	Operation
	Check the oil pressure as described in See Test See Test 2127D OIL PRESSURE CHECK	Continue to Step 4	Pressure < 40 bar	Continue to Step 3
3	ELECTRIC PUMP OPERATION CHECK	All OK	Problems met	Operation
	Check the correct operation of the pump as described in See Test See Test 2127E ELECTRIC SPEED SELECTION SYSTEM	Continue to Step 4	Voltage below 11 V	Check the battery Continue to Step 3
		Continue to Step 4	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 4
4	CONTROL UNIT ERRORS CHECK	All OK	Problems met	Operation
	Check that there are no control unit errors. In particular: Clutch sensor error Clutch solenoid current error Pump relay error Load relay error	Continue to Step 9	Presence of one or more of the errors included in the list	Continue to Step 5
5	CHECKS ON FAULTS DETECTED	All OK	Problems met	Operation
	Check the faults in accordance with See Test See Test 2127I What to do for error in Selespeed control unit	Continue to Step 7	Faulty connections	Repair/replace the wiring Continue to Step 7
		Continue to Step 7	The active diagnosis is not successful and no faults are detected at the wiring (Clutch solenoid valve current)	Continue to Step 6
6	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. 2127C56 and check the operation by carrying out a C.M.	Continue to Step 7
7	POTENTIOMETER REPLACEMENT	All OK	Problems met	Operation
	If there is a clutch sensor error and no faults are detected at the connections/wiring, replace the clutch position sensor Op. 2127E44 and check the correct reading of the position by carrying out a series of C.M.	Continue to Step 8
8	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 9
9	CLUTCH PUSH ROD ADJUSTMENT CHECK	All OK	Problems met	Operation
	Carry out the clutch push rod check as described in See Test See Test 2127M CLUTCH PUSH ROD ADJUSTMENT CHECK	Continue to Step 10	The position is outside the permitted range	Restore the correct position Tighten to torque
10	AFTER THE CLUTCH PUSH ROD ADJUSTMENT	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

The vehicle remains with the gearbox stuck in neutral

Some gears can be engaged and then the vehicle is stuck

Preliminary check: It is advisable to carry out a preliminary check on the battery voltage

0	OIL LEVEL CHECK	All OK	Problems met	Operation
		Results of the tests
	Check the oil level as described in See Test See Test 2127B OIL LEVEL CHECK	Continue to Step 2	Level below the Max reference	Top up the oil level Continue to Step 1
		Continue to Step 2	Level above the Max reference	Reduce to the Max level Continue to Step 2
1	CHECK FOR OIL LEAKS	All OK	Problems met	Operation
	Check that there are no oil leaks as described in See Test See Test 2127C HYDRAULIC GEAR SELECTION SYSTEM	Continue to Step 2	Oil leaks detected	Replace/repair the parts concerned, and top up the oil level Continue to Step 1
2	OIL PRESSURE CHECK	All OK	Problems met	Operation
	Check the oil pressure as described in See Test See Test 2127D OIL PRESSURE CHECK	Continue to Step 4	Pressure < 40 bar	Continue to Step 3
3	ELECTRIC PUMP OPERATION CHECK	All OK	Problems met	Operation
	Check the correct operation of the pump as described in See Test See Test 2127E ELECTRIC SPEED SELECTION SYSTEM	Continue to Step 4	Voltage below 11 V	Check the battery Continue to Step 3
		Continue to Step 4	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 4
4	CHECK ON BRAKE PEDAL SWITCH	All OK	Problems met	Operation
	Check that the brake pedal switch is working properly as described in See Test See Test 2127F CHECK ON BRAKE PEDAL SWITCH	Continue to Step 5	The brake pedal switch is not working properly	Check the state of the connections, the wiring and the switch. Repair/replace the part that is not working
5	CONTROL UNIT ERRORS CHECK	All OK	Problems met	Operation
	Check that there are no control unit errors. In particular: Clutch sensor error Even gear engagement error Odd gear engagement error Clutch solenoid current error 1st/2nd selection solenoid valve error 5th/Reverse selection solenoid valve error Load relay error	Continue to Step 10	Presence of one or more of the errors included in the list	Continue to Step 6
6	CHECKS ON FAULTS DETECTED	All OK	Problems met	Operation
	Check the faults described in Test 2127I	Continue to Step 8	Faulty connections	Repair/replace the wiring Continue to Step 8
			The active diagnosis for the solenoid valve is not successful and no faults are detected at the wiring (Odd or even gear engagement, Clutch solenoid valve current error and/or Selection solenoid valve error)	Continue to Step 7
			Battery run down (Load relay error)	Restore the correct battery charge Op. 5530C14 Continue to Step 6
7	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. 2127C56 and 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. 2127C52 and check the operation If this step has been reached for the active diagnosis of the selection solenoid valve, replace it Op. 2127C54 and check the operation	Continue to Step 8
8	POTENTIOMETER REPLACEMENT	All OK	Problems met	Operation
	If there is a clutch sensor error and no faults are detected at the connections/wiring, replace the clutch potentiometer sensor Op. 2127E44 and check that the position reading is correct by carrying out a series of C.M.	Continue to Step 9
9	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 10
10	GEAR LEVER CHECK	All OK	Problems met	Operation
	Check that the gear lever is working properly following See Test See Test 2127L GEAR LEVER CHECK	Continue to Step 11	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 11	There is no change of state and/or the ''CITY'' button is not displayed	Check the switch and the wiring Repair/replace the part that is not working
11	CLUTCH PUSH ROD ADJUSTMENT CHECK	All OK	Problems met	Operation
	Carry out the clutch push rod check as described in See Test See Test 2127M CLUTCH PUSH ROD ADJUSTMENT CHECK	Continue to Step 12	The position is outside the permitted range	Restore the correct position Tighten to torque
12	SELF CALIBRATION	All OK	Problems met	Operation
	With the Examiner Plus or Smart, in active diagnosis, start end of Service line self-diagnosis and make sure that the result is successful	End of diagnosis	The self-calibration is not successful the first time	Continue to Step 13
		End of diagnosis	The self-calibration is not successful the second time	Replace the even gear engagement, odd gear engagement Op. 2127C52 and selection solenoids Op. 2127C54 Continue to Step 13
13	NEW SELF-CALIBRATION	All OK	Problems met	Operation
	After replacing the solenoids with the Examiner Plus or Smart, carry out a new end-of-line/Service self-calibration procedure and make sure that the result is positive	End of diagnosis	The self-calibration is not successful	Contact Technical Service for further information on the problem

Following a gear change in manual or automatic, the gearbox goes into 5th gear (even with the vehicle stopped)

0	CHECK THE CLUTCH DISC SPEED SENSOR	All OK	Problems met	Operation
		Results of the tests
	Check the clutch disc speed signal following See Test See Test 2127A HYDRAULIC TRANSMISSION EXTERNAL LINKAGE	Continue to Step 2	There are problems with the sensor signal	Continue to Step 1
1	CHECK THE STATE OF THE CONNECTIONS	All OK	Problems met	Operation
	Check the state of connections and wiring of the speed sensor. Remember that this sensor is on the gearbox bellhousing near the reversing lights sensor In some cases, when the sensor is dismantled, there may be iron filings deposited on the sensor head	Continue to Step 2	There are faults detected	Repair/replace the part that is not working
2	CHECK THAT THE FAULT IS NO LONGER PRESENT	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

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