22 · Diagnostics

The gearbox is stuck

Make: Fiat
Model: Stilo Factory Service Manual
Year: 2001–2007
Section: Gear shift › The gearbox is stuck

‹ Prev The vehicle does not run Next › The gearbox is noisy

Fault diagnosisThe gearbox is stuck

THE GEARBOX IS STUCK

2.4 20v

It remains blocked in one gear with the vehicle stopped, and during acceleration the engine revs increase (the engaged gear is displayed)

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	Continue to Step 3	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 See Test 2127I What to do depending on the error' present in the Selespeed control unit No accelerator pedal information.	End of diagnosis	Faulty connections	Repair/replace the wiring Continue to Step 2
		End of diagnosis	There are no faulty connections	Replace the clutch actuator (CSC) anc check its operation by carrying out a gear change. Continue to Step 2
2	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 3
3	CHECK THE LAYOUT OF THE CLUTCH SENSOR WIRING	All OK	Problems met	Operation
	Check the state of the connections, continuity of the wiring (it is important to pay particular to the layout of the clutch position sensor wiring in the engine compartment: the wire must not be too taut, and it must have sufficient slack)	Continue to Step 4	There is a fault	Repair/replace the part that is not working Continue to Step 5
4	CARRY OUT CLUTCH PARAMETER CALIBRATION USING THE EXAMINER	All OK	Problems met	Operation
	In active diagnosis carry out the calibration of the clutch parameters through the 'clutch self-calibration enablement'	Continue to Step 5	The calibration is not successful	Continue to Step 6
5	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	Continue to Step 6
6	THE FAULT PERSISTS	All OK	Problems met	Operation
	Contact Technical Service for further information on the problem	End of diagnosis	Fault persists	Search for the fault starting from another symptom'

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, etc.). 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 See Test 2127B OIL LEVEL CHECK	Continue to Step 2	Level below the Max reference	Top up the oil level Continue to Step 1
	Check the oil level See Test 2127B OIL LEVEL CHECK	Continue to Step 2	Level above the Max reference	Reduce to Max level Continue to Step 2
1	CHECK FOR OIL LEAKS	All OK	Problems met	Operation
	Check that there are no oil leaks See Test 2127C CHECK FOR FLUID LEAKS	Continue to Step 2	Oil leaks detected	Replace/repair the relevant parts, top up the oil level Continue to Step 1
2	OIL PRESSURE CHECK	All OK	Problems met	Operation
	Check the oil pressure See Test 2127D OIL PRESSURE CHECK	Continue to Step 4	Pressure < 40 bar	Continue to Step 3
3	CHECK THE PUMP OPERATION	All OK	Problems met	Operation
	Check that the pump is working properly See Test 2127E ELECTRIC PUMP OPERATION CHECK	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 3
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 valve current error Pump relay error Load relay error Selespeed pump error	Continue to Step 3	Presence of one or more of the errors included in the list	Continue to Step 1
5	CHECKS ON FAULTS DETECTED	All OK	Problems met	Operation
	Check the faults See Test 2127I What to do depending on the error' present in the Selespeed control unit No accelerator pedal information.	End of diagnosis	Faulty connections (Clutch sensor, Clutch solenoid current, Pump relay error, Load relay error, Selespeed pump, and/or Engagement sensor)	Repair/replace the wiring Continue to Step 6
			There are no faulty connections (Clutch sensor)	Replace the clutch actuator (CSC) and check its operation by carrying out a gear change. Continue to Step 6
			There are no faulty connections (Clutch solenoid current)	Replace the solenoid Op. 2127C56valve and check its operation by carrying out a gear change. Continue to Step 6
			Faulty pump relay and/or fuse (Selespeed pump)	Replace the component Continue to Step 6
			Pump winding faults (Selespeed pump)	Replace the component Op. 2127C30 Continue to Step 6
6	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
7	CHECK CLUTCH SENSOR WIRING LAYOUT	All OK	Problems met	Operation
	Check the state of the connections, continuity of the wiring (it is important to pay particular attention to the layout of the clutch position sensor wiring in the engine compartment: the wire must not be too taut, and it must have sufficient slack)	Continue to Step 8	A fault is detected	Repair/replace the part that is not working Continue to Step 9
8	CARRY OUT CLUTCH PARAMETER CALIBRATION USING THE EXAMINER	All OK	Problems met	Operation
	In active diagnosis carry out the calibration of the clutch parameters through the 'clutch self-calibration enablement' with a positive result	Continue to Step 9	The calibration is not successful	Continue to Step 10
9	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	Continue to Step 10
10	THE FAULT PERSISTS	All OK	Problems met	Operation
	Contact Technical Service for further information on the problem	End of diagnosis	Fault persists	Search for the fault starting from another symptom'

The vehicle remains with the gearbox stuck in neutral

Some gears can be engaged and then the vehicle is stuck

The gearbox jams after it is attempted to engage reverse gear

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 See Test 2127B OIL LEVEL CHECK	Continue to Step 2	Level below Max reference	Top up the oil level Continue to Step 1
	Check the oil level See Test 2127B OIL LEVEL CHECK	Continue to Step 2	Level above Max reference	Reduce to Max level Continue to Step 2
1	CHECK FOR OIL LEAKS	All OK	Problems met	Operation
	Check that there are no oil leaks See Test 2127C CHECK FOR FLUID LEAKS	Continue to Step 2	Oil leaks detected	Replace/repair the parts concerned, top up the oil level Continue to Step 1
2	OIL PRESSURE CHECK	All OK	Problems met	Operation
	Check the oil pressure See Test 2127D OIL PRESSURE CHECK	Continue to Step 4	Pressure < 40 bar	Continue to Step 3
3	CHECK THE PUMP OPERATION	All OK	Problems met	Operation
	Check that the pump is working properly See Test 2127E ELECTRIC PUMP OPERATION CHECK	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 3
4	CHECK ON BRAKE PEDAL SWITCH	All OK	Problems met	Operation
	Check the operation of the brake pedal switch See Test 2127F CHECK ON BRAKE PEDAL SWITCH	Continue to Step 6	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. Continue to Step 5
5	AFTER THE CHECK ON THE BRAKE PEDAL SWITCH	All OK	Problems met	Operation
	Check that the fault is no longer present	End of diagnosis	The fault persists	Continue to Step 6
6	CONTROL UNIT ERRORS CHECK	All OK	Problems met	Operation
	Check that there are no control unit errors. In particular: Clutch sensor error Control unit faulty error (microprocessor) Even gear engagement error Odd gear engagement error Clutch solenoid current error Electromagnetic brake error (Selection solenoid) Engagement sensor error (keeps the gearbox in neutral only if the engine is off)	Continue to Step 9	Presence of one or more of the errors included in the list	Continue to Step 7
7	CHECKS ON FAULTS DETECTED	All OK	Problems met	Operation
	Check the faults See Test 2127I What to do depending on the error' present in the Selespeed control unit No accelerator pedal information.	End of diagnosis	Faulty connections (Clutch sensor, Odd or even gear engagement, Clutch solenoid Current, Electromagnetic brake and/or Engagement sensor)	Repair/replace the wiring Continue to Step 8
			There are no faulty connections (Clutch sensor)	Replace the clutch actuator (CSC) and check its operation by carrying out a gear change. Continue to Step 8
			The test is not successful (Odd or even gear engagement)	Replace the solenoid valve Op. 2127C52 Continue to Step 8
			There are no faulty connections (Clutch solenoid current)	Replace the solenoid valve Op. 2127C56and check its operation by carrying out a gear change. Continue to Step 8
			The test is not successful (Electromagnetic brake)	Replace the solenoid valve Op. 2127C54 Continue to Step 8
			There are no faulty connections (Engagement sensor)	Replace the engagement potentiometer and check the correct reading of the position by carrying out a series of gear changes. 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	CHECK THE LAYOUT OF THE CLUTCH SENSOR WIRING	All OK	Problems met	Operation
	Check the state of the connections, continuity of the wiring (it is important to pay particular attention to the layout of the clutch position sensor wiring in the engine compartment: the wire must not be too taut, and it must have sufficient slack)	Continue to Step 11	A fault is detected	Repair/replace the part that is not working Continue to Step 10
10	CHECK THAT THE FAULT IS NO LONGER PRESENT	All OK	Problems met	Operation
	Check that the fault is no longer present To check that the fault is no longer present, the battery cage need not be refitted If the problem persists, the next intervention could involve the solenoid valves (as stated in Step 8); it is therefore advisable not to refit the battery cage	End of diagnosis	The fault persists	Continue to Step 11
11	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	Continue to Step 14	The self-calibration is not successful	Continue to Step 12
12	SELF-CALIBRATION REPETITION	All OK	Problems met	Operation
	Carry out a second self-calibration and make sure that the result is successful	Continue to Step 14	The self-calibration is not successful	The causes could be: battery voltage, oil pressure/oil level, clutch mechanism problems and mechanical problems on the engagement/selection valves; out of these cases only the last one has not been taken into consideration by the points prior to this chart. It is advisable to focus attention on the engagement/selection solenoid valves Replace the even gear engagement, odd gear engagement Op. 2127C52and selection solenoids. 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	Continue to Step 14
14	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

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 See Test 2127A Check on operation of clutch plate speed sensor through road test	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 Continue to Step 2
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	Continue to Step 3
3	CHECK THAT THE FAULT IS NO LONGER PRESENT	All OK	Problems met	Operation
	Contact Technical Service for further information on the problem	End of diagnosis	The fault persists	Search for the fault starting from another symptom'

‹ Prev The vehicle does not run Next › The gearbox is noisy

Parts & tools for this job For 2001 Fiat Stilo

Links open Amazon search results in a new tab. As an Amazon Associate I earn from qualifying purchases.