22 · Diagnostics

The gears do not engage

Make: Fiat
Model: Stilo Factory Service Manual
Year: 2001–2007
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

2.4 20v

First and/or Reverse after a stop.

0	OIL LEVEL CHECK	All OK	Problems met	Operation
		Results of the tests
	Check oil level See Test 2127B OIL LEVEL CHECK	Continue to Step 2	Level below Max reference	Top up the level Continue to Step 1
	Check 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 FLUID 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 Continue to Step 1
2	OIL PRESSURE CHECK	All OK	Problems met	Operation
	Check oil pressure See Test 2127D OIL PRESSURE CHECK	Continue to Step 4	Pressure < 40 bar	Continue to Step 3
3	CHECK 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	Gear changes cannot be made 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 that the brake pedal switch is working 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 BRAKE PEDAL SWITCH CHECK	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 Lever switch errors 0/1/2/3 Lever switch error (any of the 4 switchess or auto switch) Control unit faulty error (microprocessor) Even gear engagement error Odd gear engagement error Clutch solenoid valve current error Electromagnetic brake error (Selection solenoid) Control unit earths error - Loads relay error	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	Fault on the connections (Clutch sensor, Odd or even gear engagement, Clutch solenoid current, Electromagnetic brake, ECU earth error and/or Load relay error)	Restore/replace the wiring Continue to Step 8
			There are no faulty connections (Clutch solenoid current)	Replace the solenoid Op. 2127C56and check its operation by carrying out a gear change. 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 (Electromagnetic brake)	Replace the solenoid valve Op. 2127C54 Continue to Step 8
			The test is not successful (Odd or even gear engagement)	Replace the solenoid valve Op. 2127C52 Continue to Step 8
			The state displayed is not correct (Lever switch error 0/1/2/3 and/or Lever switch error - Check lever)	Check the connections, the continuity of the wiring and the gear lever Continue to Step 8
			There is no change of state and/or the word 'AUTO is not displayed (Lever switch error - Check auto button)	Check the button and the wiring Continue to Step 8
8	AFTER THE CHECKS ON FAULTS DETECTED	All OK	Problems met	Operation
	Check that the fault is no longer present	End of diagnosis	The fault persists	Continue to Step 11
9	CHECK THAT THE LEVER AND THE AUTO BUTTON ARE WORKING PROPERLY	All OK	Problems met	Operation
	Check that the lever and auto button are working properly See Test 2127G CHECK ON BUTTONS ON STEERING WHEEL AND GEAR LEVER	Continue to Step 11	The lever or the button is not working properly	Check the state of the connections and the wiring. Repair/replace the part that is not working Continue to Step 10
		Continue to Step 11	There is no change of state and/or the 'AUTO button is not displayed	Check the button and the wiring. Continue to Step 10
10	AFTER THE CHECK ON THE CORRECT OPERATION OF THE LEVER AND AUTO BUTTON	All OK	Problems met	Operation
	Check that the fault is no longer present	End of diagnosis	The fault persists	Continue to Step 11
11	CHECK THAT THE CLUTCH IS NOT DRAGGING	All OK	Problems met	Operation
	Check that the clutch is not dragging See Test 2127K CLUTCH DRIVE CHECK	Continue to Step 13	The clutch drags	Proceed with checking the clutch/flywheel kit and, if necessary, replace any components that do not conform. Continue to Step 12
12	AFTER THE INTERVENTION ON THE CLUTCH KIT	All OK	Problems met	Operation
	Check that the fault is no longer present	End of diagnosis	The fault persists	Continue to Step 13
13	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'

With the engine warm

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 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 the Max reference 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 fluid 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 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	Gear changes cannot be made 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 Lever switch errors 0/1/2/3 Lever switch error (any of the 4 switches or auto switch) Control unit faulty error (microprocessor) Even gear engagement error Odd gear engagement error Clutch solenoid valve current error Electromagnetic brake error (Selection solenoid) Control unit earth error Load relay error	Continue to Step 7	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 See Test 2127I What to do depending on the error' present in the Selespeed control unit No accelerator pedal information.	End of diagnosis	Fault on the connections (Clutch sensor, Odd or even gear engagement, Clutch solenoid current, Electromagnetic brake, ECU earth error and/or Load relay error)	Repair/replace the wiring Continue to Step 6
			There are no faults on the connections (Clutch solenoid current)	Replace the solenoid Op. 2127C56and check its operation by carrying out a gear change. 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
			The test is not successful (Electromagnetic brake)	Replace the solenoid valve Op. 2127C54 Continue to Step 6
			The test is not successful (Odd or even gear engagement)	Replace the solenoid valve Op. 2127C52 Continue to Step 6
			The state displayed is not correct (Lever switch error 0/1/2/3 and/or Lever switch error - Check lever)	Check the connections, the continuity of the wiring and the gear lever Continue to Step 6
			There is no change of state and/or the word 'AUTO is not displayed (Lever switch error - Check auto button)	Check the button and the wiring 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 THAT THE CLUTCH IS NOT DRAGGING	All OK	Problems met	Operation
	Check that the clutch is not dragging See Test 2127K CLUTCH DRIVE CHECK	Continue to Step 9	The clutch drags	Proceed with checking the clutch/flywheel kit and, if necessary, replace any components that do not conform. Continue to Step 8
8	AFTER THE INTERVENTION ON THE CLUTCH KIT	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 THAT THE LEVER AND AUTO BUTTON ARE WORKING PROPERLY	All OK	Problems met	Operation
	Check that the lever and button are working properly See Test 2127G CHECK ON BUTTONS ON STEERING WHEEL AND GEAR LEVER	Continue to Step 11	The lever or the button is not working properly	Check the state of the connections and the wiring. Repair/replace the part that is not working Continue to Step 10
		Continue to Step 11	There is no change of state and/or the word 'AUTO is not displayed	Check the button and the wiring. Continue to Step 10
10	AFTER THE CHECK ON THE CORRECT OPERATION OF THE LEVER AND AUTO BUTTON	All OK	Problems met	Operation
	Check that the fault is no longer present	End of diagnosis	The fault persists	Continue to Step 11
11	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 13	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 12
12	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 13
14	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'

Reverse gear cannot be engaged sometimes

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 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 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	Gear changes cannot be made from the lever	Activate the 'clutch bleed' service from the Examiner Plus or Smart to activate the pump Continue to Step 3
4	CHECK THAT THE LEVER AND AUTO BUTTON ARE WORKING PROPERLY	All OK	Problems met	Operation
	Check that the lever and auto button are working properly See Test 2127G CHECK ON BUTTONS ON STEERING WHEEL AND GEAR LEVER	Continue to Step 6	The lever or the button is not working properly	Check the state of the connections and the wiring. Repair/replace the part that is not working. Continue to Step 5
		Continue to Step 6	There is no change of state and/or the word 'AUTO is not displayed	Check the button and the wiring. Continue to Step 5
5	AFTER THE CHECKIN ON THE CORRECT OPERATION OF THE LEVER AND AUTO BUTTON	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: Lever switch errors 0/1/2/3 Lever switch error (any of the 4 switches or auto switch) Electromagnetic brake error (Selection solenoid)	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	Connections faulty (Electromagnetic brake)	Repair/replace the control unit concerned Continue to Step 6
			The state displayed is not correct (Lever switch error 0/1/2/3 and/or Lever switch error - Lever check)	Check the connecctions, continuity of the wiring and the gearlever Continue to Step 8
			There is no change of state and/or the word 'AUTO is not displayed (Lever switch error - Auto button check)	Check the button and the wiring 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 THAT THE CLUTCH IS NOT DRAGGING	All OK	Problems met	Operation
	Check that the clutch is not dragging See Test 2127K CLUTCH DRIVE CHECK	Continue to Step 11	The clutch drags	Proceed with checking the clutch/flywheel kit and, if necessary, replace any components that do not conform. Continue to Step 10
10	AFTER THE INTERVENTION ON THE CLUTCH KIT	All OK	Problems met	Operation
	Check that the fault is no longer present	End of diagnosis	The fault persists	Continue to Step 11
11	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'

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

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	Leve 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	CONTROL UNIT ERRORS CHECK	All OK	Problems met	Operation
	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 Control unit broken error CAN network error	Continue to Step 5	Presence of one or more of the errors included in the list	Continue to Step 3
3	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 (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 4
			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 4
			There are no faulty connections (Selection sensor)	Replace the selection potentiometer and check the correct reading of the position by carrying out a series of gear changes. Continue to Step 4
			Faulty connection (Engine speed)	Repair/replace the relevant part Continue to Step 4
			There are no faulty connections (Clutch disc speed)	Replace the clutch disc speed sensor and check that the reading of the position is correct by carrying out a series of gear changes Continue to Step 4
			One of the control units does not dialogue (CAN network errors)	Repair/replace the control unit concerned 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	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 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	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 relevant parts, top up the oil level Continue to Step 1
2	CONTROL UNIT ERRORS CHECK	All OK	Problems met	Operation
	Check that there are no control unit errors. In particular: Engagement sensor error Selection sensor error	Continue to Step 5	Presence of one or more of the errors included in the list	Continue to Step 3
3	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 (Engagement sensor, Selector sensor)	Repair/replace the wiring Continue to Step 4
			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 4
			There are no faulty connections (Selection sensor)	Replace the selector potentiometer and check the correct reading of the position by carrying out a series of gear changes. 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	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 8	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 6
6	SELF-CALIBRATION	All OK	Problems met	Operation
	With the Examiner Plus or Smart, in active diagnosis start end-of-line/Service self-calibration	End of diagnosis	The self-calibration is not successful	Continue according to the instructions for the diagnostic equipment
7	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
8	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	Fault persists	Search for the fault starting from another symptom'

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Parts & tools for this job For 2001 Fiat Stilo

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