| No. | Complaint | Possible cause of fault | Rectifying fault |
| 1 | Vehicle does not move forwards or backwards | Multi-function switch -F125- defective| l
| Contact in switch damaged |
| l
| Wiring/plug connection to switch damaged/not connected according to the Current Flow Diagram |
| | –
| Analysing measured value block 004 → Chapter |
| –
| Inspecting multi-function switch -F125-. |
| –
| Performing electrical test, test step 2 → Chapter. |
|
| l
| Wiring and insulation defective |
| |
| Plug in slide valve body broken | |
| Selector lever control cable loose at one of its supports: |
or
| –
| Replacing and adjusting the selector lever control cable → Chapter. |
|
| Shaft retainer (circlip) defective/not clipped |
| |
| The driver panel is torn because the dowel sleeves in the engine/gearbox flange are missing | | –
| Replace the engine/gearbox dowel sleeves and driver panel. |
|
| 2 | Vehicle does not move forwards | 1. 1st through 3rd gear clutch -K1- defective | | –
| 1. Repair 1st through 3rd gear clutch -K1- → Chapter. |
|
| 3 | Vehicle does not reverse | Reverse gear-brake -B1- defective | | –
| Repairing reverse gear-brake -B1- → Chapter. |
|
| Reverse gear clutch -K2- defective | |
| 4 | Gearbox oily | Seals or components outside gearbox leak | | –
| Clean the engine/gearbox and locate where the gearbox or engine leaks if necessary use leak-oil search spray spare part No. G 001 900 A1. |
| –
| Seal or replace defective components on a leaking gearbox. |
| –
| Replace gasket rings, gaskets, screwed connections or gearbox housing (converter housing). |
|
| Gearbox leaking |
| Engine leaks | |
| ATF level too high, ATF expelled by fresh air system | | –
| Clean gearbox, check ATF level if necessary drain off → Chapter. |
|
| 5 | ATF escapes around the torque converter | Distance dimension of the driver panel N.O.K. | |
| Gasket ring for torque converter defective | | –
| Replacing the gasket ring for torque converter; if the contact surface on the torque converter is damaged also replace the torque converter → Chapter. |
|
| Bush in torque converter defective/loose |
| ATF pump leaks | | –
| Disassemble and assemble ATF pump and replace defective components → Chapter. |
| –
| Inspect converter for damage (visual inspection). |
|
| 6 | Visible soiling of the ATF and/or engine coolant | ATF-radiator defective, this causes the coolant and ATF level to drop | | l
| Precondition: no engine oil in the coolant (cylinder head seal etc. O.K.) |
| –
| Replace the coolant and ATF. |
|
The coolant may damage plates and seals in the gearbox. After replacing the coolant and the ATF:| –
| Perform a test drive and inspect the “solenoid valve and position of the shift elements” → Chapter. |
If there are functional problems repair the gearbox → Chapter. |
| 7 | Gearshift mechanism is stiff | Gearshift mechanism is stiff outside the gearbox | | –
| Remove selector lever control cable from the lever/gearshift shaft. |
| –
| Repairing the gearshift mechanism → Chapter. |
| –
| Always replace a buckled selector lever control cable → Chapter. |
|
| Gearshift mechanism in gearbox stiff | | –
| Disassembling and assembling the parking position → Chapter. |
|
| 8 | Not all selector lever positions can be engaged, engaged driving positions are not operational | Selector lever control cable loose at its support: |
or
| –
| Replacing and adjusting the selector lever control cable → Chapter. |
|
| Shaft retainer (circlip) defective/not clipped |
| |
| 9 | Parking position does not catch | Selector lever control cable defective or incorrectly set | | –
| Replacing and adjusting the selector lever control cable → Chapter. |
|
| Selector lever control cable loose at its support: |
or
| –
| Replacing selector lever control cable → Chapter. |
|
| Shaft retainer (circlip) defective/not clipped |
| |
| Locking lever, parking gear or locking lever activation defective | | –
| Repairing locking lever, parking gear or locking lever activation → Chapter. |
|
| 10 | Parking position “jerks” out of catch (selector lever occasionaly stiff from “P” to “R”) | Ferraria effect of the locking lever for parking gear if: | | –
| Apply handbrake before engaging parking position. |
|
| Vehicle parked on a hill or the parking position catch is put under tension because of repeated gearshifting. |
| 11 | Noises in the final drive | Tapered-roller bearing loud | | –
| Replacing tapered-roller bearing → Chapter. |
|
| Input shaft loud | |
| Drive gear loud | | –
| Replacing drive gear with output gear → Chapter. |
|
| Output gear loud |
| Drive train (input shaft with differential ring gear) loud | |
| 12 | Driveability: jerking during idling or jerking during certain engine/gearbox motions | Throttle valve supports leak | |
| 13 | Engine speed drops when a driving position is engaged | Parking/Neutral (P/N) signal is not recognised by the engine control unit | |
| Engine control unit defective | |
| 14 | Vehicle does not start or also starts in “R-D-3-2-1” | Wiring of the multi-function switch -F125- or of the starter inhibitor relay -J207- defective | |
| Vehicle voltage control unit -J519 - defective | |
| Multi-function switch -F125 - defective | | –
| Inspecting and if necessary replacing the multi-function switch -F125- → Chapter. |
|
| Starter inhibitor relay -J207- defective | | –
| Replace starter inhibitor relay -J207- → Chapter. |
|
| 15 | Selector lever can be shifted out of “N” or “P” without pressing the brake. | Selector lever lock solenoid -N110- defective | | –
| Analysing measured value block 004 → Chapter. |
| –
| Inspect selector lever lock solenoid -N110- → Chapter. |
|
| Vehicle voltage control unit -J519 - defective | |
| Wiring for selector lever lock solenoid -N110- interrupted | |
| no signal from brake light switch -F- | | –
| Analysing measured value block 004 → Chapter. |
|
| Data BUS defective | |
| l
| Read-out on display of -V.A.G 1552-: “no fault detected!” |
Automatic gearbox control unit -J217- defective | | –
| Select control unit from spare part catalogue and replace → Chapter. |
|
| 16 | Selector lever cannot be shifted out of “N” or “P” even though the brake is pressed. | Brake light switch -F- defective/no signal | |
| Data BUS defective | |
| 17 | Shifting does not occur (or only sporadically) | Plug of the vehicle speed sender -G68- and gearbox speed sender -G38- interchanged | |
Multi-function switch -F125 - defective| l
| Contacts in switch damaged |
| l
| Wiring/plug connection to switch damaged/not connected according to the Current Flow Diagram |
| | –
| Inspecting multi-function switch -F125- → Chapter. |
|
| l
| Wiring and insulation defective |
| |
| Plug in slide valve body broken | | –
| Replace slide valve body. |
|
| Piston slide valve or solenoid valve in slide valve body stuck | | –
| Replacing slide valve body, ATF and ATF strainer → Chapter. |
| –
| Perform test drive with -V.A.G 1552 - and check whether all solenoid valves and shift elements are activated while driving → Chapter. |
|
| Pulse gear for vehicle speed sender -G68- loose/broken | |
| 18 | When shifting gears all gearshifts “stiff/jerky” | Plug of the vehicle speed sender -G68- and gearbox speed sender -G38- interchanged. When interrogating the fault memory in this instance the gearbox speed sender -G38- displays “implausible signal”. | | –
| perform self-diagnosis with the engine off, erase fault memory, initiate basic setting → Chapter. |
|
| no signal from gearbox oil temperature sender -G93-/sender defective | | –
| Analysing measured value block 002 → Chapter. |
| –
| Performing electrical test, test step 11 → Chapter. |
| –
| Replace gearbox oil temperature sender -G93-. |
|
| Short-circuit between the valve wires | | –
| Inspecting/replacing valve wires → Chapter. |
|
| Incorrect control unit fitted/control unit defective | | –
| Read out control unit identification → Chapter. |
| –
| Select control unit from spare part catalogue, compare and if necessary → Chapter |
|
| Piston slide valve in slide valve body or solenoid valve defective | |
| 19 | when shifting gears one gearshift is “stiff/jerky” | one shift element (a clutch or a brake) defective | Check in which gearshift the gear is hard:| –
| Connect vehicle system tester -V.A.G 1552-; read measured value block → Chapter |
| –
| Perform a test drive. The table “solenoid valves and position of the shift elements” in the Workshop Manual indicates which shift elements are affected → Chapter. |
| –
| replacing the affected shift elements → Chapter. |
|
| 20 | Gearshifts too “drawn out” | a clutch or a brake is defective | Check in which gearshift the faulty gear occurs:| –
| Connect vehicle system tester -V.A.G 1552-; read measured value block → Chapter. |
| –
| Perform a test drive. The table “solenoid valves and position of the shift elements” in the Workshop Manual indicates which shift elements are affected → Chapter. |
|
| Torque converter defective | |
| Piston slide valve is slide valve body stuck | |
| 21 | Stiff gearshift immediately after repairs | | l
| Read-out on display -V.A.G 1552-“no fault detected”! |
| l
| Damage to the wiring excluded (plug connections !) |
Basic setting not initiated | |
| 22 | Gearbox shifts down at constant speed without visible reason | ATF is insufficiently cooled, by shifting down the gearbox performs a safety function. | | –
| Check why the ATF temperature rises unacceptably. Check out additional installations or modifications to the vehicle that are likely to affect the cooling. Also the subsequent installation of a trailer coupling device without corresponding modificaton of the fan motor may result in cooling problems. |
|
| Engine speed signal is not detected by the automatic gearbox control unit | | –
| Analysing measured value block 001 → Chapter. |
|
| 23 | Gearbox does not shift during kickdown | Accelerator pedal position sender -G79- defective/no signal | |
| 24 | Gearbox only shifts as heating increases | Piston slide valve in slide valve body or solenoid valve defective | |
| Given an ATF temperature below 15° C the gearbox does not shift into 4th gear. No fault. | |
| 25 | Gearbox shifts into emergency running mode | Read-out on display of -V.A.G 1552-gearbox speed sender -G38-“implausible signal” plug connection of the gearbox speed sender -G38- and vehicle speed sender -G68- interchanged | | –
| perform self-diagnosis with the engine off, erase fault memory, initiate basic setting → Chapter. |
| –
| Perform self-diagnosis again |
|
Plug connection at gearbox damaged/loose contact| l
| Soiling or corrosion of contacts |
| l
| Plug contacts in plug housing damaged (not fully inserted) |
| l
| Short-circuit/interruption in wiring loom |
| |
| Short-circuit/interruption between the valve wires or wires to the solenoid valves | | –
| Perform self-diagnosis and electrical test, subsequently replace wiring or components → Chapter. |
|
| Plug in slide valve body broken | |
| Piston slide valve is slide valve body stuck | |
| l
| Read-out on display of -V.A.G 1552-: “no fault detected!” |
Incorrect control unit fitted/control unit defective | | –
| Read out control unit identification → Chapter. |
| –
| Select control unit from spare part catalogue and replace if necessary |
|
| 26 | Selector lever position “1” automatic gearbox does not shift into 1st gear (no power transmission in 1st gear) | 1st through 3rd gear-clutch -K1- or reverse gear-brake -B1- defective | | –
| Observe the safety measures and notes: “PInspecting the solenoid valves and shift elements while driving” → Chapter. |
| –
| Repairing reverse gear-brake -B1- → Chapter. |
| –
| Repair 1st through 3rd gear clutch -K1- → Chapter. |
| –
| Repairing the overrunning clutch → Chapter. |
|
| 27 | Selector lever position “D, 3 or 2” automatic gearbox does not shift into 1st gear (no power transmission) | 1. 1st through 3rd gear clutch -K1- or overrunning clutch defective | | –
| Observe the safety measures and notes: “PInspecting the solenoid valves and shift elements while driving” → Chapter. |
| –
| Repair 1st through 3rd gear clutch -K1- → Chapter. |
| –
| Repairing the overrunning clutch → Chapter. |
|
| 28 | Selector lever position “D, 3 or 2” automatic gearbox does not shift into 2nd gear | 2nd and 4th gear-brake -B2- defective | | –
| Observe the safety measures and notes: “PInspecting the solenoid valves and shift elements while driving” → Chapter. |
| –
| Repairing 2nd and 4th gear-brake -B2- → Chapter. |
| –
| Repairing the overrunning clutch → Chapter. |
|
| 29 | Selector lever position “D or 3” automatic gearbox does not shift hydraulically into 3rd gear (3H) | 3rd and 4th gear-clutch -K3- defective | | –
| Observe the safety measures and notes: “PInspecting the solenoid valves and shift elements while driving” → Chapter. |
| –
| Repair 3rd and 4th gear clutch -K1- → Chapter. |
|
| 30 | Selector lever position “D or 3” automatic gearbox does not shift mechanically into 3rd gear (3M) | Lockup clutch defective | | –
| Observe the safety measures and notes: “PInspecting the solenoid valves and shift elements while driving” → Chapter. |
|
| 31 | Selector lever position “D” automatic gearbox does not shift mechanically into 4th gear (4M) | Lockup clutch defective | | –
| Observe the safety measures and notes: “PInspecting the solenoid valves and shift elements while driving” → Chapter. |
|
| 32 | Selector lever position “R” automatic gearbox does not shift into reverse gear | Reverse gear-clutch -K2- defective
reverse gear-brake -B1- defective | | –
| Observe the safety measures and notes: “PInspecting the solenoid valves and shift elements while driving” → Chapter. |
| –
| Repairing reverse gear-brake -B1- → Chapter. |
|
