AMT System Troubleshooting

After-sales Service Department

Failure analysis about DTC of AMT system

Ordinal

DTC

P0715

P0720

P0725

P1741/P1742

Definition

Analysis

Fault phenomenon

Solution

Friction Plate
angular velocity

1.Clutch speed sensor

open or short circuit
2.Malfunction of operatorclutch
3.Friction Plate of clutch
worn out and skip

1. Unable to shift gear

2. Only can shift on the 1st
gear, the 2nd gear and the
reverse gear.

1.Replace clutch
position sensor
2.Replace operating
mechanism of clutch
3.Replace friction
plate or clutch assy.

Car velocity

1.Odometer sensor open

or short circuit
2. Malfunction of
instrument. If instrument
was failure, the signal of
car velocity cant be
transmitted.
3. Odometer sensor didnt
gear well with the
Differential.

1. Only can shift on the 1st

gear, the 2nd gear and the
reverse gear.
2. Out-of-gear spontaneously.

1. Replace odometer
sensor.
2.Replace instrument
3.Remove and
reinstall odometer
sensor

Engine angular
velocity

1.Engine speed sensor

open or short circuit
2.Malfunction of cable
which connect engine
speed sensor to ECU or
connect ECU to TCU

Out to natural position

spontaneously 1.8 seconds
later stepping on the brake
pedal.

1Replace engine
speed sensor
2.Check whether the
cable connection is
in good condition.

Malfunction of position
sensor-selection.

1. Engine was unable to

restart or gear was unable to
shift with engine stalling.
2. Only can shift on the 1st
gear, the 2nd gear and the
reverse gear.

Replace the failure

solenoid valveselection

Stroke Sensor
clutch/selection

After-sales Service Department

Ordinal

DTC

P1743

P1744

Definition

Analysis

Fault Phenomenon

Solution

Clutch Position sensor

1. Clutch position sensor

open or short, or with
water inflow.
2.Cable-selespeed open or
short

1.Unable to shift gear

2.No power output on the 1st gear ,
the 2nd gear or the reverse gear,
when the speed of the car below
4Km/h, the engine speed below
1800rpm, and throttle opening below
45%.

Replace clutch position

sensor or cable-selespeed

Hydraulic Circuit Pressure

Sensor

1. Malfunction of
Hydraulic Circuit Pressure
Sensor.
2. Cable-selespeed open or
short.

1. Fuel pump work continually or

didnt work at all.
2. Unable to shift gear in AUTO.

Replace Hydraulic Circuit

pressure sensor or cableselespeed

Shift on 1st gear spontaneously

when stepping on brake pedal in
AUTO, unable to shift on the reverse
gear.

Replace Selespeed assy

P1772

Switch Lever stuck (any)

Switch lever was unable to

work normally.

P1752

Driver Relay Pump

Driver relay burn-out

Unable to shift gear at all.

Replace driver relay

P1770

No information about
accelerator pedal

1.Malfunction of cable
connect accelerator pedal
to ECU
2.Malfunction of ECU

1. Only can shift on the 1st gear,

the 2nd gear and the reverse
gear.

Replace cable or ECU.

After-sales Service Department

Ordinal

10

11

12

13

14

DTC

P1771

P1773

P1810

P0790

P1818

Definition

Analysis

Fault Phenomenon

Solution

High leakage hydraulic

group

1. Low pressure of
hydraulic circuit as
leakage of hydraulic group.
2. Fuel pump didnt work
as fuel pump relay burnout,
3.Malfunction of fuel
pump

1. Only can shift on the 1st gear,

the 2nd gear and the reverse
gear.
2. Unable to shift gear at all.

1. Replace the leak parts.

2. Replace fuel pump relay.
3. Replace fuel pump.

Insufficient
Capacity/Pressure

1. Fuel pump didnt work

as fuel pump relay burnout,
2. Malfunction of fuel
pump

Unable to shift gear at all.

1. Replace fuel pump relay.

2. Replace fuel pump

Error on friction undersystem

1. Malfunction of clutch
position sensor
2. Friction Plate of clutch
worn out and skip

1. Unable to shift gear as clutch

didnt work normally.
2. Repair as the procedure of P1743,
if the DTC P1743 and P1810
occurred together.

1. Replace clutch position

sensor or cable-selespeed
2. Replace friction plate or
clutch assy.

Switch lever self-stuck

Automatic switch lever

was unable to self-return
as the return spring didnt
work normally.

1. AUTO and Manual Mode were

unable to switch each other.
2. Unable to shift on the reverse
gear.

Repair automatic switch

lever or replace return
spring.

Error on speed gear case

under-system

1. Friction Plate of clutch

worn out and skip
2. Internal mechanical
failure of transmission.

1. Unable to shift gear as clutch

didnt work normally.
2. Lack of one gear position when
driving.

1. Replace friction plate or

clutch assy.
2. Disassemble and
assemble transmission to
replace the failure
mechanical parts.

After-sales Service Department

 Case 1Only can shift on the 1st gear, the 2nd gear and the reverse gear with
DTC P0715
Measures
Step 1:
Check whether clutch speed sensor have bump marks.
1) The input shaft should be replaced, if clutch speed sensor has bump marks and the
input shaft of transmission is loosening with axial and radial runout.

Check whether
this surface have
bump marks

After-sales Service Department

Check whether this

shaft is loosening

2 Check transmission oil, if found no input shaft runout, but clutch speed sensor
have bump marks: If there were scrap iron and impurities in the oil, replace
transmission oil.

Check whether
the oil outflow
have scrap iron
and impurities

After-sales Service Department

Check whether
the oil outflow is
going bad and
have odors

3DTC P1818 occurred with P0715 together, both clutch speed sensor and input
shaft of transmission are normal: Disassemble transmission and check whether the
synchronizers are normal, If necessary, replace the failure parts.
All above is OK, go to next step.

Check
whether the
synchronizers
are normal

After-sales Service Department

Step 2:
Check whether clutch was matched with TCU version: The version CAA04QHO must be
equipped with clutch supplied by 1CU, the version CAA05QM5 must be equipped
with clutch supplied by 1CW.
Otherwise, vehicle will be caused some problems, such as, move automatically, didnt
run when stepping on the accelerate pedal, hard shift etc.
All above is OK, go to next step.

Check TCU version

After-sales Service Department

Step 3:
Check clutch position reference data with X-431: If the value deviate from the standard
value much, means clutch disc was wearing seriously and should be replaced.
END line/service AUTO-set and friction AUTO-set enabling should be preformed after
replacing.
All above is OK, go to next step.

The standard value

of clutch position
reference can be
found when
Checking the actual
reference.

After-sales Service Department

If the value deviate

from the standard
value much, check
the clutch.

Step 4:
Check the operating mechanism of clutch:
1)Replace clutch disengaging bearing if it is wearing;
2)Replace the spline of shaft assy-clutch release if it is wearing;
3)Replace clutch disengaging push rod if it is wearing.
All above is OK, go to next step.

Check
the spine of

shaft
assy-clutch

release

Check clutch
disengaging bearing

After-sales Service Department

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Step 5:
Check cable of selespeed:
1)Malfunction of clutch position sensor: If there were water inflow into clutch
position sensor, it will be failure with DTC P1810 and P0715 exist.
Clean and dry the water, then replace a new clutch position sensor.
END line/service AUTO-set and friction AUTO-set enabling should be preformed
after replacing.
2) Other failures: Damage of cable or cable open to the ground.

Check whether connector

of clutch position sensor
was normal.

After-sales Service Department

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Attachment 1:
END line/service AUTO-set and friction AUTO-set enabling .

END line/service
AUTO-set and
friction AUTO-set
enabling

After-sales Service Department

Both END line/service

AUTO-set and friction
AUTO-set enabling
should be preformed
for three times,
ignition switch should
turn off for ten second
every AUTO-set
course.

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Case 2Shift down one or more gear

automatically while normal driving, with

DTC P1818.
Measures
Step 1:
Check transmission:
1) Shift down one gear or gear free automatically: Disassemble transmission and
check whether synchronizers are failure, replace the failure parts if necessary.

Check whether
synchronizers and
gears were normal.

After-sales Service Department

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2Gear free automatically: Disassemble transmission and check whether shifting

forks are failurereplace the failure parts if necessary.

Check whether
shifting forks were
normal.

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3Wrong signal of vehicle speed: Vehicle speed showed on X-431 was zero while
driving, gear shift down to the 1ST gear or gear free automatically.

a. Malfunction of odometer sensor: Replace it.

Check
the connector

of
odometer sensor

After-sales Service Department

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b. Malfunction of instrument cluster: Replace instrument cluster or cable.

The signal of car velocity will be unable to transmit if instrument was failure, as
instrument receives the signal from odometer sensor, then transmit it to TCU
and ECU .

4Odometer sensor didnt gear well with the Differential: Remove and reinstall
odometer sensor.
All above is OK, go to next step.

Remove odometer

sensor and check

whether the sensor

was normal.

After-sales Service Department

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Step2:
Check driver door contact switch : Replace the switch if it was failure,.
All above was OK, go to next step.

Turn the lamp in position of

lighting when doors were open,
then press driver door contact
switch. If the lamp still light,
replace the switch.

Step3:
Check engine problems with X-431: Replace knock sensor if it was short to ground.

After-sales Service Department

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Case 3Leakage of selespeed hydraulic oil.

Measures:
Step 1
Check whether the air hole of tank lid was in good ventilation:
The air hole would be obstructed if the O-ring of oil tank lid didnt be removed when
installing selespeed on the vehicle, which could cause crack of oil tank as
abnormal pressure in it.

The O-ring of oil tank lid.

After-sales Service Department

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Step2
Replace operator-clutch if it leakage.
END line/service AUTO-set and friction AUTO-set enabling should be preformed
after replacing.

Leakage because of
eccentric wear of cable
of operator-clutch

Leakage because of
damaged of internal oil
seal of operator-clutch

After-sales Service Department

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Step 3
Leakage of gear shifting shaft:

Leakage of piston of gear

shifting shaft, replace the
piston and washer.

Leakage of solenoid
valves, replace the failure
part.

Leakage of gear shifting

shaft, replace selespeed
kit assy.

END line/service AUTO-set and friction AUTO-set enabling should be preformed

after replacing.

After-sales Service Department

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Case 4Lack of one gear or unable to shift gear at all, with DTC P1810 or
P1743.
Measures
Step 1
Regarding DTC P1743: Check clutch position sensor, if there were water in flowed,
clean and dry the water, then replace a new sensor.
END line/service AUTO-set and friction AUTO-set enabling should be preformed
after replacing.

Clutch position sensor is located

under transmission.

After-sales Service Department

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Step 2
Regarding DTC P1810: Check clutch position reference data with X-431, if the value
deviate from the standard value much, means clutch disc was wearing
seriously and should be replaced.
END line/service AUTO-set and friction AUTO-set enabling should be preformed
after replacing.

The standard
value of clutch
position reference
can be found
when Checking
the actual
reference.

After-sales Service Department

If the value
deviate from the
standard value
much, check the
clutch.

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Case 5The warning lamp of transmission light occasionally when driving, then
gear was unable to shift and engine was unable to restart after stopping until one
minute later, with DTC P1773 or P1744 usually.
Measures:
Step 1:
Check whether cable of selespeed was normal.
All above was OK, go to next step.

Confirm
that the cable is normal, no

short
or open circuit, the connector

pins
are
normal and connect well.

After-sales Service Department

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Step 2:
If DTC P1755 exist, check whether drive relay starting was connect well. Replace
the relay if it was burn out.
All above was OK, go to next step.

The relay was located under

the dashboard left side.

After-sales Service Department

Check whether the

relay was normal.

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Step 3:
Check the hydraulic circuit pressure when failure, comparing with normal
pressure , which between 39bar to 52bar usually. If the pressure wasnt
covered with normal value, replace fuel pump.
END line/service AUTO-set and friction AUTO-set enabling should be preformed
after replacing.

The pressure should be

covered with normal
value.

Fuel pump.
Check hydraulic circuit
pressure.

After-sales Service Department

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Case 6Engine stop suddenly when normal driving, then engine is unable to
restart and gear is unable to shift.
Measures
Step 1:
Power-lack of battery: Check whether the voltage of battery was normal.
All above was OK, go to next step.

Check the voltage

of battery.

After-sales Service Department

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Step 2:
Check clutch position reference data with X-431: If the value deviate from the
standard value much, means clutch disc was wearing seriously and should
be replaced.
END line/service AUTO-set and friction AUTO-set enabling should be preformed
after replacing.
All above was OK, go to next step.

The standard value

of clutch position
reference can be
found when
Checking the actual
reference.
If the value deviate
from the standard
value much, check
the clutch.

After-sales Service Department

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Step 3:
If DTC P1755 occurred, check whether drive relay starting was connect well. Replace
the relay if it was burn out.
All above was OK, go to next step.

The relay was located under

the dashboard left side.

After-sales Service Department

Check whether the

relay was normal.

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Step 4:
Check hydraulic circuit pressure: If the pressure wasnt covered with normal
value, which is between 39bar to 52bar usually, replace fuel pump.
END line/service AUTO-set and friction AUTO-set enabling should be
preformed after replacing.

The pressure should

be covered with normal
value.

Fuel pump.

After-sales Service Department

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Case 7The warning lamp of transmission light when up-shift to the 5th gear,
unable to shift to the reverse gear.
Measures
Step 1
Check whether cable of selespeed was normal. If there were DTC exist, repair as
the description of DTC.
All above was OK, go to next step.

Confirm
that the cable is normal, no

short
or open circuit, the connector

pins
are normal and connect well.

After-sales Service Department

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Step 2
Perform action-text about the 5-R gears selection solenoid valve with X-431,
replace the solenoid valve if the action-text was failure.

END line/service AUTO-set and friction AUTO-set enabling should be preformed

after replacing.

All above was OK, go to next step.

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Step 3
Disassemble transmission and check whether the internal mechanism parts
were normal.

Check whether
synchronizers and
gears were normal.

Check whether the

reverse gear shifting
fork was normal.

After-sales Service Department

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Case 8Unable to up-shift when driving, starter of engine fail to work when
start the engine.
Measures
Step 1:
Check whether cable of selespeed was normal. If there were DTC occurred, repair
as the description of DTC.
All above was OK, go to next step.

Confirm that the cable is normal, no

short or open circuit, the connector

pins are normal and connect well.

After-sales Service Department

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Step 2:
If DTC P1755 exist, check whether drive relay starting was connect well. Replace the
relay if it was burn out.
All above was OK, go to next step.

The relay was located under

the left side dashboard.

After-sales Service Department

Check whether the

relay was normal.

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Step 3:
Check hydraulic circuit pressure: If the pressure wasnt covered with normal
value, which is between 39bar to 52bar usually, replace fuel pump.
END line/service AUTO-set and friction AUTO-set enabling should be preformed
after replacing.

The pressure should be

covered with normal
value.

Fuel pump.

After-sales Service Department

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Case 9: Lack of one up-shift gear when driving, which was normal when
shifting down and parking, sometimes with DTC P1810.
Measures :
Step 1:
Check clutch position reference data with X-431: If the value deviate from the
standard value much, means clutch disc was wearing seriously and should be
replaced.
END line/service AUTO-set and friction AUTO-set enabling should be preformed
after replacing.

Step 2:
Disassemble transmission and check whether synchronizers and gears were
normal, replace the failure parts if necessary.

After-sales Service Department

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Case 10:
1Run automatically without pressing accelerator pedal when shift on the 1st gear.
2Vibrate heavily while starting, then all is normal.
Measures
Step 1:
Perform END line/service AUTO-set and friction AUTO-set enabling, ignition switch
should be turned off for ten second every AUTO-set course.
NOTE: If ignition switch didnt turn off for ten seconds, the AUTO-set course will
failure.
All above was OK, go to next step.
Step 2:
Check clutch position reference data with X-431: If the value deviate from the
standard value much, means clutch disc was wearing seriously and should be
replaced.
END line/service AUTO-set and friction AUTO-set enabling should be preformed
after replacing.

After-sales Service Department

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All above was OK, go to next step.

Step 3:
Replace clutch position sensor.
END line/service AUTO-set and friction AUTO-set enabling should be preformed
after replacing.
All above was OK, go to next step.

Step 4:
Check whether clutch was matched with TCU version: The version CAA04QHO
must be equipped with clutch supplied by 1CU, the version CAA05QM5
must be equipped with clutch supplied by 1CW.

After-sales Service Department

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Case 11The warning lamp of transmission light when driving, then gear was
unable to shift.
Measures
Wrong signal of clutch speed sensor: Remove the sensor, then reinstall it
adding a 0.2mm thick washer, up-date TCU to the latest version(CAA05QN0).
END line/service AUTO-set and friction AUTO-set enabling should be preformed
after the repair work.

Add a 0.2mm thick

washer here.

After-sales Service Department

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Thanks

After-sales Service Department

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