156 sillyspeed gear selection

[Alfa156Melb 9]

Morning all! It's been a while since I've played in here, the car's been working perfectly.. how boring..

 

Anyway, all that changed tonight when my partner took it to work.. So I'm looking for some advice...

 

This afternoon I recalibrated the Selespeed using FES because it was starting to kangaroo jump on a cold clutch...

 

So today, Mrs Alfa156Melb took it to work. It's a 40 min drive and when she arrived, she went to park, with the car in 1st, she tried to select reverse, but the system got stuck in neutral. Thats when the gear lever apparently got stuck. She tells me it would move left and right no problem, but not up/down...

 

She turned the car off, and restarted it which fixed the problem and parked the car.

 

Later, on a cold engine, she had to move the car, this time the system selected 1st gear fine, but she tells me the clutch was sluggish to engage, the engine would rev to 2000rpm and slip (at least that what I understand she meant anyway).

 

After that, the car has been faultless. Ive taken it for a drive and everything is perfect.

 

Finally, just now I plugged fes into it again for error codes and nothing came up, except there's been a number of missed shifts recorded. 2 in 1st gear and 1 in 5th gear. None of which were there last time i looked about a month ago.

 

If anyone can shed some light on this, I'd appreciate it.. I know its vague but I wasnt there when it happened.

 

I also should mention that I noticed about a month ago that the shift lever feels a little loose, there's more play in it than normal.. Maybe that has something to do with it? Does anyone know (smaky?) how to tighten it?

[Alfa156Melb 9]

Update..

 

The missed shifts were: 1 miss in 1st, and 2 misses in 5th.. not what I had noted above.

 

Also, below is the FES log... there's 1 count of the clutch not releasing properly.. I'm guessing that happened last night...

 

here's the log - is there anything there I should be worried about?

 

FESLog_1206240202_ALFA 156 '02 JTS SELESPEED

READING PARAMETERS:

Number of rewrites: 0

Gear/engage position: 21.774 mm

Selection position: 18.095 mm

Clutch pressure plate travel: 12.684 mm

Clutch pressure plate reference: 12.726 mm

Accelerator pedal position: 0.0 %

Hydraulic circuit pressure: 45.481 bar

Coolant temperature: 85.0 °C

Battery voltage: 13.8814 V

Engine speed: 852 rpm

Clutch RPM: 0 rpm

Vehicle speed: 0.000 km/h

Odd number gears current: 0 mA

Even number gears current: 0 mA

Clutch solenoid valve current: 967.2 mA

Actual torque: -5 Nm

Calculated engine torque: 1 Nm

A/T selector lever position: No request

Gear engaged: N

Desired gear: N

Automatic transmission: OFF

Driver's door: Open

Brake pedal position: Released

Ignition key ON/OFF: ON

Pump relay control: OFF

Engine startup: Not allowed

Acoustic signal: OFF

High gear selection: Not active

Low gear selection: Not active

Load relay: ON

Starter circuit: Not requested

Clutch engaged position (self-adjusted): 27.846 mm

PIS closed position (self-adjusted): 11.634 mm

Solenoid Valve current at Zero flow: 1014.0 mA

Gearbox oil temperature: 58.7 °C

Clutch temperature: 105.2 °C

Neutral engaged counter: 26220

First gear engaged counter: 44668

Second gear engaged counter: 57042

Third gear engaged counter: 11941

Fourth gear engaged counter: 14049

Fifth gear engaged counter: 21198

Reverse gear engaged counter: 69

Pump ON counter: 65445

System ON time: 59706 Min

Clutch overtemperature time: 386 Min

Missed selection/shift counter: 0

Clutch RPM too high counter: 0

Missed gearshift counter: 0

Clutch insufficient release counter: 1

Clutch engaging problem counter: 0

Not disengaged counter: 0

Selection in excessive temp. counter: 0

Missed shift counter: First gear: 1

Missed shift counter: Second gear: 0

Missed shift counter: Third gear: 0

Missed shift counter: Fourth gear: 0

Missed shift counter: Fifth gear: 2

Missed shift counter: Reverse gear: 0

Lever request fault counter: 0

Insufficient hydraulic pressure counter: 0

Gearbox/clutch self-calibration: Correct

Distance covered in neutral: 33 km

Distance covered in 1st gear: 430 km

Distance covered in 2nd gear: 7842 km

Distance covered in 3rd gear: 13527 km

Page

[Sphinx 7]

Engine startup: Not allowed

 

 

Sent from my HTC EVO 3D X515m using Tapatalk 2

[Alfa156Melb 9]

helpfull

[Smaky 73]

Engine startup: Not allowed

 

 

Sent from my HTC EVO 3D X515m using Tapatalk 2

 

First you need to understand why.

[Smaky 73]

 

Clutch engaged position (self-adjusted): 27.846 mm

 

 

There's your problem, adjust, lock and calibrate again.

[Alfa156Melb 9]

Engine startup: Not allowed

 

 

Sent from my HTC EVO 3D X515m using Tapatalk 2

 

First you need to understand why.

 

The engine was RUNNING when that log was taken.

[Alfa156Melb 9]

 

Clutch engaged position (self-adjusted): 27.846 mm

 

 

There's your problem, adjust, lock and calibrate again.

 

Thanks Smaky. I should have known better, although I didn't think 1.5 mm would make that much difference.

 

I'll sort it this weekend.

[Smaky 73]

That would be the Sele pump relay infront of the battery.

[Alfa156Melb 9]

That would be the Sele pump relay infront of the battery.

 

Wait a sec.. sele pump relay? Whats that got to do with the Clutch Engaged position?

 

Also, got a Motor control warning this morning on a cold start - about 8 degrees c. Plugged in FES and I have a PO300 and PO304 fault showing up..

 

Would that he a faulty coil on number 4?

[Smaky 73]

Wait a sec.. sele pump relay? Whats that got to do with the Clutch Engaged position?

 

Also, got a Motor control warning this morning on a cold start - about 8 degrees c. Plugged in FES and I have a PO300 and PO304 fault showing up..

 

Would that he a faulty coil on number 4?

 

Yes that is pack 4, either plugs or coil the system can't distinguish, but 99% ott it's coil. Clear code and see if it reappears before panicing.

 

 

Failure of the sele pump relay causes drops and delayed recovery of pressure, as this system requires hydraulics and loss will affect the position of components (pistons) so sensors will give incorrect readings, but I think that the posts are out of order and you can forget about that one.

Edited July 21, 2012 by Smaky

[Alfa156Melb 9]

Ah ok, that makes sense. I haven't had a chance to readjust the clutch engaged position yet... I'll check the relay tomorrow and see what comes up.

 

I figured it might be the coil - I've had the other 3 replaced over the last few years, so i guess it was time.. anyway i reset the codes and so far not other errors.. so I'll just hold out till it drops i guess.

Edited July 23, 2012 by Alfa156Melb

[Smaky 73]

Don't wait too long if it does fail again though as it will cook the cats if left, maybe even burn out the coil too....

 

 

[Alfa156Melb 9]

hmm - OK, cheers.

 

What order are the cylinders in respect to the Aux belt?

[Smaky 73]

1,2,3,4,battery.

[Alfa156Melb 9]

Thanks.

[Alfa156Melb 9]

Hey Smaky, I finally got around to adjusting the clutch engaged position today.. the closest I could get was 28.200 (oscillating +/- .05) and the difference is amazing.

 

The clutch engagement is perfectly smooth, the gear changes are smooth and a bit faster.. it's never been so good. Thanks for the heads up. Only had one problem - after I finished the job and went to calibrate, FES kept on throwing a gearbox error.. So I took the car for a drive and tried again and that time it calibrated fine. Not sure what happened there? I have a feeling the pump is getting a bit weak, and a drive gave it a kick.

 

I cleared the fault codes last week for the ignition and the problem hasn't come back, so I haven't touched the coil yet.

[Smaky 73]

There we go.

[Alfa156Melb 9]

And.... today, on a cold clutch, there was slight kangaroo jumping again. went away as the system warmed.

 

Might try the "Self Callibration Enable" routine in FES.. maybe that will help.