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Discussion Starter · #1 ·
Figured I'd start a new topic on this as the refresh is technically complete.

I've had an intermittent red cog following the rebuild that sometimes prevents any shifting at all, or, prevents shifting into even number gears (R,1,4,6). An ignition reset clears the error and typically the car runs fine the rest of the drive, and it tends to occur mainly during warm-up.

I finally took a drive with my laptop and recorded the following behaviors:

ISTA (don't mind the other codes, I'm chasing an alternator or voltage regulator issue as well but have a good handle on that diagnostic routine)
Font Technology Screenshot Number Multimedia


INPA SMG stored fault:

"5501 control gear valve drv2"
Font Screenshot Electronic device Multimedia Number

(14.53V looks high, could this be partial to a failing voltage regulator)

Real-time read in INPA:

Rectangle Font Material property Parallel Screenshot


I was able to drive an observe, for each shift using valve 1 (1,3,5,7) the pressure would drop to 53-56 and for each shift on valve 2 (R,3,5,7) the pressure would spike up to 73-73 bar.

So, question being, is there an issue with the valve and I'll need to swap it for a spare - or is it possible I just need to bleed and recheck?
 

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(14.53V looks high, could this be partial to a failing voltage regulator)
Not considerably high, the DME will regulate based on battery soc, if the battery soc is low for example at morning startup the DME will boost the battery charging power then start to drop down charging power after driving good distance. But if there is a fault these normal routine may not apply, but still 14.53 is not alarming. You may need to replace the alternator or voltage regulator since ISTA reported it and you had a christmas tree instance.

So, question being, is there an issue with the valve and I'll need to swap it for a spare -
Not at this time.
The fault details telling that 4th gear requested the DRV2 didn't move when supplied with current so line break is a suspect here. It could be intermittent and yeah may be related to previous damaged wires. Just remember this circuit has nothing to do with gps.
You can monitor Analog 3 and shift 2nd gear and DRV2 should open and close to direct pressure, if intermittent the valve will move and function as requested, if a hard fault it shouldn't move and the gear shift request will not be executed.
prevents shifting into even number gears (R,1,4,6)
R/1 are not even numbers and they are not controlled by DRV2, only 2/4 6/7 are controlled by DRV2.
 

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Discussion Starter · #6 ·
Thanks for the input all, some more love diagnosis will be required then. Remember though, the car drives perfect 90+ percent of the time. But this is occurring frequently enough and it is shifting to the requested gears (normally at the seat of the pants) while these pressure spikes are being observed.

only when the smg ecu diverts to a protective program does skip shifting or any noticeable negative behavior occur.
 

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Discussion Starter · #8 ·
Had to travel to Austin on business for a few days but got a chance to work with the car a bit more this afternoon. While driving I can see that both hall sensors (transmission input, output speed) are reading consistently and from what I can tell accurately. In 6th, which is 1:1 they are reading equal value which was as good of test as I could come up with. But as you'll see they don't seem in sync with speeds read over the CAN circuit.

Secondly, I'm definitely having an issue with proportional valve 2. I need to get under the car and test continuity in that wire (due to having repaired a number on the pinched run of loom) but I believe I've isolated it to pin 25 which is the pressure decrease circuit, although I'll test them both.

I can see in INPA when I shift from 1st to 2nd (for example), pressure rises continuously to 68 bar and remains until shifting back unto a DRV1 valve controlled gear where the system pressure is then returned back to 58ish bar.

Secondly, I'm being rev-limited at 6500 rpm on a warm engine that should be ready to go. The limiter hits hard, when emposed, and I get an array of errors including yellow cog, FTM system inoperable, DSC error. DSC indicator on dash is illuminated but not necessarily an MIL lamp.

Here's the translated SMG error memory pulled from INPA:


H I S T O R Y M E M O R Y
---------------------------------------
Date: 19.05.2022 14:48:04
ECU: SMG_60
JobStatus: OKAY
Variant: SMG_60
-------------------------------------------------------------
RESULT: 9 error in error memory !
-------------------------------------------------------------
5501 Control of DRV2 gear valve
Error counter: 6
Logistic counter: 38
  • environment record
Mileage 175848 km
Power supply Ubatt raw value 14.63 V
Actual current DRV2 raw value 15.00 mA
Set current DRV2 0.00 mA
Setpoint current PWV3 0.00 mA
Setpoint current PWV4 0.00 mA
Hydraulic pressure actual value 69.30 bar
Gear position sensor shift rod 2/4 setpoint 497.00 Ink
Gear position sensor shifting rod 6/7 setpoint 497.00 Ink
Gear position sensor shift rod 2/4 actual value 492.00 Ink
Gear position sensor shift rod 6/7 actual value 487.00 Ink
Duty cycle pressure controller 2 0.00 %
Error status valve: line interruption 0-n
  • environmental record
Mileage 175880 km
Power supply Ubatt Raw value 14.63 V
Actual current DRV2 raw value 15.00 mA
Setpoint current DRV2 957.00 mA
Setpoint current PWV3 0.00 mA
Setpoint current PWV4 850.00 mA
Hydraulic pressure actual value 58.20 bar
Gear position sensor shift rod 2/4 setpoint 496.00 inc
Gear position sensor shifting rod 6/7 setpoint 898.00 Ink
Gear position sensor shift rod 2/4 actual value 486.00 Ink
Gear position sensor shift rod 6/7 actual value 486.00 Ink
Duty-cycle pressure controller 2 61.31 %
Error status valve: line interruption 0-n
  • environmental record
Mileage 175960 km
Voltage supply Ubatt Raw value 14.63 V
Actual current DRV2 raw value 12.00 mA
Setpoint current DRV2 1015.00 mA
Setpoint current PWV3 900.00 mA
Setpoint current PWV4 0.00 mA
Hydraulic pressure actual value 66.40 bar
Gear position sensor shift rod 2/4 setpoint 499.00 Ink
Gear position sensor shifting rod 6/7 setpoint 484.00 Ink
Gear position sensor shift rod 2/4 actual value 177.00 Ink
Gear position sensor shift rod 6/7 actual value 480.00 Ink
Duty-cycle pressure controller 2 67.55 %
Error status valve: Line interruption 0-n

Gear valve DRV2 line interruption
Test conditions fulfilled
Error currently not present, but already stored
Error would cause a warning lamp to light up
Error code: 55 01 A4 00 00 06 26 55 DD 3A 80 00 0F 00 00 00
00 00 02 B5 01 F1 01 F1 01 EC 01 E7 00 00 04
55 E1 3A 80 00 0F 03 BD 00 00 03 52 02 46 01 F0
03 82 01 E6 01 E6 9C F0 04 55 EB 3A 80 00 0C 03
F7 03 84 00 00 02 98 01 F3 01 E4 00 B1 01 E0 AC
E8 04
-------------------------------------------------------------
5200 Evaluation of motor speed (CAN)
Error counter: 4
Logistic counter: 38
  • environment record
Mileage 175856 km
Power supply Ubatt raw value 14.38 V
Drive speed error indicator 1 30.00 -
Input speed 2 error indicator 0.00 -
Gearbox input speed actual value 6187.00 1/min
Motor speed actual value 6202.00 1/min
Engine speed raw value (sensor) 6200.00 1/min
Engine speed (CAN) 6202.00 1/min
Actual gear 0= Neutral, 1-7= Gear, 8= Reverse gear 2.00 -
Transmission output speed 2451.00 1/min
Status engine speed CAN: engine speed CAN ok 0-n
Gearbox status: shifted 0-n
Clutch status: closed 0-n
  • environment record
Mileage 175952 km
Power supply Ubatt raw value 14.28 V
Drive speed error code 1 82.00 -
Input speed 2 error indicator 0.00 -
Gearbox input speed actual value 6345.00 1/min
Motor speed actual value 6354.00 1/min
Engine speed raw value (sensor) 6349.00 1/min
Engine speed (CAN) 6354.00 1/min
Actual gear 0= Neutral, 1-7= Gear, 8= Reverse gear 1.00 -
Transmission output speed 1637.00 1/min
Status engine speed CAN: engine speed CAN ok 0-n
Gearbox status: shifted 0-n
Clutch status: closed 0-n


  • environment record
Mileage 175952 km
Power supply Ubatt raw value 14.22 V
Drive speed error indicator 1 42.00 -
Input speed 2 error indicator 0.00 -
Gearbox input speed actual value 6310.00 1/min
Motor speed actual value 6406.00 1/min
Engine speed raw value (sensor) 6327.00 1/min
Engine speed (CAN) 6406.00 1/min
Actual gear 0= Neutral, 1-7= Gear, 8= Reverse gear 3.00 -
Transmission output speed 3537.00 1/min
Status engine speed CAN: engine speed CAN ok 0-n
Gearbox status: shifted 0-n
Clutch status: closed 0-n
Engine speed (CAN signal) implausible signal
Test conditions fulfilled
Error currently not present, but already stored
 

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Discussion Starter · #9 ·
Clearly I need to get to the bottom of the shift valve issue, seems reasonably probable it will be a wire issue I'll need to trace down. But, that second set of errors is strange, why is the signal considered implausible when the values are all so very close? Why and FTM error when I can clearly see in INPA all 4 wheel speeds are measured to be the same? And why the imposed rev limiter?
 

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Will look into these logs.
What are the other 7 errors?.
You sure the solenoid connector pushed and snug?.
Yeah trace the wire and yes pin 25 red color wire and green pin 7 for ground. TRy to shake it while testing for intermittent possibility.
If you can catch the error while driving and monitoring Analog 3, does the valve close and open normal?.
 

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Discussion Starter · #11 ·
I would fare to say I'm certain the connector is snug, I replaced all of the rings (carefully as you could imagine being the third time) and would have ensured the plugs were snapping back. I'll proceed with tracing that wire today and reporting back.

Ah I hadn't noticed the full log hadn't translated. See below:
  • 5502 Control of gear valve PWV1
    • Error counter: 1
    • Logistic counter: 40
    • Mileage 175760 km
    • Power supply Ubatt raw value 14.63 V
    • Actual current PWV1 raw value 17.00 mA
    • Set current PWV1 0.00 mA
    • Set current DRV1 0.00 mA
    • Hydraulic pressure actual value 62.60 bar
    • Gear position sensor shift rod R/1 setpoint 509.00 Ink
    • Gear position sensor shift rod R/1 actual value 507.00 Ink
    • Duty cycle shift cylinder R/1 0.00 %
    • Status control HSD 1 (digital output) Raw value 1.00 0/1
    • Error status valve: line interruption 0-n
    • Gear valve PWV1 Line interruption
    • Test conditions fulfilled
    • Error currently present and already stored
    • Error would cause a warning lamp to light up
    • Error code: 55 02 E4 00 00 01 28 55 D2 3A 80 00 11 00 00 00
    • 00 02 72 01 FD 01 FB 00 00 E0 80 04
  • 510D Evaluation clutch position sensor main sensor
    • Error counter: 1
    • Logistic counter: 40
    • Mileage 175720 km
    • Sensor voltage supply A raw value 5.00 V
    • Coupling position raw value main sensor 1.00 Ink
    • Clutch position raw value redundant sensor 1.00 Ink
    • Gearbox input speed actual value 0.00 1/min
    • Engine speed actual value 0.00 1/min
    • Hydraulic pressure actual value 0.00 bar
    • Clutch position actual value -254.00 inc
    • Clutch position setpoint 642.00 Ink
    • Faulty clutch position sensor identification: no fault present 0-n
    • Coupling status: open 0-n
    • Clutch position sensor (main sensor) signal below threshold
    • Test conditions fulfilled
    • Error currently not present, but already stored
    • Error would cause a warning lamp to light up
    • Error code: 51 0D A2 00 00 01 28 55 CD 14 00 00 01 00 00
    • 00 00 00 00 FF 02 02 82 00 00
  • 5106 Evaluation of transmission position sensor shift rod R/1 main sensor
    • Error counter: 1
    • Logistic counter: 40
    • Mileage 175720 km
    • Gearbox input speed actual value 0.00 1/min
    • Transmission output speed 0.00 1/min
    • Actual gear reset fixed 0= Neutral, 1-7= Gear, 8= Reverse gear 0.00 -
    • Sensor voltage supply A raw value 5.00 V
    • Sensor voltage supply B raw value 5.01 V
    • Gear position sensor shift rod R/1 raw value 1023.00 Ink
    • Redundant gear position sensor shift rod R/1 Raw value 1023.00 Ink
    • Gear position sensor shift rod R/1 actual value 1023.00 Ink
    • Redundant gearbox position sensor shift rod R/1 actual value 1023.00 Ink
    • Gear position sensor shift rod 5/3 raw value 1023.00 Ink
    • Gearbox status: preload 0-n
    • Faulty gear position sensor identification R/1: No fault present 0-n
    • R/1 (main sensor) Carrier frequency PWM out of range
    • Test conditions fulfilled
    • Error currently not present, but already stored
    • Error would cause a warning lamp to light up
    • Error code: 51 06 A4 00 00 01 28 55 CD 00 00 00 00 14 00
    • 14 0A 03 FF 03 FF 03 FF 03 FF 06 00
  • 5107 Evaluation of transmission position sensor shift rod R/1 redundant sensor
    • Error counter: 1
    • Logistic counter: 40
    • Mileage 175720 km
    • Gearbox input speed actual value 0.00 1/min
    • Transmission output speed 0.00 1/min
    • Actual gear reset fixed 0= Neutral, 1-7= Gear, 8= Reverse gear 0.00 -
    • Sensor voltage supply A raw value 5.00 V
    • Sensor voltage supply B raw value 5.01 V
    • Gear position sensor shift rod R/1 raw value 1023.00 Ink
    • Redundant gear position sensor shift rod R/1 Raw value 1023.00 Ink
    • Gear position sensor shift rod R/1 actual value 1023.00 Ink
    • Redundant gearbox position sensor shift rod R/1 actual value 1023.00 Ink
    • Gear position sensor shift rod 5/3 raw value 1023.00 Ink
    • Gearbox status: preload 0-n
    • Identification of faulty gear position sensor R/1: No fault present 0-n
    • R/1 (redundant sensor) Carrier frequency PWM out of range
    • Test conditions fulfilled
    • Error currently not present, but already stored
    • Error would cause a warning lamp to light up
    • Error code: 51 07 A4 00 00 01 28 55 CD 00 00 00 00 14 00
    • 14 0A 03 FF 03 FF 03 FF 03 FF 06 00
  • 5108 Evaluation gear position sensor shift rod 5/3
    • Error counter: 1
    • Logistic counter: 40
    • Mileage 175720 km
    • Gearbox input speed actual value 0.00 1/min
    • Transmission output speed 0.00 1/min
    • Actual gear 0= Neutral, 1-7= Gear, 8= Reverse gear 0.00 -
    • Sensor voltage supply B Raw value 5.01 V
    • Gear position sensor shift rod R/1 raw value 1023.00 Ink
    • Gear position sensor shift rod 5/3 raw value 1023.00 Ink
    • Gear position sensor shifting rod 2/4 raw value 1023.00 Ink
    • Gear position sensor shifting rod 6/7 raw value 1023.00 Ink
    • Gear position sensor switching rod 5/3 actual value 1023.00 Ink
    • Error status PWM output switching cylinder 5/3: No error present 0-n
    • Gearbox status: Preload 0-n
    • 5/3 Carrier frequency PWM out of range
    • Test conditions fulfilled
    • Error currently not present, but already stored
    • Error would cause a warning lamp to light up
    • Error code: 51 08 A4 00 00 01 28 55 CD 00 00 00 00 14 0A
    • 03 FF 03 FF 03 FF 03 FF 00 06
  • -------------------------------------------------------------
  • 5109 Evaluation of transmission position sensor shift rod 2/4
    • Error counter: 1
    • Logistic counter: 40
    • Mileage 175720 km
    • Gearbox input speed actual value 0.00 1/min
    • Transmission output speed 0.00 1/min
    • Actual gear 0= Neutral, 1-7= Gear, 8= Reverse gear 0.00 -
    • Sensor voltage supply B Raw value 5.01 V
    • Gear position sensor shift rod R/1 raw value 1023.00 Ink
    • Gear position sensor shift rod 5/3 raw value 1023.00 Ink
    • Gear position sensor shifting rod 2/4 raw value 1023.00 Ink
    • Gear position sensor shifting rod 6/7 raw value 1023.00 Ink
    • Gear position sensor switching rod 2/4 actual value 1023.00 Ink
    • Error status PWM output switching cylinder 2/4: No error present 0-n
    • Gearbox status: Preload 0-n
    • 2/4 Carrier frequency PWM out of range
    • Test conditions fulfilled
    • Error currently not present, but already stored
    • Error would cause a warning lamp to light up
    • Error code: 51 09 A4 00 00 01 28 55 CD 00 00 00 00 14 0A
    • 03 FF 03 FF 03 FF 03 FF 00 06
  • 510A Evaluation of transmission position sensor shift rod 6/7
    • Error counter: 1
    • Logistic counter: 40
    • Mileage 175720 km
    • Gearbox input speed actual value 0.00 1/min
    • Transmission output speed 0.00 1/min
    • Actual gear 0= Neutral, 1-7= Gear, 8= Reverse gear 0.00 -
    • Sensor voltage supply B Raw value 5.01 V
    • Gear position sensor shift rod R/1 raw value 1023.00 Ink
    • Gear position sensor shift rod 5/3 raw value 1023.00 Ink
    • Gear position sensor shifting rod 2/4 raw value 1023.00 Ink
    • Gear position sensor shifting rod 6/7 raw value 1023.00 Ink
    • Gear position sensor switching rod 6/7 actual value 1023.00 Ink
    • Error status PWM output switching cylinder 6/7: No error present 0-n
    • Gearbox status: Preload 0-n
    • 6/7 Carrier frequency PWM out of range
    • Test conditions fulfilled
    • Error currently not present, but already stored
    • Error would cause a warning lamp to light up
    • Error code: 51 0A A4 00 00 01 28 55 CD 00 00 00 14 0A
    • 03 FF 03 FF 03 FF 03 FF 00 06
 

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5501 Control of DRV2 gear valve:
The shift valve failed to move the shift rod to set position, once out of 6th gear and once out of 4th gear, in the second and third case, in the first case no movement occurred, here not sure at what gear request or condition the fault triggered. If you are troubleshooting you should delete a fault after taking a snap shot of the details and keep testing and monitoring, it is not good to stack faults over so when the fault trigger you know at what condition or request it happened, this will help understand the cause.
It doesn't seems it is hydraulic issue but electrical, what confirm this is fault not present which is intermittent.

5200 Evaluation of motor speed (CAN):
I think the sensor may be the issue, sometimes we are forced to replace parts as part of troubleshooting if we don't have logical explanation of what happened, since we measured different resistance for this sensor we have a reason to replace it or compare it with other good working sensor. The DME didn't report it though but the SMG did. The SMG compare the gearbox output speed and sense a deviation from a preset value.

5502 Control of gear valve PWV1:
This fault is currently present, you should be able to confirm when viewing Analog 3.

510D Evaluation clutch position sensor main sensor.
5106 Evaluation of transmission position sensor shift rod R/1 main sensor.
5107 Evaluation of transmission position sensor shift rod R/1 redundant sensor.
5108 Evaluation gear position sensor shift rod 5/3.
5109 Evaluation of transmission position sensor shift rod 2/4.
510A Evaluation of transmission position sensor shift rod 6/7.
All the above faults are not currently present and they triggered while the car not moving and may be not even running.

510D Evaluation clutch position sensor main sensor:
This fault return with negative value which means internal short, but since it triggered at the same time as the above fault I would wait and troubleshoot it further

I conclude that all the fault are intermittent and related to electrical issue. I would suggest you inspect and clean connector X1 (big round main connector on the left side) this connector house all solenoids, connector X11 for PLCD wiring, and connector X012 for the gear position sensor. Since it is odd that all these connectors have connection issue it is better after inspecting and cleaning to trace the wirings up to the SMG control unit as all connector wirings will be side by side and a chance that these wires pinched is high. Inspect the SMG control unit pins condition and reseat the connectors 2 or 3 times.

I couldn't link all these faults with missing ground (pin 4 on 40 pin connector), this ground is used on all components in the SMG system but pressure sensor, temperature sensor, and other control solenoids didn't report a fault so most likely ground is not the issue.
 

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Discussion Starter · #13 ·
I went to begin more diagnostics work over the weekend and was greeted by limp mode, misfire code on cyl 5 and 7 and white smoke from the exhaust. I pulled the plugs and injectors and baggied them individually per their cylinder number. Plugs don't look amazing for only 10k miles (must mean I need to redline more :sneaky:) and while testing the injectors I found that cylinder 5 would pass the resistance test (12.9-13.0 ohm steady) and even the pules test with my injector testing unit, but when pulse-tested under pressure would stick open. Unfortunately I had a situation where I ran the tank dry (waiting for a fuel-lock ring tool to show up to replace the filter/pickup assembly) as a result of the dash not showing an accurate fuel level - and best I can conclude something got picked up and passed the old filter that jammed up a couple injectors.

Skirted disaster there and waiting for a couple new injectors and baskets for those and the rest now. While I have the plenums pulled though I'm going to continuity test valve 2 and the exhaust temp and 02 sensors that keep throwing errors (although the above paragraph my fully explain that happening) while it would be easy to pull that loom back topside for more repair if necessary.
 

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Possible the emission components you are going to test has a relation with the stuck open injector. Why don't you replace all injectors to prevent future issues with the fuel filter. For the the fuel level issue I would also replace the pump as the pump has part of the mechanical jet valves that control the transfer of fuel between both side consequently controlling the distribution of fuel to get better fuel level reading.
 
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