HELP!....Weird Trans. Failsafe Prog. Alert on 2004 TD6 | |
I have a 2004 L322 TD6 with the GM 5L40-E gearbox with 116,000 km and fully serviced.
Last week I decided to change the ATF fluid, filter and gasket, and drained sump and replaced filter with genuine LR THE50031 Filtran filter. Filled the transmission using Texamatic 7045E ATF strictly following RAVE procedure and using GAP IID tool to set fluid level at correct gearbox temp. Then also replaced Transfer box oil using recommended Castrol BOT 26 FMB1 Transfer Box oil and filled same using LR procedure.
I then went out to road test vehicle and drove approx. 400m down the road and initially all working fine. Stopped vehicle and set to Low Ratio, all appeared ok, then with vehicle stopped and in Neutral selected back to High Ratio and went to Drive on gear selector and initially it appeared that the vehicle was stuck in LOW ratio, after some switching off and on ignition and toggling High a few times, vehicle drove as if in High, however shortly afterwards I received Trans. Failsafe Prog and car went into limp home mode (5th gear). I drove vehicle back home and using GAP IID tool diagnosed the following faults:-
Transfer Box
1/2 (0x5212) Battery Under Voltage
2//2 (0x5223) Signal Noise in Acctuator
Transmission
TCM Transmission - Pressure Line Solenoid 4 : General Fault.
I am currently awaiting clarification from GAP as to which Solenoid this is.
I then cleared the faults using GAP tool and fully charged up battery for 24 hrs.
I have test driven the vehicle a few times since, and all works ok in 1st to 3rd gears in manual mode and I am able to drive several km without issue, however if I go upto 4th gear in manual mode, the Failsafe Prog. Limp home initiates immediately. In automatic Drive mode I am able to get approx 800m (4th gear) before the Trans. failsafe Prog appears. If I turn ignition off then on, the vehicle returns to normal operational mode and gearbox functions in all 5 speed gears, until the dreaded failsafe returns after about the same distance driven. I am assuming that this rules out temperature?, so more likely a Control or command related fault?. (Actual gearbox temp around 54 Deg C, with max gearbox temp recorded at 88 Deg C).
Is it merely coincidence that all of this has happened immediately after new transmission oil change?, or more likely a transfer box systematic Fault such as a faulty transfer box stepper motor potentiometer?, or could my gearbox have suddenly junked when new higher viscosity fluid introduced?. Note no metal filings observed in sump when drained and cleaned.
I have reviewed several blogs indicating Trans. Failsafe Prog can be caused by Faulty Stepper Motor, Gearbox Faulty Neutral Sensor Switch, Faulty ECU or possibly blown seals, sensors solenoids etc. Within gearbox.
I am in Norway which is the most expensive place on the Planet with respect to LR parts and labour, therefore not to keen on going through the high cost of process of elimination.
Has anyone suffered exact or similar Fault?
Further to above when test driving and connected to GAP IID tool live values on Transfer Box, Range, The GAP tool displays Low - Stop, however vehicle is in High.
I came across this comprehensive Trans. Failsafe Prog diagnosis article which eventually pointed to the Stepper Motor potentiometer requiring replacement. http://www.valvebodypros.com/assets/range-...roblem.pdf
I have also found a supplier in UK called LRO4x4 which claim to fully refurbish the Stepper Motor and replace the potentiometer with a more robust Potentiometer for 385 pounds, has anyone any experience with this company?. They supposedly provide a 12 Month warranty for the refurbished Stepper Motor.
http://4x4lro.co.uk/home
Finally when reviewing many threads on GM 5L40E and Failsafe modes it would appear that these gearboxes are prone to failure, however mine has only accumulated 116,000 km (72,000 miles) and has not been used for excessive towing or anything, so this would appear a little premature. Also gearbox was working perfectly prior to filter and oil change and selecting Low Ratio, which makes this a little weird?
Anyone have any suggestions or advice?. Should I try to fix or simply trash the gearbox and go for a remanufactired replacement transmission?. [/b]
Last edited by jms001 on 24th Apr 2018 8:32am. Edited 1 time in total
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