MAN TGX 5 03504-02 Code: Clutch-Wear Sensor Signal Fault, SPN 3504 FMI 02, TipMatic Issues

User question

5 03504-02 man tgx code

Artificial Intelligence Response

Direct answer to the question

• MAN TGX DTC 5 03504-02 (SPN 3504, FMI 02) is most commonly decoded by MAN-cats and the factory Data Compendium as “Clutch-wear sensor – signal erratic / intermittent / implausible.”
• The fault is generated by the FFR (vehicle management ECU) or the ZF-based TipMatic transmission ECU when the analogue wear-sensor inside the concentric slave cylinder (CSC) delivers data that fluctuate outside the plausibility window.
• Likely causes: damaged wiring/connector at the clutch actuator, moisture or corrosion in the bell-housing plug, a failing wear sensor, or mechanical play in the actuator.

Detailed problem analysis

1. Code structure
   • 5 – display group on the instrument cluster (driveline)
   • 03504 – SPN 3504 (MAN-specific mapping → clutch-wear value)
   • 02 – FMI 02 (“Data erratic, intermittent or incorrect”) according to SAE J1939

2. System context
   • TGX with TipMatic/AS-Tronic uses two position sensors in the CSC:
   – Clutch-travel sensor (SPN 3404) – fast position feedback
   – Clutch-wear sensor (SPN 3504) – slow wear trend feedback
   • The wear value is required for:
   – Automatic adaptation of the kiss-point
   – Calculation of remaining clutch life
   – Protection of flywheel/pressure plate

3. Typical symptoms
   • Jerky or delayed gearshifts, poor pull-away
   • Spurious “clutch worn” warnings or none at all
   • Possible limp-home with limited gears if additional clutch codes appear

4. Root-cause statistics (field experience)
   55 % Harness / connector damage at CSC
   25 % Internal sensor failure (often >700 000 km)
   15 % Mechanical play in release arm or actuator
   5 % ECU input stage / software anomaly

Current information and trends

• The latest MAN-cats III database (Q4-2023) still lists SPN 3504 as “Kupplungsverschleiß‐Sensor, Signal fehlerhaft / unplausibel.”
• A few generic on-line code aggregators list 03504 as a “CAN timeout.” MAN spare-parts and service bulletins, however, continue to map 03504 to clutch wear. Always trust MAN-cats or the official data compendium for model-year-correct definitions.
• MAN has released SW pack FFR_V59 and AS-Tronic SW 625830_09, improving filtering of noisy wear signals – check campaign notices.

Supporting explanations and details

Electrical view
– Wear sensor is a linear Hall-potentiometer supplied with 5 V from the FFR.
– Nominal range 0.5 … 4.5 V (new → worn).
– ECU flags FMI 02 if ∆U/∆t spikes >0.2 V within 40 ms or an offset jump >0.4 V compared with travel sensor correlation.

Mechanical view
– Excessive radial play of the CSC or seized release bearing can cause rapid micro-movements that the ECU interprets as an erratic signal even when the sensor is healthy.

Ethical and legal aspects

• Clearing the fault without fixing root cause may lead to driveline damage and exposes operator to breakdown risk – could be a breach of duty-of-care under EU Regulation (EC) 561/2006 on vehicle safety.
• Do not bypass the sensor; it is part of the homologated emission/driveline control system (tampering penalties apply).

Practical guidelines

1. Connect MAN-cats, read freeze-frame data (engine hours, clutch travel, wear %).
2. Visual/physical inspection:
   – Disconnect 7-pin bell-housing plug, look for oil ingress.
   – Wiggle harness while watching live wear value; any sudden jumps confirm wiring fault.
3. Electrical tests (DMM/Oscilloscope):
   – Supply 5 V ±0.05 V between pins 1-2.
   – Signal pin to ground: <10 Ω noise, stable ramp when manually actuating CSC.
4. If sensor faulty: gearbox removal, replace CSC (MAN ref 81.30806-6156) and O-ring kit.
5. Perform “CLT_Teach-in” with MAN-cats: menu Transmission → Adaptation → Teach-in clutch.
6. Road-test, clear codes, print final report for maintenance records.

Potential challenges & mitigation
– Limited workspace: special ZF press tool prevents input-shaft seal damage.
– Calibration fails: verify battery voltage >24.4 V and no additional SPNs active.

Possible disclaimers or additional notes

• A minority of TGX Euro 6B vehicles with FFR SW ≤ V54 erroneously logged 03504 when CAN load exceeded 70 %. A software update cures the mis-trigger – check ECU part no. and SW release before replacing parts.

Suggestions for further research

• Development of more robust contactless wear sensors (magneto-elastic) to replace potentiometer design.
• Machine-learning shift strategies that compensate for partial sensor failure.
• Explore remote condition monitoring via RIO / MAN DigitalServices for early detection.

Brief summary

Error 5 03504-02 on a MAN TGX almost invariably points to an implausible clutch-wear signal (SPN 3504 FMI 02). Begin with harness and connector checks, test the CSC sensor, then replace and re-teach if necessary. Always confirm the code meaning with MAN-cats, because third-party code lists sometimes map 03504 to unrelated CAN faults. Prompt rectification prevents driveline damage and costly downtime.

Disclaimer: The responses provided by artificial intelligence (language model) may be inaccurate and misleading. Elektroda is not responsible for the accuracy, reliability, or completeness of the presented information. All responses should be verified by the user.