MAN TGA ZF ASTRONIC: TCU Fault Codes 03160-00 & 03124 - Switching Group Sensor & Clutch Path Error

As I wrote in the topic, the TCU code 03160-00 (Uninterrupted signal of the switching group switching group sensor) and occasionally 03124 (clutch path error) is displayed. The question is how much will it cost? ......

Added after 4 [minutes]:

https://obrazki.elektroda.pl/7268808300_1299368609.jpeg

The 1st error is actually a signal from the cylinder position sensor in the gearbox actuator, the one in the picture.
The second error comes from the sensor from the clutch activator, located under the box.
It is best to connect to the computer and see the actual position / change of positions of these elements during the operation of the box.

Thank you very much for your answer, today the car is running smoothly, but the time for renovation is approaching . I understand that these two errors are not related to each other ????

Theoretically, they should not be related to each other, but electronics play various tricks.
It suggests that you deal with the position sensor on the activator cylinder first.

Hello again, today I have tcu 03144 not going to turn on the gear the engine is burning ????? on Friday the car was on the diagnosis and no box errors, the car is ok, they see nothing bad ..... nobody knows anything ... .

It's quite interesting what you write, he was diagnosed. Nobody knows anything ... gray smoke !! Everything is fine and not working. I say it like this: good God did what he could, now you need to call a professional . AS Tronic is quite an interesting box and, as far as I know, even some services are good for them, despite having service documentation, there is no imagination and knowledge of how the box works. Nobody can help you over the Internet. Unless you have a lot of money to get kicked out, we can start fixing it by trial and error. And as a colleague Krisbrumm wrote, through such guesswork, the shepherdess will probably find you, and you will still not know what's going on. Best regards and good luck, it will definitely be useful to you.

All the time the same sensor error on the activator cylinder of the halves.

If you want to rummage yourself, change the sensors on the actuator cylinders / pistons.
Drive a little and the error should shift to another cylinder ... then you have to replace the sensor itself (preferably all at once), and if the error remains on the same piston, check the wiring harness from the driver to the activator.
If you are not able to do it yourself, suggest this method on the website, even if you do not find errors.

It will be better, this post of mine did not contribute anything, and why should someone take it personally ...

tomekooo, dear friend. Just don't talk about CAN topics unless you are raising your ranking. So far, we talked about the failure of the box, not about safety and information stored in FFRs and ZBRs. If the sensor is released, why do you drill down so hard. If you want to talk about the diagnosis, I'll be happy to find out something. After all, when you read my posts, it turns out that he keeps asking questions. I wish you would repair this chest yourself. You will save a lot of money. And you will gain secret knowledge As for the prophecy, it seems to me that it cannot be called otherwise, as one looks for a method of repair in the forum. This is just a guess. What equipment was the diagnosis made, what are the readings of the box parameters from the actuator position sensors? If there is a sensor fault, there should be no change in its position or the wrong range of its stroke. Or maybe the gearbox is mechanically damaged, hence the sensor error. If I'm wrong, have someone correct me, as long as a competent, not a desperate owner. Sorry for the unsuccessful post.

PS You can still see the rotation of the shaft in the parameters, after the change and before the change of the halves. But it must be your diagnostician who knows. So much for the aforementioned CAN. This is my last post in this discussion. You can request removal. Regards

Also, it's a pity for words, desperation is too much said ... you did not understand me ... Thinking that I question your knowledge about topics that I certainly have no idea about because I do not sit in it. But in my "backyard" I like to know what is going on. And believe me, I do not repair myself, as I can see, I will not be able to handle it ... So I send the car for a diagnosis, I have 3 services and one workshop around me. After the diagnosis Ok. N is displayed, the car burns the manual with the car, but it does not react to the selection knob, what was I supposed to do ???? first the car needs to be taken from the company because it blocks. ?? how the car is as bricked ... They do not know to tow .... I say that it displays TCU 3144 error, road sensor signal, dividing system, self-adjustment ????? I know where the dividing system is, I know where the road sensor is, but I do not understand what the adjustment means ...... And this is probably the reason why the gears do not jump, because the car enters some mode of operation, but this is not my concern anymore ... these are "professionals" who are trying to stretch me for expensive repairs so far and nobody likes it who knows what transport means nowadays .... So, buddy with all due respect, but I already had such proposals as replacing the box? head? etc. It's a waste of time ... If no one can or wants to explain in a simple way what this ADJUSTMENT means, it started to seem like a mystery ... Until then, I was doing myself and it is better to ask on the forum than in the service because they will say that it is definitely my fault that it broke down ... Today it comes back from the road and it's ok ... What should I think, the car is not in working order but damaged too because diagnoses and ok .... Let it stand by the fence. I'm sorry if I offended anyone ....

I am not angry But I know that websites have a problem with As Tronikami. I highlight some, it's not that simple. But it is also not difficult and you cannot do it without a computer. If a visitor from the website, having the ability to read the detailed parameters of its work, cannot find a fault, he congratulates the service. A lot of things can cause this error as the half shift is at the beginning of the gearbox test and if the controller fails to read the change in speed of the intermediate shaft after the shift, it will try to "re-adjust" the actuator. But when he fails, he will crash a bug. And stop the test. There are two options: either a failure of the switching module or a mechanical failure of the halves. Replacing the chest is the best way. Ask the service about changing the driver software they can change you soft and the problem may disappear.

Thanks for your understanding TCU 03160-00 (Uninterrupted signal of the switching group dividing sensor) it started and now it's fine-tuning I think I already know where I can start myself and then I will keep thinking, I am going to part of the car today, only what will lose my time and I will save some nerves related to theories in the service. And thank you, gentlemen, from this forum ..... I will inform you about the results. Regards. If someone else adds something, it will definitely be useful ...

Added after 5 [minutes]:

And there was a driver at the diagnosis, so I don't know what the test was, but I have printouts from all drivers and, apart from a few non-significant errors in other drivers, the box was clean on the day of the test .......

tomekoooo how can you describe how the problem was solved, i had similar symptoms, the services are spreading their hands (they wanted to start with the demolition of the box) shock

Describe exactly what and how What are the errors, are they active, when and under what conditions the defect occurs and what is it manifested, is the defect accompanied by any mechanical sensations such as grinding / jerking? What you can describe it.
Tomekoooo was active on May 1st, so it's probably better to go priv.

complications began after replacing the clutch (pressure plate and bearing of a new type, all brand sachs). the forks and the clutch actuator were not replaced. now the symptoms: after firing everything is ok, after a few dozen (sometimes several hundred) km the gearbox goes into manual mode and all gears are lost, sometimes you can shift the gear on the manual, but with a great grinding noise. this happens when downshifting, never up. to regain gears, you have to turn off the engine, wait and after firing for some time it is fine (until the next reduction). Errors 03160 and 03124 appear and are inactive after the engine is turned off. The service suggests two possibilities: the wrong clutch to the machine or a damaged clutch actuator

Do these clashes occur at specific gears or always?
After driving this trouble-free section, is the fault continuous, or does it appear only once (until the next reduction, i.e. moments?)?
Was everything ok before replacing the clutch, was the clutch replaced due to a fault or wear?

the clutch was replaced prophylactically, a long time elapsed from the moment of pressing the gas to start (about 2-3 seconds), for some time it was jerking when switching from 5 to 6, and only then. currently, when slowing down, if the car reduces gear, it goes into manual mode, the display shows gear, e.g. 5, but it does not pull. it is no longer possible to switch to automatic mode or select a different gear manually. only after the engine is turned off everything works properly. sometimes, when it goes into manual, it allows you to change gears manually, but then it jerks and grinds a lot.

So when reducing 6-5, I will always show 5 on the display, but it does not pull and only after a while an error pops up?
Or maybe, during the reduction, flashing 5 will be displayed immediately?

The method of displaying the gear can bring us closer to the type of fault, whether it is only on the clutch system (then the display shows a continuous 5) or in the gearbox itself (in this case the 5th will flash on the display and the gearbox will not allow you to lock the gearbox).

sec, except that there are no errors on the display, they remain in memory but are not displayed. the gear indicated is displayed continuously, it does not flash

So theoretically, the gearbox activates the gear "sees 5th" and the parameters from the position sensors are ok.
Does the scratch in the chest occur just before the display of the continuous 5 or ideally with it, or does the scratch occur a moment after the appearance of the continuous 5?
Do you sometimes "fall out" of the gear?

The car rolled off today, I drove around, I did some 20 km and everything was ok. Strange thing, from the driver's report it looks like this: the car is cold, everything works fine, after warming up when reducing to low gears (3-5), the car switches to manual and stops Pull. But this is not always the case. Sometimes, after the reduction and switching to manual, there are gears, but it grinds when shifting. I do not know if it grinds before or after the gear is displayed. I wonder why it happens only with reduction (and not with every one) and why the problems started after replacing the clutch

Added after 2 [minutes]:

there are errors in the memory: FFR 00098 PAS, DIAG 03407-02 five items including one AKT, TCU 03124-00 PAS and 03160-00 PAS

Added after 4 [minutes]:

I checked this FFR and DIAG not related to the gearbox

Added after 9 [minutes]:

there is a strange date next to TCU 03124: 08 -. 1985 -: 00

You have two errors in mind. One about the lack of change of the "halves", and one about the incorrect position of the clutch actuator. I think that mechanical damage to the gearbox cannot result in an error on the clutch, and damage to the clutch may result in a "half" error.
Generally, when starting the engine, the gearbox calibrates the clutch and establishes the so-called "biting point" - the position in which the clutch is shorted. For all subsequent driving time, it remembers this position and shifts gears according to it, the next measurement of this position is made only when we turn off and restart the engine.
In my opinion, the error in the position of the clutch pops up when the "biting point" changes while driving due to the heating of the clutch. The gearbox sets the clutch to a given position to be changed, but this value has shifted and in fact the clutch is still slightly clamped, which is confirmed by grinding when shifting gears. Such problems occur when the clutch bearing is damaged, but more often there is no lubrication on the gearbox / clutch shaft. We have had many such cases that the shaft was dry as pepper and the bearing stuck in different positions on the roller, then the astronic stupid.
There were also cases of lubrication with the wrong type of grease, the grease must be high-temperature and very thick. Usually greases, e.g. in a central grease pump / for sacks, dry quickly and do not fulfill their role.
If you have prepared the bearing itself, the more it will get stuck on the shaft.
I do not know why TCU only complains about "halves". If we connect the fault with the coupling, he should complain about more translations.

So the second option is to check exactly which gears are scratching, if you find the correctness of individual gears, you may have to look for the fault in the gearbox itself (which may not cause an error in the position of the clutch, but who knows it). The changes in Astronic gears are not comparable to the changes in the manual. Astronic 12 speed is 3 gears, half and range, 16 speed is 4 gears, half and range.
I do not have a detailed list in front of me, but for example, 1st gear is a change to gear, 2nd gear is the same gear but with a different "half", 3rd is the next ratio and "half returns back, 4th gear is the same ratio as the 3rd gear, but with the next a half-letter. Jakos takos.
"Half" are used most often, therefore the gearbox may complain about it and not about other functions.
I do not rule out that you have damage to the "half" moss, but in my opinion, the greater probability of a failure is a failure of the clutch engagement.

Personally, I would measure the "biting point" when the chest is cold, and measure the same with the chest hot. That is, connect ManCat, read the positions when cold, go to the stop until a fault occurs, then turn off the engine, start again and read the positions of the "biting point" while hot. If it changes, boldly disassemble the clutch. water in oil or mechanical fault).
In ManCat there is also an option to manually set the "biting point" without turning off the engine, a good diagnostician should know how to read it, but it is difficult to find a good one .
We will not repair the box on the forum for sure, but I hope that I will introduce you to the operation of this system a bit, and it will help in further diagnosis.

(apropos ... we have clutch discs and sets that practically fit the MAN, but while driving there are problems with shifting gears, I don't know the details, but it's worth itcheck the exact specifications of the replacements, I will not give you my hand to cut it, but it was probably "Sasch". I try to find out in the company.
I asked, it was about a customer who brought his Sasch clamp, it generally fit as well, but the pressure plate was too thick and MAN's clutch did not want to cooperate ... but it probably does not apply to your fault)

I shifted the clutch actuator from my other car and all the pains are gone. and surprisingly, this "broken" actuator in the other car also works properly.
thanks to everyone for the advice. and who said that the car is not repaired on the forum

Such miracles do not happen, so we are waiting for a fault in one of the cars .
But who knows ........

RENO-MAX wrote:

Welcome to my eye, for calibration, the clutch actuator may be replaced with a new one and after the problem

The next friend who calibrates the clutch in the astronik .......
Hello colleagues svavecone, rambo01 ..
I repaired myself it was not easy but I will say this: a mistake I made before these miracles began to happen to me is the replacement of the clutch set from the 510 model that I had in stock for 410 does not fit anymore I do not remember where the difference was, but it was 2 mm and the clutch is already It did not work as before. Unfortunately, I did it in the dark because when I gave the numbers from the parts, everyone said that it should match from 510 and it fit like .......
And then replacing the disc, clamp, spare wheels ..., brake discs, I bought road sensors, but not necessarily because there is nothing to break down there. I just washed, changed the oil, the filter and knock on it, but it still goes on. It is true that sometimes it hangs and something does not jump at the intersection, but I choose these pneumatic cylinders because it is ordinary rubber bands that seal them and certainly after years and these cycles The second method is to get the driver used to a certain behavior in a situation where, with 80 km / h, he knows that he will brake to zero, e.g. before the roundabout, do not drive the machine then, because it makes no sense to reduce and overhaul what I put on the manual, I stay on the 12th gear as I already see that I will continue to drive, while rolling the car, I slowly hammer the automatic gear and then adjust the gear to the speed (when it is in motion, it has easier). give me a message I'll send you something .... Regards.
A friend of svavecone will surely help you check for me out of curiosity the set of this clutch if you really have an astronica and did you also replace the flywheel ??????

Hello friends ..... Maybe someone else is following the topic ??? I have two EDC errors 03101 and this one is active and lights up TCU 03198-08 with it, abs failure lights. I want to remove it before frosts ... Is it the wheel speed sensor on the left side ????? and is the TCU error related to it .... ???? 2003 car ...

Added after 5 [hours] 57 [minutes]:

WELCOME again, I have repaired the wheel speed sensor itself, it was to be replaced ...

Hello

I can see that the topic is mastered but ...,
so for the future, errors for Man are on the site:

Link

It may come in handy

Connects to the topic of the 2006 MAN TAG automatic machine
The automatic gearbox sometimes hangs on the 10th when reducing the car you need to put out and restart it on the 5th as it goes up, but from yesterday whether on the car or on the manual control
She does what she wants
I found errors 3146,3155,3145,3158,3117,3102,3192,3163
I am asking for help where and what to look for

When asked by Man tgx the automaton error TCU 3099-08 and then ZBR 3500-00 appeared
Tcu 3099-08 error of the box sensor, the sensor above the tacho sensor is this one? and the other?