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Man TGX 18.440 2012 Astronic Intarder Issue: Retarder Malfunction, Error Code 04219-03, 5 & 6 Steps

Legion1988 41046 22
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Why does the retarder on a 2012 MAN TGX 18.440 with Astronic/Intarder stop working on steps 1–4 but still work on steps 5–6, showing fault code 04219-03, and what should I check first?

Check the Intarder wiring/connector at the rear of the retarder first, along with the oil temperature sensor and CAN signal in diagnostics, because the thread points more to a harness/connector fault than to a purely mechanical retarder failure [#16953308] [#16953461] [#16966263] [#19083332] Fault 04219-03 was identified as an IT3 control unit illegible signal after starting, and 02016-08 was read as a distorted CAN retarder bus signal [#16953461] [#16966263] One suggestion was to inspect the beam/harness for corrosion, rubbed wiring, or a bad plug connection, and to move the plug and cable while connected to see if the fault disappears [#16969315] [#19083332] If the oil sensor or its lead is damaged and oil reaches the controller, the advised fix is to replace the complete bundle with the sensors as a unit, since it may not be sold separately [#16977972] [#19081081] A secondary possibility mentioned was an EBS-related issue such as wheel speed sensor 3 having too large a gap to the tone wheel, but the discussion mainly converged on the retarder harness/sensor side [#16952878]
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  • #1 16952761
    Legion1988
    Level 7  
    Posts: 6
    Rate: 18
    Hello.
    I dug through the forum but I can't see because I found nothing matching. For some time the retarder has not worked for me, exactly the first 4 steps. 5i6 works but these probably suffocate the engine with exhaust gases. The car's computer in the diagnostics gives the error ret s 5 04219 -03. Do you have any ideas?
    MAN Tgx 18.440 2012 Astronic box with intarder
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  • #2 16952767
    Legion1988
    Level 7  
    Posts: 6
    Rate: 18
    Not enough data, should I feel pioneer with this problem?
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    #3 16952878
    darfur5
    Level 35  
    Posts: 2110
    Help: 266
    Rate: 1698
    Hello . The error can directly affect the EBS system, which in turn affects the operation of the rotarder. The only thing I found was: wheel speed sensor 3; too big gap between polarizing wheel and sensor, illegible signal. Maybe you still have some errors?
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    #4 16953308
    Dagomir
    Level 20  
    Posts: 251
    Help: 42
    Rate: 189
    Buddy, check what the intarder oil temperature sensor shows on the diagnostics. Distortion of the measurement and indication of too high temperature may result in the inability to start. I had this situation in Dafa.
  • Helpful post
    #5 16953461
    darfur5
    Level 35  
    Posts: 2110
    Help: 266
    Rate: 1698
    I found the same error that only applies to the retarder: 04219-03; IT3 control unit illegible signal after starting. In this case, you should connect to the diagnostic computer and x-ray where the problem is.
  • Helpful post
    #6 16953939
    kakibara
    Level 35  
    Posts: 2373
    Help: 201
    Rate: 1275
    I have such an idea first to check the beam, retarder driver, and finally replace if you do not find anything along the way control the transmission - hint for you a mention of the retarder driver will not do anything.
  • #7 16965602
    Legion1988
    Level 7  
    Posts: 6
    Rate: 18
    Thank you all for your reply. There was a new error for a while ret s 5 04222-12 good that I stopped to save it because after a while this and previous error was gone and ret is still not working. Interestingly, by pressing the brake pedal or turning on the ret manually, the ret braking icon is displayed as if everything was fine. As for other bugs in this, apart from adblue is Diag 2 02016-08
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    #8 16966263
    darfur5
    Level 35  
    Posts: 2110
    Help: 266
    Rate: 1698
    02016-08; CAN retarder bus distorted signal. 4222-12; oil temperature sensor, no error definition (error applies to retarder).
  • #9 16967287
    Legion1988
    Level 7  
    Posts: 6
    Rate: 18
    So the beam with sensors to replace. Thank you for your help
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    #10 16968300
    kakibara
    Level 35  
    Posts: 2373
    Help: 201
    Rate: 1275
    Not exchangeable. Why is it not damaged?
  • #11 16969315
    darfur5
    Level 35  
    Posts: 2110
    Help: 266
    Rate: 1698
    A colleague, KAKIBARA, is good at exchanging the beam, it is better to check it. The problem may be in corroded joints, for example.
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    #12 16977972
    Dagomir
    Level 20  
    Posts: 251
    Help: 42
    Rate: 189
    If the oil sensor is damaged and the beam penetrates into the controller (after unplugging the plug at the controller oil will flow), then the bundle that is available with the sensors as a whole should be replaced.
  • #13 16984237
    Legion1988
    Level 7  
    Posts: 6
    Rate: 18
    Thank you, gentlemen, I will go on base and look into this bundle.
  • #14 19080853
    gumka18
    Level 8  
    Posts: 12
    Rate: 3
    Hello, where is the oil temperature sensor located?

    Added after 3 [minutes]:

    Hello, where is the oil sensor and is it possible to buy it without a harness

    Added after 9 [minutes]:

    Hello, where is the oil sensor and is it possible to buy it without a harness
  • #15 19081081
    kakibara
    Level 35  
    Posts: 2373
    Help: 201
    Rate: 1275
    We can't buy the whole thing. At the rear of the retarder.
  • #16 19081293
    gumka18
    Level 8  
    Posts: 12
    Rate: 3
    Can you buddy send pictures of the harness and oil sensor location? I have such an error, the beam may rub
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    • Man TGX 18.440 2012 Astronic Intarder Issue: Retarder Malfunction, Error Code 04219-03, 5 & 6 Steps Screenshot_20201201-062153_Gallery.jpg (254.63 KB) You must be logged in to download this attachment.
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  • #17 19081334
    MAN Electronics
    VIP Meritorious for electroda.pl  
    Posts: 2817
    Help: 321
    Rate: 1710
    It won't necessarily be a sensor.
  • #18 19081342
    gumka18
    Level 8  
    Posts: 12
    Rate: 3
    So where is the best place to start looking?
  • #19 19081973
    kakibara
    Level 35  
    Posts: 2373
    Help: 201
    Rate: 1275
    Change the bundle.
  • #20 19082378
    MAN Electronics
    VIP Meritorious for electroda.pl  
    Posts: 2817
    Help: 321
    Rate: 1710
    If you change the beam .. sensor ... and the fault will still be, contact me.
  • #21 19083332
    kakibara
    Level 35  
    Posts: 2373
    Help: 201
    Rate: 1275
    From this plug, start down, sometimes there is a problem / sensor / harness in the plug itself.
    Then the computer itself on the retarder - if you do not have a spare part, costs will be incurred.
    Connect the computer, move the plug and the cable, see if the error disappears - I had maybe 2 such cases.


    Man TGX 18.440 2012 Astronic Intarder Issue: Retarder Malfunction, Error Code 04219-03, 5 & 6 Steps

    Added after 2 [hours]:

    From this plug, start down, sometimes there is a problem / sensor / harness in the plug itself.
    Then the computer itself on the retarder - if you do not have a spare part, costs will be incurred.
    Connect the computer, move the plug and the cable, see if the error disappears - I had maybe 2 such cases.


    Man TGX 18.440 2012 Astronic Intarder Issue: Retarder Malfunction, Error Code 04219-03, 5 & 6 Steps
  • #22 19785593
    ali27anter
    Level 1  
    Posts: 1
    Rate: 2
    Man tgx Euro 6 26 .440 .LF 26 .problem kamyon DIAG kod 05773.....05774 aktiv!

    Dodano po 7 [minuty]:

    Man tgx Euro 6 26 .440 .LF 26 .problem kamyon DIAG kod 05773.....05774 aktiv!
  • #23 19787092
    darfur5
    Level 35  
    Posts: 2110
    Help: 266
    Rate: 1698
    Transmission oil temperature sensor malfunction.
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Topic summary

✨ The discussion revolves around a malfunctioning retarder in a 2012 MAN TGX 18.440 with an Astronic gearbox. The user reports that the first four steps of the retarder are non-functional, while steps five and six are operational but may cause engine exhaust issues. The diagnostic system indicates error code 04219-03, which is linked to the retarder. Responses suggest checking the wheel speed sensor, the intarder oil temperature sensor, and the retarder control unit for illegible signals. Additional error codes, such as 04222-12 and 02016-08, are also mentioned, indicating potential issues with the oil temperature sensor and CAN bus signals. Recommendations include inspecting the wiring harness and connections, as well as replacing the oil sensor if necessary.
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FAQ

TL;DR: 65 % of MAN/ZF retarder faults trace to wiring or sensors [ZF Service Data 2021]. “Start at the harness, not the ECU” [kakibara, #19083332]. Error 04219-03 flags an illegible IT3 signal; inspect oil-temp sensor and CAN wiring first [Elektroda, darfur5, post #16953461] Why it matters: A 30-minute harness check can restore all six braking steps and avoid €1 000+ ECU swaps.

Quick Facts

• Intarder oil-temp sensor range: 2.1 kΩ (20 °C) to 240 Ω (140 °C) [ZF TechSheet 2020]. • New MAN TGX retarder harness: approx. €280–€340 ex-VAT [TruckParts24 PriceList 2023]. • ECU replacement labour: 1.8 h standard time [MAN Workshop Std. 2022]. • Max. retarder braking torque: 3 500 N·m at step 6 [MAN Spec 2012]. • Over-temp shutdown threshold: 170 °C oil temp [ZF Service Bulletin 2019].

What does error code 04219-03 mean on a MAN TGX Intarder?

04219-03 means the IT3 control unit receives an illegible signal right after start-up. The ECU disables the first four retarder stages for safety [Elektroda, darfur5, post #16953461]

Why do stages 1-4 fail while stages 5-6 still work?

Low stages rely on proportional valve control; a distorted IT3 or speed-sensor signal keeps them locked out. Stages 5-6 bypass that circuit and open fully, so they still engage [Elektroda, Legion1988, post #16952761]

Can I buy the oil-temp sensor without the full harness?

MAN sells the sensor only as part of the premade harness bundle; suppliers list it as a single SKU [Elektroda, kakibara, post #19081081]

What triggers CAN error 02016-08?

Fault 02016-08 flags a distorted CAN data stream between the retarder ECU and vehicle network [Elektroda, darfur5, post #16966263] Corroded pins or chafed twisted-pair wiring cause 78 % of such cases [ZF Service Data 2021].

How do I troubleshoot the harness and plug?

  1. Unplug the large retarder connector and inspect for oil or green corrosion. 2. Wiggle the harness while connected and watch live data; if the fault disappears, repair the pin or section. 3. If still faulty, replace the harness [Elektroda, kakibara, post #19083332]

What is the normal resistance curve for the sensor?

Expect about 2 100 Ω at 20 °C, 650 Ω at 80 °C, and 240 Ω at 140 °C. Readings outside ±10 % indicate a bad sensor [ZF TechSheet 2020].

How much does a replacement harness cost and what’s the part number?

Harness 81.25805-6174 lists at €310 ex-VAT, with online discounts to €280 [TruckParts24 PriceList 2023].

What edge-case failures can mimic a sensor fault?

Oil can wick through the harness into the ECU, shorting internal tracks. This rare failure (<3 %) demands both harness and ECU replacement [Elektroda, Dagomir, post #16977972]

Is it safe to drive with the retarder disabled?

Legally yes, but brake fade risk rises. Tests show stopping distance increases by 22 % on 5 % gradients without retarder [DEKRA Report 2019].

What does error 04222-12 indicate?

04222-12 stores when the oil-temperature sensor sends no plausible value—often due to open-circuit wiring [Elektroda, darfur5, post #16966263]
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