Second Clutch Actuator - Stuck Again

[bumpa]

I'm really sorry about the long winded story but I want to provide as much information as possible. 
A couple of years ago I had to replace and "reteach" the clutch actuator on my 2008 Smart car when it wouldn't shift and showed the error code P0805 (clutch position sensor circuit).
A few weeks ago it started "lurching" on the way home and again wouldn't shift properly. Then it stopped dead and wouldn't start. I waited a few minutes and managed to start it, "reteach" the transmission and drove it home. A few weeks later... same drill. This time the "reteach" didn't work but I was able to cripple it home. I topped up the transmission fluid which was a bit low and then I pulled the error code P0805 again. 
I ordered and installed a new clutch actuator... and went through a number of different "reteach" procedures (3bars/brake down/gas down/disconnect battery) but I can only get 1st and 2nd gears to show on the dashboard. Something under the car makes a sound when the transmission is shifted but it's not the actuator. I tried the actuator in different notch positions but now I can't even move the actuator back and forth any more at all. It seems to have a lot of pressure pushing it backwards. I'm afraid to remove it because last time I couldn't get it back in. The plunger was stuck in the out position.
The wiring seems to be fine and I'm not getting a P0900 (circuit open) or P0901/P0903 (circuit malfunction) code. 
Please somebody help!

[Ravk]

I know this is an old thread, but it sounds like a stuck shift motor.  Its allowing the trans to shift up to 2nd, and stopping.  Either replace or repair.

[stickman007]

I'm not that familiar with the 451, but if I remembered correctly, some of the them has issues with the clutch plate binding to transmission input shaft. When the ECM sees rpm on the input shaft when the clutch is supposed to be engaged, it will prevent starting and sometimes have very rough/weird shifts.

 

Good Luck,

 

Iz