Second Clutch Actuator - Stuck Again

[bumpa]

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!

[stickman007]

If you are getting circuit codes, then the basic thing to do is the check your wiring. They may appear okay on the outside, but internally wires can be broken due to vibrations.

 

Disconnect your ECM and test each circuit going to the actuator. Load test your power and ground circuits to start.

 

Evilution.co.uk will have some sort of wiring schematics to help.

 

Good luck,

 

Izzy

[bumpa]

Thanx Stickman... Jonathan saidU might have some ideas!!!

 

I'm not getting P0900/P0901/P0903... only P0805!!! Manual compression didn't work on the actu8or... I'm gonna try the power blast on pins 3&6 L8R this morning!!! 

 

Also... I'm not sure if the clutch fork is part of the problem!!! I tried2 push it in manually with my fingers... no go!!! I have another motor/transmission & tried pushing the fork in... no go!!! MayB I'm just a darn weakling!!! 

 

Any suggestions???

[stickman007]

The clutch actuator position may trip the P0805, but it’s unclear at this point.

 

You should be able to push the actuator rod all the way back in before installation.

 

Make sure the clutch fork pivot point where the rod goes in is not worn or punched through. You will not be able to push the fork with your fingers - it’s basically the spring tension that keeps the clutch engaged.

 

If you’ve already changed the clutch actuator, then you’ll need to check your wires/harnesses.

 

You'll also need a scanner that can do clutch/drag point calibration similar to the STAR. I have an Autel Mk906 pro that can do that. I’m sure there are plenty of other scanners out there that can do it as well.

[nodes2k]

could be a bad actuator....was it a no name brand off amazon or a Sachs?

[bumpa]

Thanx stickman & nodes... I've had 4new actu8ors including the initial unit in the car when I bought it!!! I've only ever retaught the units by doing what I learned from different people on the internet (3bars/brake down/gas down/disconnect battery)!!! Un4tun8ly... there's a lotta conflicting info... but it always worked until now!!! I've never used a scanner!!!

 

&nodes... yes... I only buy after market parts... I H8 getting bent over by the Stealerships... I've never installed OEM parts on any of my cars!!! The 1st unit I bought worked 4a few years... the 2nd I sent back cos it didn't work right off the hop... & this1 mayB the same!!! If it doesn't work after further tests 2day... I'll order a different after market unit & take my chances!!!

 

I would just like things2 work consistently!!! & I'd really like2 meet up withU guys 4the rally on Sunday!!!

 

Thanx again4 the info!!!

[stickman007]

We're meeting on Sat in St. Albert Triple-O at 5pm.

[bumpa]

Ooooopies...I thought it was a Sunday rally!!! My bad!!!

 

I have a Community League AGM on Saturday!!! Hopefully next time!!!

 

DoU guys drive UR smarties in the winter??? I don'tC many braving the elements!!!