VT2-VT3 for Haima ZZ. Service Manual

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2.7. Checklist of the electronic components in the

transmission

In most cases the error codes from the TCU will indicate if there is something wrong
with one of the electronic conponents inside the transmission.
The following resistor measurements can be performed to check if the electronic
components are faulty or not.
All measurements indicated here are performed on the main harness connector of the
transmission.

Drive Mode Sensor
Check the internal resistance between the different DMS pins.
DMS_GND = pin 6
DMS_A= pin 13
DMS_B= pin 14
DMS_C= pin 15
DMS_D= pin 16
DMS_Supply= pin 9

DMS_Supply DMS_A

DMS_B

DMS_C

DMS_D

DMS_Supply X

17.2MOhm 17.2Mohm

17.2Mohm

DMS_A

17.2Mohm

9Kohm

DMS_B

17.2Mohm

9Kohm

DMS_C

17.2Mohm

9Kohm

DMS_D

17.2Mohm

9Kohm

DMS_GND

4.5Kohm

Oil Temp Sensor
Check the internal resistance of the Temp. sensor.

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3.1. Leaks

Fault

Action

Leak from gearbox oil pan gasket

Ensure oil pan bolts are correctly tightened

Replace oil pan gasket

Replace drain plug

Replace oil pan complete

Leak from gearbox drain plug

Ensure plug is correctly tightened

Replace drain plug

Replace oil pan complete

Leak from primary cover

Ensure that cover is correctly tightened

Replace O ring

Replace primary cover

Leak from secondary cover

Ensure that cover is correctly tightened

Replace cover O-rings

Replace secondary cover complete

Leak from selector shaft lever

Replace selector shaft lever seal

Leak from input shaft

Replace input shaft seal

Leak from differential oil seal(s)

Replace differential oil seals

Leak from oil cooler pipe connections

Ensure that pipes are correctly tightened

Replace pipe to oil cooler connection sealing rings

Replace pipes

3.2. Noise problems

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Sound description:
Sound best heared with a vehicle speed between 60kph to 90kph while slowly
accelerating. When releasing the gas pedal, sound normally is getting smaller, give
throttle again, the sound comes back.
The sound is like a

whistle sound. The frequency of the sound goes up with vehicle

speed.

This is a normal sound from the CVT which comes from the secondary gear running
into the pinion shaft gear.

3.2.2. Reverse sound

Sound description:
When standing still and shift to Reverse, a small whistle sound can be heared.
When releasing brake and start driving in Reverse the sound gets bigger and turns
into a whining sound.
This is a normal sound from the planetary gear set inside the transmission.

3.2.3. Low speed gear sound

Sound description:
When the vehicle speed is around 40kph, release gas pedal, while car is slowing down,
a whistle sound can be heared. This whistle sound is much lower in frequency than
3.2.1. And is much more difficult to hear.
This is a normal sound from the pinion and crown wheel.

3.2.4. Primary ball bearing noise and inside bearing noise

Primary Ball bearing noise:

Sound description:
During driving in D, from low speeds on the car makes a noise like “wengweng”. The
frequency and volume of the noise gets higher with engine speed!
The noise goes up with engine speed and not with vehicle speed!

How to check and repair:

1. Drive in D at a constant speed, fix gas pedal and vehicle speed around 60kph.

Shift to S (Sport) mode: the engine speed will go up about 500rpm within 1 or 2
seconds while keeping the same vehicle speed. If the sound also goes up (that
means it goes up with engine speed and not with vehicle speed), than there is a
big chance the primary ball bearing is damaged.

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2. Drive in manual mode 4

gear and fix your gas pedal so you have a vehicle

speed of around 60kph.

Shift to 3

gear while keeping vehicle speed 60kph. The engine speed will go

up about 800rpm. If the sound also goes up (that means it goes up with engine
speed and not with vehicle speed), than there is a big chance the primary ball
bearing is damaged.
Replace Primary ball bearing according 2.6.2.7.

Transmission inside bearing noise:

Sound description:
During driving in D, from low speeds on the car makes a noise like “wengweng”.

How to check and repair:
According the primary ball bearing noise, if the frequency and volume of the noise
does not go up or down with related engine speed but the sound is related to vehicle
speed then the noise could come from transmission inside bearings.
These cannot be replaced and so complete transmission needs to be replaced.

NOTE: Noise problems are very hard to evaluate so before to decide to replace a
part of the transmission or change the complete transmission, be sure that the
noise is actually coming from the transmission. Check or replace other parts of
the car first which are easier to replace.

Use following chart to help to locate the origin of the noise:

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3.2.5. Noise due to water or contaminated oil inside transmission

Sound description:
Car standing still, brake and shift to D or R. As soon as you release the brake a
„gegege“ sound can be heared. This can be heared from the first mm the car is
moving!
From creeping speed (10kph) by giving throttle to accelerate a „zhi---“ sound can be
heared between 10kph to 40kph.
In the beginning stage of water contamination it is possible you only hear the
„gegege“ sound and not yet the „zhi---“ sound.
Some cars when taking off can have shocks also, depending on the level of
contamination.

How to check and repair:
Drain the oil and remove oil pan and primary cover:

“wengweng” bearing noise

From transmission

side

From engine side

Check parts in the car

Go up with engine

speed

Go up with vehicle

speed

Primary ball bearing

noise

Transmission inside

bearing noise

Change primary ball

bearing

Change transmission

Half shaft and wheel

bearing noise

Change half shaft or

wheel bearing

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If the inside of primary cover and oil pan shows white stuff inside, than it is fully clear
the transmission has been contaminated with water or other oil or liquid.
Drain the oil as much as possible and discard oil filter.
Place new oil filter and re-fill the transmission according 2.1.
Drive the car for about 5 min at different speeds and accelerations.
Drain the oil and refill again. (Do this 2 or 3 times with driving the car in between until
the noise disappears).
T

he “gegege” sound should disappear and the “zhi---“ sound as well.

The “zhi---“ sound you can make disappear with heating up the clutch by doing stall
test: shift to D with foot on brake and apply throttle”
While doing the stall test you can get fault code P2787 (clutch temperature too high)
This is just a self protection of the transmission against over-heating of the clutch. The
fault code will disappear automatically and you can perform the stall test again until the
“zhi---“ sound gets better or disappears.

If the contamination was too big you will not be able to remove the sound and shocks.
In that case the transmission needs to be replaced.

3.2.6. Noise in N or P

1. Frequency and volume of noise goes up with engine speed

Try to find out if the noise comes from engine side or transmission side
If engine side, check parts related to engine
If transmission side, the only part you can check is the pump.
Replace pump to check if the noise is gone.
If noise does not disappear by replacing the pump then either input shaft needle
bearing or planetary gear set can be the source of the noise. In this case the
transmission needs to be replaced.

2. Frequency and volume of noise does not go up with engine speed

The noise should come from other parts of the car

Use following chart to help to locate the origin of the noise:

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Noise in N or P

Noise goes up with

engine speed

Noise not goes up
with engine speed

Pump noise

Input shaft bearing

or planetary gear

set noise

Change pump

Change

transmission

Check other parts in

the car

Noise come from

engine side

Check all engine

parts

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3.3. Shocks and no creep problems

3.3.1. Shocks

Problem description:
During driving in D the car shows small vibrations in speed or small shocks can be felt.

Check and repair:
There could be many possibilities for this problem:

1.  Clutch adaptation not fully finished: check procedure 1.6.
2.  Water or contaminated oil inside transmission: check 3.2.5.
3.  Primary speed sensor: replace by instruction 2.6.2.14.
4.  Hydraulic unit problem: replace by instruction 2.6.2.12. and redo clutch

adaptation procedure 1.6

5. Secondary speed sensor: replace by instruction 2.6.2.13.
6. If still has the problem after trying 1. to 5. please contact After Sales team

3.3.2. No creep

Problem description:
Shift to D, release brake, the car does not move. Give throttle and the car start moving
with or without shock from about 2000rpm.

Check and repair:

1. Check if there is a fault code active: check according 3.4.
2. If the problem happens normally in cold condition: redo and check clutch

adaptation 1.6.

3. Brake signal problem: if brake is not applied but brake signal is activated (see

with tester tool or MLT). Check brake switch and car cable harness.

4. Hydraulic unit problem: replace hydraulic unit by instruction 2.6.2.12. and redo

clutch adaptation procedure 1.6

5. If still has the problem after trying 1. to 4. please contact After Sales team

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General remark:
Whenever there is an error (DTC) detected by the transmission electronics (TCU),
the warning lamp on the dashboard will be activated or flashing.
When reading out the DTCs with the tester tool and a P-code is found, first
check if this P-code is a sporadic fault, that did not occur in the last driving cycle
(Should be indicated with an „H“ from History). If so, just delete the FC and check if it
does not come back. If not a sporadic fault, but currently active (Should be indicated
with a „C“ from Currently), folow the action steps described below for each error code.
Always check if the latest software is present. If not flash to the latest TCU
software and check the faultcodes again.

Do not perform all „Man actions“, stop the sequence of actions whenever the problem
is solved.

P0710 Oil temperature sensor fault

Reaction from TCU：

Warning lamp，Substitute transmission oil temperature

Man actions:

1、measure the oil temperature online with tester tool; if the signal value is
feasible, just clear the FC and check if it does not come back
2、check wiring (SG, SB, OC), based on this replace either transmission cable
harness or vehicle cable harness
3、measure resistance between two pins on transmission connector (20deg =
980 to 1000 Ohm) to see if sensor is defective.  If it's defective, skip next step
and directly replace transmission cable harness
4、replace TCU by known good one
5、if still has problem, please inform of the Punch in time.

P2765 Primary pulley speed sensor fault

Reaction from TCU：

High side* off，Warning lamp

Man actions:

1、measure the primary speed sensor value online with tester tool; if the signal
value is feasible, just clear the FC and check if it does not come back
2、check wiring (SG, SB, OC), based on this replace either transmission cable
harness or vehicle cable harness
3、replace TCU by known good one
4、replace speed sensor

5、if still has problem, please inform of the Punch in time.

P0720 Secondary pulley speed sensor fault

Reaction from TCU：

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Man actions:

1、measure the secondary speed sensor value online with tester tool; if the
signal value is feasible, just clear the FC and check if it does not come back
2、check wiring (SG, SB, OC), based on this replace either transmission cable
harness or vehicle cable harness
3、check the car whether use original tyres or not? If use spare tyres or not
original tyre, replace tyres;
4、replace speed sensor
5、replace TCU by known good one

6、if still has problem, please inform of the Punch in time.

P0840 Secondary pressure sensor fault

Reaction from TCU：

High side* off， Warning lamp

Man actions:

1、measure the actual and target secondary pressure online with tester tool; if
the signal value is feasible, just clear the FC and check if it does not come
back。
2、check wiring based on the values read out in step one (SG: 0 bar (actual
pressure), SB: 60 bar, OC: 60 bar): replace either transmission cable harness or
vehicle cable harness
3、replace hydraulic unit

4、replace TCU by known good one

5、if still has problem, please inform of the Punch in time.

P0641 Pressure sensor supply fault

Reaction from TCU：

High side* off，Warning lamp

Man actions:

1、measure the 5V supply voltage online with tester tool; if the signal value is
feasible, just clear the FC and check if it does not come back。
2、measure voltage between pressure sensor supply and pressure sensor
ground, based on result you get in step 1
3、check wiring (SG, SB, OC), based on this replace either transmission cable
harness or vehicle cable harness
4、replace TCU by known good one
5、replace hydraulic unit
6、if still has problem, please inform of the Punch in time.

P0651 DMS and speed sensor supply fault

Reaction from TCU：

High side* off，Warning lamp

Man actions:

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P0659 High side* SCB

Reaction from TCU：

High side* off，Warning lamp

Man actions:

1、measure the HS voltage ，the same voltage level as the battery should be
read out .  If so, check wiring (check if shortcut between battery + and VHS,
transmission connector).  This means fix the harness (transmission harness or
vehicle harness) .  If not (same as battery) but higher than 3.4 V, then exchange
the TCU.

P0658 High side* SCG or OC

Reaction from TCU：

High side* off，Warning lamp

Man actions:

1、measure the HS voltage: compare it to the battery voltage.  If the battery
voltage is ok, and the high side voltage is smaller than 3.4 V, then there is a SG.
If the battery voltage is ok, and the high side voltage is higher than 3.4 V, then
it's an OC.  In both cases, check the harness (transmission harness or vehicle
harness), dependant on the type of problem (mention the pin nbs). If, after
checking, the harness is ok, change the TCU. If the battery voltage was not ok,
then check the battery.

P0702 Watchdog test failed (during init)

Reaction from TCU：

High side* off，Warning lamp

Man actions:

replace TCU

P0962 EDS1* (primary pulley) SCG

Reaction from TCU：

High side* off，Warning lamp

Man actions:

1、measure resistance of EDS1 - should be 5.05 Ohm +- 6%.
2、check wiring (SG), based on this replace either transmission cable harness
or vehicle cable harness
3、replace hydraulic unit
4、if still has problem, please inform of the Punch in time.

P0963 EDS1* (primary pulley) SCB

Reaction from TCU：

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High side* off，Warning lamp

Man actions:

1、measure resistance of EDS1
2、check wiring (SB), based on this replace either transmission cable harness
or vehicle cable harness
3、replace hydraulic unit
4、if still has problem, please inform of the Punch in time.

P0960 EDS1* (primary pulley) OC

Reaction from TCU：

High side* off，Warning lamp

Man actions:

1、measure resistance of EDS1
2、check wiring (OC), based on this replace either transmission cable harness
or vehicle cable harness
3、replace hydraulic unit
4、if still has problem, please inform of the Punch in time.

P0966 EDS2* (secondary pulley) SCG

Reaction from TCU：

High side* off，Warning lamp

Man actions:

1、measure resistance of EDS2
2、check wiring (SG), based on this replace either transmission cable harness
or vehicle cable harness
3、replace hydraulic unit
4、if still has problem, please inform of the Punch in time.

P0967 EDS2* (secondary pulley) SCB

Reaction from TCU：

High side* off，Warning lamp

Man actions:

1、measure resistance of EDS2
2、check wiring (SB), based on this replace either transmission cable harness
or vehicle cable harness
3、replace hydraulic unit
4、if still has problem, please inform of the Punch in time.

P0964 EDS2* (secondary pulley) OC

Reaction from TCU：

High side* off，Warning lamp

Man actions:

1、measure resistance of EDS2
2、check wiring (OC), based on this replace either transmission cable harness
or vehicle cable harness

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P0902 EDS3* (clutch) SCG

Reaction from TCU：

High side* off，Warning lamp

Man actions:

1、measure resistance of EDS3
2、check wiring (SG), based on this replace either transmission cable harness
or vehicle cable harness
3、replace hydraulic unit
4、if still has problem, please inform of the Punch in time.

P0903 EDS3* (clutch) SCB

Reaction from TCU：

High side* off，Warning lamp

Man actions:

1、measure resistance of EDS3
2、check wiring (SB), based on this replace either transmission cable harness
or vehicle cable harness
3、replace hydraulic unit
4、if still has problem, please inform of the Punch in time.

P0900 EDS3* (clutch) OC

Reaction from TCU：

High side* off，Warning lamp

Man actions:

1、measure resistance of EDS3
2、check wiring (OC), based on this replace either transmission cable harness
or vehicle cable harness
3、replace hydraulic unit
4、if still has problem, please inform of the Punch in time.

P1768 Backlight SCG

Reaction from TCU：

Warning lamp

Man actions:

1、check the wiring

2、replace TCU

P1769 Backlight SCB or OC

Reaction from TCU：

Warning lamp

Man actions:

1、check the wiring

2、replace TCU

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Reaction from TCU：

High side* off，Warning lamp

Man actions:

1、check oil level and oil type

2、replace pump and oil filter
3、replace hydraulic unit

4、if still has problem, please inform of the Punch in time.

P0811 Clutch (forward or reverse) slipping

Reaction from TCU：

Warning lamp，Clutch open

Man actions:

1、measure the clutch pressure and the difference speed online with tester tool;
if the signal value is feasible, just clear the FC and check if it does not come
back.
2、If it's not feasible (for example 10 bar clutch pressure and a high difference
speed), go to the next step.
3、check oil level and oil type
4、replace 2 speed sensors
4、replace hydraulic unit and oil filter
5、if still has problem, please inform of the Punch in time.

P0730 Ratio control fault

Reaction from TCU：

High side* off，Warning lamp

Man actions:

1、check signal from speed sensors with the tester tool, as well as

target current and actual current for the primary pressure and target and actual

primary pressure itself;

2、depending on previous results, speedsensor problem or hydraulic pressure

problem

3、check oil type and oil level
4、check the belt is broken or not
5、replace speed sensors or hydraulic unit

6、replace pump
6、if still has problem, please inform of the Punch in time.

P1765 Secondary pulley pressure too low

Reaction from TCU：

High side* off，Warning lamp

Man actions:

1、measure the actual and the target pressure in dynamic driving situations like
tip ins, launch, ...
2、check oil level and oil type
3、do a proper clutch adaptation (this faultcode can come out when clutch
adaptation is not optimal)

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6、replace oil pump and oil filter
7、if still has problem, please inform of the Punch in time.

P1766 Secondary pulley pressure too high

Reaction from TCU：

Warning lamp

Man actions:

1、measure the actual and the target pressure in dynamic driving situations like
tip ins, launch, ...
2、check oil level and oil type
3、replace hydrailic unit and  oil filter
5、 if still has problem, please inform of the Punch in time.

P0701 Double fault requiring high side* open

Reaction from TCU：

High side* off，Warning lamp

Man actions:

check other FCs

P0218 High oil temperature

Reaction from TCU：

Warning lamp

Man actions:

1、Check oil cooler

2、Try to reproduce in normal driving condition - if not reproducable, ask
customer about driving conditions when the FC occurred.
3、while trying to reproduce it, you can check the transmission temperature
with the tester tool。T_trans > 120 (longer than the filter time of 30 minutes!);
measures to avoid further temperature increase

P1767 Critical oil temperature

Reaction from TCU：

High side* off，Warning lamp

Man actions:

1、try to reproduce in normal driving condition - if not reproducable, ask
customer about driving conditions when the FC occurred (uphill driving or high
speed driving?).
2、check oil cooler
3、check the oil level and oil type
4、replace hydraulic unit
5、if still has problem, please inform of the Punch in time.

P0219 Powertrain speed out of range

Reaction from TCU：

High side* off，Warning lamp

Man actions:

1、should never occur in principle

VT2-VT3 for Haima ZZ. Service Manual - part 5