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› Mercedes W211 Gearbox Lever Module Issue (Gear Stuck on 2) Analyse and Fix

Анадырь Дизайна Человека рассчитать Тест на тип характера.

16
gearbox_level_module-IMG_20210703_170356-1000px.jpg
Mercedes W211 Gearbox Lever Module Issue (Gear Stuck on 2) Analyse and Fix
RustyOx Offline
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#1
05-07-2021, 10:37 AM (This post was last modified: 05-07-2021, 10:54 AM by RustyOx.)
  • The Problem



The gear information is not shown in dashboard display. The gearbox is believe to be stuck on 2nd gear, the car speed is 30miles per hour while the engine is running at 3000 rpm.
This is for Mercedes E-Class W211 (2002 - 2006).






  • Check with iCarsoft
iCarsoft shows there are two related code:



(please make sure clear the "store" error codes, and read the error code again to double check for each errors).

  • P240C
[The selector lever position sent from control unit A80(Intelligent servo module for DIRECT SELECT) via the CAN bus is mplausible.]



or [(216/221) The selector leverl position sent from control unit N15/5(Electronic selector leverl module control unit) via the CAN bus is implausible.

   

  • P1856
Selector leverl position detectoin has failed.

   
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RustyOx Offline
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#2
05-07-2021, 01:26 PM (This post was last modified: 25-06-2022, 04:57 PM by RustyOx.)
[*]Search online
shows it is a common problem that the gearbox selector is faulty. Someone also mentioned the break ligth switch may also cause this issue.


[*]reference 1:
I repaired my failed shifter module in our W211 E500 wagon. I found two cracked solder joints on an SMD sensor inside the module. This internal cracked solder issue may affect other similar MB shifter modules or may have be unique to my shifter module. The repair is a bit technical but not out the realm of ability for someone with some hand tools and a soldering iron. From: https://mbworld.org/forums/e-class-w211/...epair.html


[*]Reference Youtube videos:

[*]https://youtu.be/knWF4XROaFE
[*]https://youtu.be/D6TG8IlomTA
[*]https://youtu.be/BwatjgHi4vo
[*]https://youtu.be/jwx6QhoKjFI
[*]https://youtu.be/XxOFSq4J_-E (how to remove transmission shifter)
[*]https://youtu.be/f-0l7-I2z6Y
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RustyOx Offline
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#3
06-07-2021, 07:25 PM
• Check break light (stop light) switch
Some people mentioned the break light switch can also cause this Gearbox(Transmission) problem, so check it with iCarsoft.
iCarsoft shows the break light swtich is working fine. You can also check if break light is on when break pedal pressed.
When using iCarsoft, please make sure clear the "store" error code, and read the error code again to double check for each errors.
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RustyOx Offline
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#4
08-07-2021, 07:02 PM (This post was last modified: 09-07-2021, 11:28 AM by RustyOx.)
• Remove the central arm rest

   

   

Remove two screws inside center storage (arm rest)
Use bit:  torx 15 
   
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RustyOx Offline
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#5
21-08-2021, 11:21 AM (This post was last modified: 21-08-2021, 12:14 PM by RustyOx.)
Gear Lever with central arm rest removed







   







remove the 12v socket which blocks the way to move the break latch (break position detection)

   









Turn and disconnect/remove the  break latch from the gear level module







   











remove the tab holding the link bar between lever module and the gear box







   











disconnect the link bar between gearbox lever module and the gear box







   

Seperate the white/cream cover of the gearbox lever module.

it is very strongly gluded down to the black base.

I use a knife to slowly separate them. This is the most difficult part to me, takes me more than 1 hours.



I forgot to take a picture, so borrow a picture from online.





   



   
gearbox lever module with cover removed
   
remove soft cream/white protection cover

   

remove black control box(pcb inside)

   
to be continoued ...
Open the black control box

   

to be continoused ...
Zoom in
   

to be continued ...
PCB backside detailed photo
   
[attachment=552]
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RustyOx Offline
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#6
21-08-2021, 12:15 PM (This post was last modified: 25-06-2022, 04:57 PM by RustyOx.)
Found a photo show the glue position. it is very strongly gluded down to the black base.
   

I use a knife to slowly separate them. This is the most difficult part to me, takes me more than 1 hours to seperate the white/cream cover of the gearbox lever module.
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RustyOx Offline
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#7
21-08-2021, 12:23 PM
Use high-zoom PCB camera to inspect the PCB solder joints.

   
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RustyOx Offline
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#8
21-08-2021, 12:26 PM
Check solder joints under the high zoom PCB camera
resolder the joins if needed
Pay extra attentions around the light couplers which are used to detect gear lever position and reported to failed by lots of others.

   

   

   

   
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RustyOx Offline
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#9
21-08-2021, 12:29 PM (This post was last modified: 22-08-2021, 10:42 PM by RustyOx.)
After resoldered all the light couplers (optocouplers), and resoldered most of the SMT components including resistors, sot-23 transistors and capacitors.

I reassembled the PCB back to the gearbox lever module and the problem was fixed.

hope this theads could help others, please let me know if you have any questions.
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