montybazbaz
Posts: 24
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Location: Littleborough, Lancashire UK

Gear Selector Misbehaving

Tue Feb 09, 2016 11:48 am

I've asked this on the UK SpeakEV website but haven't had a response and am now getting desperate.

Our 24000 mile Czero has developed an odd fault, The gear selector suddenly doesn't feel "right", and after being parked on our sloping driveway with the handbrake fully on, sometimes the lever goes into D position (but not fully home) and the car still thinks its in N, or does set off with D displayed by then it starts to flash and the warning and turtle mode lights come on. Usually a stop and reset, and a good pull on the lever will get it in drive, but its not right at all.

But its intermittent. The lever felt fine on my drive home, and went into R N and D with the usual clonks, but a trip to collect daughter from nursery brought the same problem . In fact, when i pushed the lever into P, the car thought it was in N until I jiggled the lever about. And then when i selected the ratios, the car faulted and the indicator flashed again.

Does the cable wear or stretch ? Chall i try and dismatle the lever assembly to look for any foreign object ? Or is the switch on the motor faulty/gummed up ? in fact, how do i access this swtich,

Its very frustrating. There is nothign wrong with the car at all - but his simple thing could immobilise it.

PV1
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Re: New weak spot - the gear selector misbehaving

Tue Feb 09, 2016 12:07 pm

If the shifter feels fine when it messes up, it sounds like it could be dirty contacts, but if you're feeling a difference in how the shifter moves, then it sounds like something mechanical.

I'd look at the selector box on the gearbox. It is a black box where the cable attaches to the gearbox on the left-hand side. See if it is damaged or if something is loose.
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kiev
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Re: New weak spot - the gear selector misbehaving

Tue Feb 09, 2016 2:15 pm

Cables do stretch over time and it may need an adjustment.

In addition sliding electrical contacts get dirty over time and may need cleaning or replacement. There are actually two sets of contacts for each gear position--sort of a redundant system but each set has a different function.
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JoeS
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Re: New weak spot - the gear selector misbehaving

Wed Feb 10, 2016 10:16 am

montybazbaz, I would stop immediately and take the cover off the shifter assembly and see if there is a mechanical problem: the two cables attached to the shifter activate the ignition lock and the parking sprag, whereas I believe the shifter mechanically activates the various microswitches. I have not taken this apart myself, but would be very very leery of driving the car until the problem was understood.
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siai47
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Re: New weak spot - the gear selector misbehaving

Wed Feb 10, 2016 4:45 pm

The shifter on the I-MiEV is connected by a cable to the transaxle. The switch that tell the car what direction the car is going to travel (i.e. reverse, neutral, forward) is mounted on the transaxle. There is an alignment pin that can be put in the switch to confirm that it is synchronized with the "gates" in the floor shifter. Like another member said, the cable can get out of adjustment. You really need to look at a service manual because you don't want to mess up the crazy key/brake interlock which is also located in the floor shifter. All that being said, the car should never be able to shift out of park by itself. It sounds like something is loose and going to fall off. If you remove the cover over the shifter (console first with screws under the rear and a couple of pushpins) you will see the two small cables out of the front of the shifter and one large cable going to the rear. The large cable the one you are interested in. Make sure the cable anchor is firmly locked in place in the front clamp and the cable end is tight where it attaches with a pin to the plastic part at the bottom of the shifter. Pull on the cable jacket to make sure it is not moving in the clamp. The cable then goes through the floor near the rear of the front passenger seats and comes out just above the left side half-shaft at the transaxle. You might be able to see it with a mirror from the top, but the battery charger will block your ability to really check it out by touch. You will most likely have to get under the car to complete this. You will see the cable jacket is anchored to a clamp (holder) on the transaxle then goes to an arm attached to the shifter shaft that passes through gear selector electrical switch. See if you can find anything loose (cables, clamps, switch mounting, nut holding the arm on, etc.). Have someone move the shifter slowly back and forth and see if you can find any slop in the linkage. The key is synchronizing the switch and the shifter gates with no slop in the system to make it work properly. BTW, the position switch is easy to remove by taking the nut off the shift arm on the transaxle. Then you remove the mounting bolts and the connector and the switch slides off the shaft if you need to replace it.

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Re: New weak spot - the gear selector misbehaving

Mon Feb 22, 2016 6:08 pm

montybazbaz: update? That sounded potentially serious and siai47 provided a excellent explanation.
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montybazbaz
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Location: Littleborough, Lancashire UK

Re: New weak spot - the gear selector misbehaving

Tue Feb 23, 2016 4:53 am

the car actually started to behave. The lever felt fine and I assumed it was some grit or debris in the switch mechanism that worked its way out. Then my son asked is the car fixed.....and it's started to mess again.

Now...it seems to be if the car is parked nose up on our drive. The handbrake holds it fine, but after being parked.overnight there is stiffness in the gear lever amd it takes a good pull to register D on the dashboard. After first tug it's better but stil not right. There's also a little squeak of brake rubbing for a couple of seconds after driving away.

Park nose down and doesn't do it as much.

Now......do the parking brake pawls need a lube ? Are they sticking ? Would movement of the car in P translate to something putting a strain on the selector Cable and mech ?

I've tried to download the manual for the car using the links here but it doesn't work on my pc. A link to an exploded diagram of the selector mech, switch and parking mech pawls would be extremely helpful and possibly provide an insight.

montybazbaz
Posts: 24
Joined: Mon Sep 29, 2014 5:50 am
Location: Littleborough, Lancashire UK

Re: New weak spot - the gear selector misbehaving

Tue Feb 23, 2016 5:50 am

For once it is sunny here so I've had a crawl.under the car. Yes siai's excellent descriptions is bang on. The cable all feels fine....it comes down into a bracket to.clamp the sleeve then there a gator around part of it to the moving arm with the switch. Now....then there is a rod at the other end of the arm to another lever about 6 inches ahead of it.

Everything feels fine. No slack, nothing loose, all gaiters intact. I tried moving stuff but everything is locked solid.

I wonder if there's some debris in the selector lever mech ?

If/when I take that apart I'll see about adding the B and C driving modes too.

It also seems that the P position brake is actually built into the transmission and therefore nothing is serviceable on it nor can be adjusted ?
It seems fine in operation as it hold the car on a hill.

JoeS
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Re: New weak spot - the gear selector misbehaving

Tue Feb 23, 2016 7:53 am

Hmmm, I wonder if part of your issue might be the manner in which you are engaging P?

Once again, siai47 gave an excellent description in this thread:

http://myimiev.com/forum/viewtopic.php?f=22&t=1741

To reiterate, one should not let the parking sprag (pawl) hold the car on an incline. For example, on an incline, you DO NOT put the car in P and take your foot off the brake without having first engaged the hand brake. Doing so will result in a lurch and a thunk as the sprag engages.

The proper way, on even the slightest incline, is to keep foot on brake, shift to P, pull hand brake, release foot brake. The parking sprag may or may not have engaged, but it is the hand brake that is holding the car in place.

Reversing the process: start car, foot on brake, release hand brake, shift out of P, and only then release foot brake.

If you are in a situation whereby you do not want to leave the car's hand brake engaged (e.g., a wet drive followed by freezing conditions) on an incline, then with foot on brake shift into P and then slowly release the brake so the car rolls slightly and the sprag engages. The steeper the incline, the sharper the clunk and jolt as the sprag engages.
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montybazbaz
Posts: 24
Joined: Mon Sep 29, 2014 5:50 am
Location: Littleborough, Lancashire UK

Re: Gear Selector Misbehaving

Wed Feb 24, 2016 5:32 am

I'd like to think I'm doing it right....but not in that order. Firstly the had brake is correctly adjusted so hold the car.

I drive onto the driveway in D or R and hold the car on the footbrake. Then apply the handbrake fully,slip the ransmission into N, release footbrake (and the car moves a tad as it settles) then apply P.

So there shouldn't be any movement of the car against the pawls.

But SOMETHING sometimes seems to pull the gear cable further towards the P position, making it hard to go to D in the morning....

Yet today it was fine. I take it the detent you can feel are all in the selector mech and not from the mech on the motor ?

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