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Persistent crank sensor code
Posted to Technical Discussion Forum on 2/9/2015 17 Replies

I cruise around on this site from time to time but rarely post, thanks for taking the time to look at my nightmare. Problem arose after used transmission installed (I know better, trying to help customer who couldn't afford $5k... no good deed...) Trans is Aisin 55/50sn and is identical part number. Thought at first problem was clutch chatter (that's what it feels like) eliminated trans internals as source. Installed Volvo OE fluid. I am aware of tsb's regarding corrosion but those problems involve extended crank/no start. This one starts every time immediately and 5200 code shows ONLY after shudder appears, which is sometimes as idle stabilizes and others not until a 1/2 mile down the road. Also aware of copper washer issue, problem is present with/without washer and with both echlin and o.e. sensor. Problem was improved drastically with new Echlin sensor and new sensor bracket made no change. We ran a pattern on the crank sensor and it is a perfect sine wave even when issue is present, output is about 4.5v. Installed new O.E. sensor and runs as bad as original. RUNS BETTER WITH AFTERMARKET? Problem never appears without 5200 code. New bracket is a supercession, has a metal mount built into it and washer does not fit with new mount bracket. Called dealer to confirm part number/application against VIN. "Shutter ring" (tone wheel) mounts to flex plate and is OE. We inspected it through CSS hole while bumping starter and it does not appear to be damaged at all. There is no foreign material on sensor and starter drive is fine. Code 641a (exhaust cam timing fault) will show after 5200 only on extended drive but not every time and drive cycles with 641a act no differently. CEL is not on, Reduced Power warning shows in DIC while vehicle is acting up and clears from screen again in same drive cycle when engine calms down, warning appears both when 641a is present and without. Vehicle had no pcm codes prior to trans. Had tcm codes for gear rationality and transmission would engage reverse and then apply third with a hard clank at same time before replacement. We did not spend a lot of time on initial diag, problem was clearly trans and clearly mechanical. Trans. shifts fine now and tcm is clear. When tech installed trans, key was left on and battery did drain. Grounding trans to engine and trans to body did not change anything. No Codes present with Snapon Solus in Global OBD2, codes show only with Volvo software. No VIDA available. Any help would be greatly appreciated, thanks again for looking!

Craig Gornik
Owner/Service Advisor
Auto Electric and Full Service Auto Repair
Robbinsdale, Minnesota, USA

17 Replies Received (View Replies)


car Vehicle Data

2002 Volvo V70 AWD 2.4L

Engine2.4 L
Trans4-speed Automatic (Electronic)