Replaced Actuator Gears and now getting actuator fault...

Car is a 2009 with 78k on it.

Well, I thought I was being proactive by doing the throttle actuator gears as I don't have any errors, but about 3 days after I did the gears I got a throttle actuator error code.

Has anyone else seen anything like this? I was trying to be smart but it looks like I just shot myself in the foot.. This was the rebuild kit from Odometer Gears...

Sigh, this car is not fun to drive anymore... Always chasing something wrong...

I believe there have been times when the problem was that the actuator was not re-plugged in properly

EJT86 wrote

I believe there have been times when the problem was that the actuator was not re-plugged in properly

Meaning the electrical connector isn't seated all the way or something?

omniphil wrote  

EJT86 wrote

I believe there have been times when the problem was that the actuator was not re-plugged in properly

Meaning the electrical connector isn't seated all the way or something?

Are you throwing codes or seeing the error on your iDrive?

omniphil wrote

Meaning the electrical connector isn't seated all the way or something?

If I'm remembering correctly yes. I'm not saying this specifically to your post I'm just saying it could be a possibility

TWiTCHY wrote

Are you throwing codes or seeing the error on your iDrive?

Yup, got the errors in iDrive. There's 4 of them. When I run the codes one is the throttle actuator...

EJT86 wrote

If I'm remembering correctly yes. I'm not saying this specifically to your post I'm just saying it could be a possibility

Certainly something to check, I will do that...

Kind of a stupid question, but make sure you clocked everything properly after you re-installed it. You need to make sure you rotate the sprung (half-gear) side of it around so that you have the proper load on it. Once you put it back together make sure it feels the same as when you took it apart and that it returns each time you place it back.

The arm on the back can also go on two ways. Make sure it isn't 180 degrees out.

Lastly, when you place the "cover" (with the circuitry) back on that the contact pins go to their respective locations.

You can always give the guys at Odometer Gears a call, they're very helpful.

I have had the gears on one of my units for about 5k miles now. Going to take it back apart this summer and reinspect.

Let us know what you figure out.

ty20404 wrote

Kind of a stupid question, but make sure you clocked everything properly after you re-installed it. You need to make sure you rotate the sprung (half-gear) side of it around so that you have the proper load on it. Once you put it back together make sure it feels the same as when you took it apart and that it returns each time you place it back.

The arm on the back can also go on two ways. Make sure it isn't 180 degrees out.

Lastly, when you place the "cover" (with the circuitry) back on that the contact pins go to their respective locations.

You can always give the guys at Odometer Gears a call, they're very helpful.

I have had the gears on one of my units for about 5k miles now. Going to take it back apart this summer and reinspect.

Let us know what you figure out.

Yup, I did clock the gears. I followed the video odometer gears put up on you tube. I was pretty careful to make sure the contacts were all in place.

Everything ran fine for 3 days, So i'm guessing if I installed it incorrectly I would have noticed something right away.

Plus when I clear the codes the car drives fine for like 45 minutes before the error pops up again.

I'll call Odometer Gears and see if they have any insight.. Sounds like a good idea...

Not sure if you've seen this yet but it's helpful

http://www.m3post.com/forums/showthread.php?t=928325

So where's the cheapest place to pickup a new throttle actuator?

omniphil wrote

So where's the cheapest place to pickup a new throttle actuator?

Not sure if you're interested but I've got two used ones. I replaced both once I got the symptoms so one or both have failed. I could clearly hear the actuator gears slipping when rev matching so maybe putting your new gears in the unit might revive them. I can't comment on the electronics there's no practical way to test them but the board appears the fine ~45k mi on both

EJT86 wrote

Not sure if you're interested but I've got two used ones. I replaced both once I got the symptoms so one or both have failed. I could clearly hear the actuator gears slipping when rev matching so maybe putting your new gears in the unit might revive them. I can't comment on the electronics there's no practical way to test them but the board appears the fine ~45k mi on both

I just bought one in the for sale section, So I should be good now. But i'm worried about the other one I just rebuilt with the new gears now.

I should have just left them alone

EJT86 wrote

Not sure if you're interested but I've got two used ones. I replaced both once I got the symptoms so one or both have failed. I could clearly hear the actuator gears slipping when rev matching so maybe putting your new gears in the unit might revive them. I can't comment on the electronics there's no practical way to test them but the board appears the fine ~45k mi on both

What did that sound like?

omniphil wrote

I just bought one in the for sale section, So I should be good now. But i'm worried about the other one I just rebuilt with the new gears now.

I should have just left them alone

It was probably inevitable that they went bad. Might have been the circuit board that was bad. Any way I'm sure you can sell the gears pretty easily

noneedlessnoise wrote

What did that sound like?

I had a video of it. It was tough to hear on camera with the wind noise. It's a lil tough to describe now. It happened about 8mo ago. When downshifting at like 3-4K rpm if you can imagine how your car sounds at the new rev matched rpm and take that sound and imagine the butterfly valve opening and closing very very rapidly. It was more the sound of the air and engine noise reverberating from the TA rapidly trying to open the valve and slipping than the TA itself making noise

Thanks man. Sometimes when I give the car throttle while moving, I hear kind of a plasticy sound, almost like a child's rattle, for a second or two. Thought maybe it was that.

noneedlessnoise wrote

Thanks man. Sometimes when I give the car throttle while moving, I hear kind of a plasticy sound, almost like a child's rattle, for a second or two. Thought maybe it was that.

No def not a plastic sound. Could be the "under steering wheel" panels inside the car rattling from the vibration from the throttle. I have a rattle in front of my left knee when I hit particular bumps and that sounds like plastic

omniphil wrote

Sigh, this car is not fun to drive anymore... Always chasing something wrong...

Wait, what was wrong? Did I miss something?

kb9uwu wrote

Wait, what was wrong? Did I miss something?

I replaced the actuators gears so I would avoid getting the actuator faults. But 3 days later it has faulted...

omniphil wrote  

kb9uwu wrote

Wait, what was wrong? Did I miss something?

I replaced the actuators gears so I would avoid getting the actuator faults. But 3 days later it has faulted...

If it ain't broke don't fix it....*




*excludes rod bearings

Let us know if you resolve this. Im planning on doing my gears as well