For the 2nd time in a month, I have come across an Onkyo or Integra surround receiver that is stuck in the Audyssey setup mode. For Both of these receivers There is no sound output from the main zone Yet will output from is heard from Zone 2. A few weeks ago, this happened on a 10 year old Integra receiver. Today I find the same on a pretty old Onkyo #/HT-RS360. Again no output in the main surround sound zone, no matter what source is selected.
Both customers do not have their original Audyssey microphone. And I do not have any in my shop. We have tried re-boots by unplugging these receivers for a few minutes and plug it back in, yet no resolve.
Has anyone else seen this and what have you done to possibly fix it?

My guess would be that something is making a contact in the microphone terminal. If I recall correctly, those avr's would automatically go into setup mode when the mic was plugged in.

Try a can of air and blow it out.

Look at the settings for inputs and HDMI, speakers, etc. Also, make sure the levels set by Audyssey aren't so low the speakers can't be heard.

Can you save the configuration, or are the AVRs too old for that? Make good notes and try a hard reset before running Audyssey again. Make sure the mic actually works, too.

If it has to do with the mic connection, perhaps a bare plug would take it out of Audyssey mode. If a mic, or a short circuit, in the mic jack could put it into that mode, perhaps a plug with nothing connected to it might kick it back out of that mode.

UPDATE: Returned to customer’s home with a mic from a new Integra rec’r that waiting for install. Plugged in mic and different Audyssey indicator comes on front display and unit looks for audio via mic. Nothing is heard because Front and rear channel amplifiers appear to be bad. Unit needs to be replaced after verifying all other settings correct & speakers good. Price quote coming to customer a couple days.
The issue that I thought I had was that I was deceived by the front panel display showing “Audessy EQ” which is actually the equalizer turned on and not the unit in a set up mode. Further floating around menus revealed where I could turn the “Audyssey” &/or the EQ off. This turned off original display of “Audyssey EQ” which I thought was the unit stuck in the setup mode. After turning off the Audyssey & EQ in the “4” menus. I plugged in the mic and a different Audyssey indicator lights on the front panel. At that point unit goes into set up mode but is unable to complete the set up because there is no output from the amplifiers in the main zone since it has died up of old age.

Always try a factory reset. You could start by holding down the VCR/DVR button then pressing the power button. “Clear” should show in the display. If that’s not it, do a Google search, or go to the Onkyo support site to get the right key sequence. A reset it is always a good plan before calling it dead.

If they have any four-legged pets, I would recommend checking the speaker wires wherever they're exposed. Four channels of amplification don't usually cack at the same time, for no apparent reason.

You tested the speakers with a battery or some kind of tone generator, right?

My first thought is its 10 YEARS OLD! It may simply be failing and lets not forget the TI chipset issue that this could be a part of as well.

Agreed, factory reset and check wiring.