Hello Ralf
I've had the same problems you're having last summer and I did the exact same steps you did until I finally called Klauss.
His first question was to know if I was using a direct crack sensor or one or two Hall Effets.
Having 2 Hall Effets installed in my set up, he told me to simply disconnect the connectors to the Hall Effets and to clean the contacts with an electrical contact cleaner which I did and I didn't have any problems since..It's working flawlessly...
Cheap solution and worth a try if you haven't done it yet. IMHO
Good luck
Bruno
rv4@videotron.ca