There have been a few threads on this issue, some inconclusive and some resolved. I am creating this thread to provide all the information in one place for the problem and resolution as I experienced it.
PROBLEM: Radio is properly configured for CTCSS tone encoding while transmitting but the radio can not raise even strong nearby repeaters that require tone encoding. Transmissions not requiring PL tone encoding are fine.
BACKGROUND: I had an FT-857D sitting in a box after being removed from a vehicle prior to sale 10 years ago. I recently installed the radio in the center console of a Jeep TJ where the factory subwoofer and amp used to be, with the control/display mounted above the rearview mirror. (The vent for the speaker leaves a large opening for cooling and I drilled some holes low on the opposite side for flow-thru ventilation.) I installed an original ATAS-100 antenna for HF/6M, and a Diamond SG-7500 for 2M and 70cm. Both of these antennas were also on the prior vehicle and stored for 10 years before this reinstall. After the install, SWR and transmit capability were good on all bands but I could not access any FM repeaters requiring CTCSS tone encoding on any band (6M, 2M, 70cm).
TROUBLESHOOTING: I used my Uniden SDS-100 scanner¡¯s ¡°Close Call¡± and CTCSS tone decoding capability to observe what the FT-857D was actually transmitting. The transmitter radio frequency was correct but the encoded PL audio tone was not. While configured for a PL tone of 100.0, 94.8 Hz was actually encoded. I tried a few other tones and, oddly, they did not encode at all or maybe were at a non-standard tone the scanner could not identify. So clearly there is an issue with CTCSS tone encoding on my radio that I did not have 10 years ago when it was last installed and used.
RESOLUTION: Google searching revealed (from this site and others) that increasing the CAT Rate setting (Menu #19) might solve this problem and that this issue might be related to having a programmer cable installed. This is the ¡±Ah Ha!¡± moment. Because the radio is mounted inside the center console and not easily accessed, I permanently installed an RT Systems USB programming cable attached to the CAT DIN interface, with the USB and excess cable in the storage box atop the Jeep center console for easy programming updates. (As an aside, I also wired the brown ¡°low power¡± wire to a grounded push button switch in the storage compartment for convenient all-band low-power enablement.) I did not want to pull the center console out again to verify the programmer cable is causing the problem. But simply changing Menu 19 CAT Rate to 38400 fully restored proper CTCSS encoding!
I find it very perplexing that attachment of the RT Systems Programmer cable, even with the USB end disconnected from any device (and power), renders CTCSS tone encoding unusable. But I am happy that I can now access my favorite repeaters in my Jeep.
Peter