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Technical Comfort-Matic Clutch fluid level

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Technical Comfort-Matic Clutch fluid level

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BrianandBeth

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We have a 3.0L diesel with the automated manual gear box, 2009 model, Comfort-Matic. It operates fine but I am concerned about the low level of the clutch fluid in the master cylinder.
The fluid level in the clutch master cylinder is only about 10-20%. Any attempt to top it up a bit results in the added fluid being expelled via the vented cap. When checked again after a long drive, about 300km's, it is back to the 10-20% level again. The handbook states the DOT 4 fluid capacity as 0.05L = 50ml. Not a lot at all to operate the clutch on a 3 litre diesel. There is some marking on the side of clutch master cylinder at about the 30% mark but it is hard to see, looks like a wine glass?

Any suggestions?
 
Can you just confirm that what you are talking about is the brake fluid reservoir which on my 3L manual also feeds the manual clutch system? Is there is an extra clutch fluid reservoir on your automatic?
 
Yes I'm with Ray here
Normally the clutch hydraulics are fed by the brake master cylinder.
I believe the reservoir you are talking about is for the gearbox not the clutch.
If your gears are changing fine then why meddle?
 
In the download section there is a handbook supplement for the comformatic which says;
"CHECKING FLUID LEVELS COMFORT-MATIC GEARBOX HYDRAULIC OPERATING SYSTEM FLUID
To check the gear oil and check/replace the hydraulic clutch operating system fluid, contact only a Fiat dealership."

I guess then that there is a separate clutch operating system reservoir? I had a Renault Master with the equivalent quickshift 6 gearbox and vaguely remember a reservoir on the outside of the gearbox.
 
Access to mine is limited due to being left hand drive but here are some pictures.
Seems to comprise of TWO reservoirs
CA_11301412060008-XL.jpg

CA_11301412080454-XL.jpg

CA_11301412085021-XL.jpg
 
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Thanks for the photos. Our Ducato ATM is exactly the same and the fluid levels are exactly the same, the DOT 4 fluid is just below the funny markings on the side. When I first looked, I thought it was all one tank and panicked, "that clutch fluid is very dark" but then discovered the rectangular one and the smaller cylinder hanging on the front of it.

With such a little volume, I will be keeping an eye on the "low" level.

Thanks again.
 
When i want to change the hydraulic clutch fluid .Someone knows how to
change the clutch fluid .Should be done every 12 months .
 
Hi. I recently purchases a 2009 Fiat Ducato motorhome from a dealer in Queensland with 68Ks on the clock. My plan was to drive it to Tasmania (2300kms) where I live. On the way I had 2 breakdowns , both with the same error message 'Check transmission fluid' followed by the loss of all gears and had to pull over and be towed to a dealer. First time discovered the small clutch fluid reservoir was hanging down (locator clip broken) and fluid gone (crossed thread on plastic cap). Dealer spotted this, relocated the reservoir and put dot 4 clutch fluid to required level after bleeding the clutch via the computer. Appeared to fix the problem. 1000k's and 2 days later same warning and problem but no clutch fluid missing. Major tow and expense to dealer (not Fiat) who has had it for several weeks due to Xmas. They suspect problem with the TCU???? but say Fiat Aust cannot supply one??? Anyone have any idea what the problem could be?
Many thanks
 
Gerry51 said:
Hi. I recently purchases a 2009 Fiat Ducato motorhome from a dealer in Queensland with 68Ks on the clock. My plan was to drive it to Tasmania (2300kms) where I live. On the way I had 2 breakdowns , both with the same error message 'Check transmission fluid' followed by the loss of all gears and had to pull over and be towed to a dealer. First time discovered the small clutch fluid reservoir was hanging down (locator clip broken) and fluid gone (crossed thread on plastic cap). Dealer spotted this, relocated the reservoir and put dot 4 clutch fluid to required level after bleeding the clutch via the computer. Appeared to fix the problem. 1000k's and 2 days later same warning and problem but no clutch fluid missing. Major tow and expense to dealer (not Fiat) who has had it for several weeks due to Xmas. They suspect problem with the TCU???? but say Fiat Aust cannot supply one??? Anyone have any idea what the problem could be?
Many thanks
Click to expand...

Hi,:)
on the smaller petrol engined versions you can PURGE the fluid of air and recalibrate via the ECU / Laptop,

are these FIAT dealers..do you have confidence in their product knowledge??

your loss of fluid is a good starting point here.., rayc may know more
Charlie
 
TCU = Transmission Control Unit. if this required replacing I suspect it would be expensive. I am no expert only having a similar robotic gearbox in a Renault Master I once had. The problem is that very few people in the service networks have much experience of them either let alone be classed as experts.
 
Gerry51 said:
Hi. I recently purchases a 2009 Fiat Ducato motorhome from a dealer in Queensland with 68Ks on the clock. My plan was to drive it to Tasmania (2300kms) where I live. On the way I had 2 breakdowns , both with the same error message 'Check transmission fluid' followed by the loss of all gears and had to pull over and be towed to a dealer. First time discovered the small clutch fluid reservoir was hanging down (locator clip broken) and fluid gone (crossed thread on plastic cap). Dealer spotted this, relocated the reservoir and put dot 4 clutch fluid to required level after bleeding the clutch via the computer. Appeared to fix the problem. 1000k's and 2 days later same warning and problem but no clutch fluid missing. Major tow and expense to dealer (not Fiat) who has had it for several weeks due to Xmas. They suspect problem with the TCU???? but say Fiat Aust cannot supply one??? Anyone have any idea what the problem could be?
Many thanks
Click to expand...



Hi, and welcome, :)

use SEARCH in "advanced" to search for "gear unavailable" in the cars sections.. you'll soon see that this is a pretty regular occurrence.., and isn't guaranteed to be ECU/TCU failure;)

https://www.fiatforum.com/grande-punto/247967-gear-unavailable-check-transmission-2.html

Charlie
 
Thanks to you both for the helpful advice and suggestion. I think pursuing the hydraulic issues first is the prudent approach. Concerned about the dark colour of the hydraulic fluid though. Usually indicates the clutch has been under stress. I will discuss with the dealer today. They are not a Fiat dealer but are the closest to that in Launceston. 250k from the only fiat dealer in Tasmania and $1200 to tow it there.
Thanks again
 
ImageUploadedByFIAT Forum1451856703.979769.jpg

Just a note on the colour of the fluid,

This photo is of my brake fluid we changed a month ago, (fiat dealer and independent garage were supposed to have changed it at 1 & 2 yrs old)

The rear fluid was black and like water!!
The front looked half better and probably had been changed, giving this colour in the bottle


On a 3 yr old van

I don't know anything about your gearbox or system but if your fluid looks the same, I would be getting it changed every year at most, and wouldn't surprise me if a sensor is picking up the quality or lack of quality in your fluid

A good starting place

Regards
Neil
 
Gerry51 said:
Thanks to you both for the helpful advice and suggestion. I think pursuing the hydraulic issues first is the prudent approach. Concerned about the dark colour of the hydraulic fluid though. Usually indicates the clutch has been under stress. I will discuss with the dealer today. They are not a Fiat dealer but are the closest to that in Launceston. 250k from the only fiat dealer in Tasmania and $1200 to tow it there.
Thanks again
Click to expand...

Hi. Look for Alfa Romeo in your area..as its a system pioneered on 1990s Alfas
 
Thanks again. The dealer it is with sells and services Alfa Romeo. That was the closest I could find to a Fiat dealer in Launceston. Spoke to them again yesterday but no progress yet.
Big thanks to forum respondents who have offered advice. Certainly worth joining you guys. Cheers from down under!
 
Hi,2013 conformatic,March last year travelling along highway,pulled over and stopped but did not stop engine and went to start journey again had no gears.Only 18,000 on clock.When we stopped noticed transmission had gone into neutral yet 5th gear was showing on dash.Tried everything to get going resulting on a transmission failure. Showing on dash. Called Fiat assist who was in the process of arranging a tow and after about ten minutes turned the key on again to check mileage and noticed all seemed normal again.Xstarted engine and proceed to the Fiat dealer.
After many checks they could not find a problem however said it could have been a small leak in clutch line so they replaced it.
Today on way home and at traffic lights same thing happened much to disgust of all traffic banked up behind me.26,000k now and again transmission failure and although in neutral dash showing 5th gear.
After 5minutes,turned engine on restarted,everything normal.
Anyone have any ideas,Des
 
Again no knowledge of the gearbox

But I would replace the earth strap gearbox to body and thoroughly clean the fixing points and bolts, (common fix to a multitude of random errors)

Maybe change hydraulic fluid

This is of no faults showing on diagnostic tool (multiecuscan or similar)
 
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Cad said:
Hi,2013 conformatic,March last year travelling along highway,pulled over and stopped but did not stop engine and went to start journey again had no gears.Only 18,000 on clock.When we stopped noticed transmission had gone into neutral yet 5th gear was showing on dash.Tried everything to get going resulting on a transmission failure. Showing on dash. Called Fiat assist who was in the process of arranging a tow and after about ten minutes turned the key on again to check mileage and noticed all seemed normal again.Xstarted engine and proceed to the Fiat dealer.
After many checks they could not find a problem however said it could have been a small leak in clutch line so they replaced it.
Today on way home and at traffic lights same thing happened much to disgust of all traffic banked up behind me.26,000k now and again transmission failure and although in neutral dash showing 5th gear.
After 5minutes,turned engine on restarted,everything normal.
Anyone have any ideas,Des
Click to expand...
Almost exactly the same story as you.. Can you please tell me how it was resolved
 
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