Technical The one and only Dualogic failure thread

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Technical The one and only Dualogic failure thread

Re: Dualogic gearbox nightmare......

I think im gonna replace my 500 to one with a manual transmission
Well with just a new failure on the dualogic from another member and no warranty for you , you are choosing the safest bet
 
Re: Problems with my semi auto gearbox

What!? You too? Is there some kind of curse with the Dualogic? Sounds like it needs a complete unit replacement to me. Either that, or do a cheap temporary repair to get it back on the road and then sell the car ASAP.

+1.

Why are we seeing such a sudden spate of dualogic failures? They're not even all on old (i.e 2008 era) cars.
 
Re: Problems with my semi auto gearbox

Hi all


I wanted to see if anyone has had a similar experience to me and my beloved 500C Abarth convertible.


Whilst driving this afternoon in 3rd gear the car came almost to a stop and went into neutral. Now its stuck in neutral and wont change gear at all. Its 2 months out of its 3 year warranty, and sat at a fiat dealership waiting to be looked at.


I've only had the car 3 weeks.


If there is anyone out there who may be able to shed some light as to what has happened, I would love to hear from you.


thanks
Lisa
by the way do let us know whats happening!
 
Re: Problems with my semi auto gearbox

I've only had the car 3 weeks.

Does the car have a complete service history? Then FIAT has some serious explaining to do.

I suspect what might be happening is that owners with faulty Dualogics are clearing the error codes and then flogging them on to some other hapless person :(
 
Re: Problems with my semi auto gearbox

+1.

Why are we seeing such a sudden spate of dualogic failures? They're not even all on old (i.e 2008 era) cars.

Yeah exactly - some of us are driving around in 2008 models without a hint of a problem. It's weird.

To the original poster; as you have had the car for so little time, I suggest liability rests with the person who sold the car to you, as you have been sold a car 'not fit for purpose' - let them sort it out?

Checking the Dualogic special hydraulic fluid (CS Speed/Selespeed fluid) level is not a regular service task - but it should be. When the level gets too low, the system will select neutral and no gears.

The reservoir is on the front of the gearbox under a heat shield - this heat shield is difficult to remove from the 500 due to a lack of space. I moved the radiator fan to one side. There is a green mark and a moulded arrow to indicate the correct 'full' level. Mine was full, but I have seen other cars that were very low. Top up only with genuine CS Speed fluid (less than 1L required).

So, there is the possibility that a simple top-up could make the system operational again and if this top-up is required less than once a year, it's not a big deal. I would also change the oil in the transmission (the gearbox part, with the gears, has separate and typical GL4 gear oil) as the special hydraulic fluid may have leaked into the gearbox.

There was a Dualogic software update - at least for the Grande Punto model - to solve a fluid leak problem. I'm not clear on how a software update stops a fluid leak, but it must be worth a try to update the software using the FIAT Examiner (can only be updated with the genuine dealer tool).

If there are obvious leaks to the outside (sometimes found on the front of the actuator) then that leaves you with a choice of two options; have someone skilled dismantle the unit and fix the leak (FIAT dealers won't do this), or have the actuator replaced complete (dealers do this).

-Alex
 
Re: Dualogic gearbox nightmare......

Well, i own a second hand 2010, Dualogic 1.4
78000 KM over it, should i worry? =/

I own a third or fourth-hand 2008 Dualogic 1.4 and I'm not worried - it's an excellent system compared to the original Alfa 156 Selespeed of ten years earlier - they were problematic and no-one knew how to fix them, I did and had several years trouble-free. The 500's system is much smoother and better coordinated than the earlier design, even when the earlier design was working properly.

Hooking up MultiECUScan shows me that everything is working correctly and will, I expect, give advance warning of any failures. For example, checking the system pressure shows whether the pump and accumulator are working correctly or are 'marginal'.

I know that at some point around 120,000km I shall need to put a new clutch (in my 500), maybe a little sooner (15,000km sooner?) than for a regular manual gearbox, but it will be about the same job to do.

I also know that at some point it might spring a leak and require regular top-ups until I either fix the leak or replace the actuator. That was a cause of two failures I know about.

Based on experience of the earlier design, when it's ten years old, the accumulator (pressurised sphere) may lose its gas charge and need to be replaced. These are available for around £100.

After about 200,000km it's likely that the pump will need replacing - I will probably change just the brushes, though I doubt I will still have the car by then. Though, my 156 Selespeed had 261,000km on the clock - three years trouble-free, remember :D

I doubt there will be any other problem other than those... and for those feeling smug about their choice of a manual gearbox instead, well good on you :p but one day you MIGHT need new gear lever cables, a new clutch pedal, a new clutch, driveshaft seals, input shaft bearing... who really knows what the future holds - will we be allowed to drive petrol-powered cars anyway? :)

Meanwhile, a friend keeps buying champagne-beige-coloured Volvo XC70s. He's on the fourth one now. He had the Japanese auto transmission rebuilt on the first one, and it failed again six months later, so he bought another car, on which the transmission lasted nine months, and a third, which lasted a year (all three failed before 120,000km).

I really don't think the Dualogic is any less reliable than some of the other options out there - Volvo? who would have thought?! - but I do agree that maybe the manual transmission is a cheaper and safer bet if you're buying second-hand and don't mind driving a manual (not an option for many people these days!)

-Alex
 
Re: Problems with my semi auto gearbox

Yeah exactly - some of us are driving around in 2008 models without a hint of a problem. It's weird.

To the original poster; as you have had the car for so little time, I suggest liability rests with the person who sold the car to you, as you have been sold a car 'not fit for purpose' - let them sort it out?

Checking the Dualogic special hydraulic fluid (CS Speed/Selespeed fluid) level is not a regular service task - but it should be. When the level gets too low, the system will select neutral and no gears.

The reservoir is on the front of the gearbox under a heat shield - this heat shield is difficult to remove from the 500 due to a lack of space. I moved the radiator fan to one side. There is a green mark and a moulded arrow to indicate the correct 'full' level. Mine was full, but I have seen other cars that were very low. Top up only with genuine CS Speed fluid (less than 1L required).

So, there is the possibility that a simple top-up could make the system operational again and if this top-up is required less than once a year, it's not a big deal. I would also change the oil in the transmission (the gearbox part, with the gears, has separate and typical GL4 gear oil) as the special hydraulic fluid may have leaked into the gearbox.

There was a Dualogic software update - at least for the Grande Punto model - to solve a fluid leak problem. I'm not clear on how a software update stops a fluid leak, but it must be worth a try to update the software using the FIAT Examiner (can only be updated with the genuine dealer tool).

If there are obvious leaks to the outside (sometimes found on the front of the actuator) then that leaves you with a choice of two options; have someone skilled dismantle the unit and fix the leak (FIAT dealers won't do this), or have the actuator replaced complete (dealers do this).

-Alex
a normally working dualogic unit should never leak fluid. if it is, this is not good news.
 
Re: Dualogic gearbox nightmare......

I own a third or fourth-hand 2008 Dualogic 1.4 and I'm not worried - it's an excellent system compared to the original Alfa 156 Selespeed of ten years earlier - they were problematic and no-one knew how to fix them, I did and had several years trouble-free. The 500's system is much smoother and better coordinated than the earlier design, even when the earlier design was working properly.

Hooking up MultiECUScan shows me that everything is working correctly and will, I expect, give advance warning of any failures. For example, checking the system pressure shows whether the pump and accumulator are working correctly or are 'marginal'.

I know that at some point around 120,000km I shall need to put a new clutch (in my 500), maybe a little sooner (15,000km sooner?) than for a regular manual gearbox, but it will be about the same job to do.

I also know that at some point it might spring a leak and require regular top-ups until I either fix the leak or replace the actuator. That was a cause of two failures I know about.

Based on experience of the earlier design, when it's ten years old, the accumulator (pressurised sphere) may lose its gas charge and need to be replaced. These are available for around £100.

After about 200,000km it's likely that the pump will need replacing - I will probably change just the brushes, though I doubt I will still have the car by then. Though, my 156 Selespeed had 261,000km on the clock - three years trouble-free, remember :D

I doubt there will be any other problem other than those... and for those feeling smug about their choice of a manual gearbox instead, well good on you :p but one day you MIGHT need new gear lever cables, a new clutch pedal, a new clutch, driveshaft seals, input shaft bearing... who really knows what the future holds - will we be allowed to drive petrol-powered cars anyway? :)

Meanwhile, a friend keeps buying champagne-beige-coloured Volvo XC70s. He's on the fourth one now. He had the Japanese auto transmission rebuilt on the first one, and it failed again six months later, so he bought another car, on which the transmission lasted nine months, and a third, which lasted a year (all three failed before 120,000km).

I really don't think the Dualogic is any less reliable than some of the other options out there - Volvo? who would have thought?! - but I do agree that maybe the manual transmission is a cheaper and safer bet if you're buying second-hand and don't mind driving a manual (not an option for many people these days!)

-Alex
yes but alex no one knows how to manage dualogics like you do, and most dealers know less than you. so for normal car owners it simply isnt worth the bother.

you think if you go to fiat they will say oh this small part is broken? they will simply say replace the whole unit!

if you are a normal driver, the dualogic is too much of a mess.
Manual gearboxes do not have actuators, they most certainly do not have pumps and accumulators = ) So many less things to go wrong on a manual, and lets not forget the dualogic is a manual (so all the drive shafts etc can go wrong + THE DUALOGIC RUBBISH THAT WILL BREAK FOR SURE AT SOME POINT IN 200,000 kms) = )))
 
Re: Dualogic gearbox nightmare......

I own a third or fourth-hand 2008 Dualogic 1.4 and I'm not worried - it's an excellent system compared to the original Alfa 156 Selespeed of ten years earlier - they were problematic and no-one knew how to fix them, I did and had several years trouble-free. The 500's system is much smoother and better coordinated than the earlier design, even when the earlier design was working properly.

Hooking up MultiECUScan shows me that everything is working correctly and will, I expect, give advance warning of any failures. For example, checking the system pressure shows whether the pump and accumulator are working correctly or are 'marginal'.

I know that at some point around 120,000km I shall need to put a new clutch (in my 500), maybe a little sooner (15,000km sooner?) than for a regular manual gearbox, but it will be about the same job to do.

I also know that at some point it might spring a leak and require regular top-ups until I either fix the leak or replace the actuator. That was a cause of two failures I know about.

Based on experience of the earlier design, when it's ten years old, the accumulator (pressurised sphere) may lose its gas charge and need to be replaced. These are available for around £100.

After about 200,000km it's likely that the pump will need replacing - I will probably change just the brushes, though I doubt I will still have the car by then. Though, my 156 Selespeed had 261,000km on the clock - three years trouble-free, remember :D

I doubt there will be any other problem other than those... and for those feeling smug about their choice of a manual gearbox instead, well good on you :p but one day you MIGHT need new gear lever cables, a new clutch pedal, a new clutch, driveshaft seals, input shaft bearing... who really knows what the future holds - will we be allowed to drive petrol-powered cars anyway? :)

Meanwhile, a friend keeps buying champagne-beige-coloured Volvo XC70s. He's on the fourth one now. He had the Japanese auto transmission rebuilt on the first one, and it failed again six months later, so he bought another car, on which the transmission lasted nine months, and a third, which lasted a year (all three failed before 120,000km).

I really don't think the Dualogic is any less reliable than some of the other options out there - Volvo? who would have thought?! - but I do agree that maybe the manual transmission is a cheaper and safer bet if you're buying second-hand and don't mind driving a manual (not an option for many people these days!)

-Alex
oh and volvos are known to have rubbish auto transmissions = )
So if you need an auto, lease it for 3 years and give it back and get a new one = ), or go Toyota and enjoy a 5 year warranty then decide on your options once the 5 years are up.
 
Re: Fiat 500c 1.4 petrol Duologic Transmission Failure - Australia

Have you tried Alfaman? www.alfamen.com.au They are in Melbourne and have a great reputation for FIAT as well as ALFA.
 
Re: Problems with my semi auto gearbox

Hi Lisa,

Exactly the same thing happened to me 2 weeks ago... Driving along and the car suddenly went into N while traveling at speed. Quite scary.
Luckily the roads were quiet as it was at night and I was able to stop the car and restart it.
The following day I had to phone the RAC as it wouldn't select a gear after I started engine.
He took me to the garage and it needed a new Actuator. As it's only 18 months old it was replaced under warranty so i'm unsure of the cost that would be involved.
I absolutely love the dualogic but I've lost all faith in it after reading so many have failed and after my experience of losing control of gears/acceleration whilst travelling at speed.
I'd be interested to know what the garage say and cost involved to you, if you could let us know?
 
Re: Problems with my semi auto gearbox

Hi Lisa,

Exactly the same thing happened to me 2 weeks ago... Driving along and the car suddenly went into N while traveling at speed. Quite scary.
Luckily the roads were quiet as it was at night and I was able to stop the car and restart it.
The following day I had to phone the RAC as it wouldn't select a gear after I started engine.
He took me to the garage and it needed a new Actuator. As it's only 18 months old it was replaced under warranty so i'm unsure of the cost that would be involved.
I absolutely love the dualogic but I've lost all faith in it after reading so many have failed and after my experience of losing control of gears/acceleration whilst travelling at speed.
I'd be interested to know what the garage say and cost involved to you, if you could let us know?
oh dear same thing happened to me under warranty. they did not replace the whole unit, just the actuator but that never completely solved the problem; it only took me until the warranty expired and then i had to replace the whole unit at my cost with a 10% discount from fiat.

Want my advice? Sell the car the second the warranty runs out.
 
Re: Dualogic gearbox nightmare......

No real update today :(

Fiat quoted parts would be with dealer Weds/Thurs this week, dealer had booked slot to fit today & all being well car would be ready to pick up tomorrow.......

Rang dealer today to be informed parts were......still on route from Italy! :bang::bang::bang:..........

Maybe week5, next week, will mean my car is nearer heading home! :rolleyes:

Sarah :)
 
Re: Dualogic gearbox nightmare......

Oops!....meant to add above to my own thread! :mad:

Must be because therer is an ever growing dualogic-failure threads! :D

Moderators note: All the currently active dualogic failure threads have now been merged into this one
 
Last edited by a moderator:
How are all fellow dualogic-failures!?...

Still waiting for parts here! (n)(n)(n)....

Fiat sent wrong parts at beginning of week! :bang:.....no sign yet of correct ones arriving....

Need my car back ASAP as waiting to part-ex it!!....

Sarah :)
 
Oh a bit of humor for you guys, we have a Lancia Ypsilon TA 85 Dualogic in the family and guess what, the gearbox broke! It was driving and suddenly refused to leave 3rd gear (no gear change possible up or down in auto or manual), would not go into neutral nothing! So when ignition was turned off and on and battery removed and reset, no change still stuck in 3rd! And with the car stuck in gear, you couldn't even start the car as it has to be in neutral for the car to start. Of course, the lovely flashing transmission light was around, with the message, check transmission - see handbook"

So finally figured out this car was going absolutely nowhere and since its a long term rental, called the company, got the recovery truck to come and pick up the car, then went and collected another Lancia Ypsilon TA 85.

They can keep the old one!

Fairly new car as well, a 2013 model with about 33,000 km's on the clock.
 
Re: Problems with my semi auto gearbox

+1.

Why are we seeing such a sudden spate of dualogic failures? They're not even all on old (i.e 2008 era) cars.

Meanwhile... our 2008 Dualogic 500 is now getting lots of use (after I destroyed our Stilo's engine following a bad mistake fitting an auxiliary belt...) - clocking up over 500km a week with my partner's commuting to a new job, our Dualogic works perfectly. They definitely like being used regularly - the clutch operation now seems smoother than ever.

When we first got it early this year, I took apart the shift lever (made in Germany) and secured the pivot blocks by making them a tighter fit, wrapping them in masking tape. This has worked and the lever has no free play at all - a delightfully light and precise action. We always drive in manual mode. Being a Lounge, it doesn't have the paddles on the steering wheel and I haven't worked out how to add them.

Did you know... the lever has a magnet and Hall-effect ICs measure the lever position - so, no switch contacts to wear out. At least that part should give no trouble! :)

-Alex
 
Re: Problems with my semi auto gearbox

Meanwhile... our 2008 Dualogic 500 is now getting lots of use (after I destroyed our Stilo's engine following a bad mistake fitting an auxiliary belt...) - clocking up over 500km a week with my partner's commuting to a new job, our Dualogic works perfectly. They definitely like being used regularly - the clutch operation now seems smoother than ever.



When we first got it early this year, I took apart the shift lever (made in Germany) and secured the pivot blocks by making them a tighter fit, wrapping them in masking tape. This has worked and the lever has no free play at all - a delightfully light and precise action. We always drive in manual mode. Being a Lounge, it doesn't have the paddles on the steering wheel and I haven't worked out how to add them.



Did you know... the lever has a magnet and Hall-effect ICs measure the lever position - so, no switch contacts to wear out. At least that part should give no trouble! :)



-Alex


Did you take any pictures of this process because I would love to stop my movement in the shifter...
 
Re: Problems with my semi auto gearbox

Did you take any pictures of this process because I would love to stop my movement in the shifter...

I didn't, sorry. Basically, the process is to pop off the entire 'triangular' section of grey plastic trim from the console (do NOT try to lever out the chrome ring or black circle! - it is permanently attached to the outer trim). Then either remove the complete lever assembly, unplugging the wiring, OR remove just the top part and the lever (unclipping it) and carefully remove while leaving the circuit board in place underneath.

Then the two square plastic blocks (which form the lever pivot) will be evident. You just need to secure these blocks - which I did by wrapping green masking tape around them, to make them a tighter fit in the housing. Ensure there is adequate silicone grease on all moving parts to prevent wear.

-Alex
 
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