Technical Removing Dualogic Gearbox Actuator

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Technical Removing Dualogic Gearbox Actuator

AndyLloyd1

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Hi, this is my first post :)

My girlfriend has an Automatic 2011 Fiat 500 0.9 TwinAir. Recently, it keeps jumping into Neutral, and wont shift back into gear without turning it off and on again.

I believe it's a problem with the Dualogic Gearbox Actuator. I noticed the unit was leaking and very low on oil. I topped it up with the Petronas CS Speed fluid, but it's happening again after just 4 hours of driving.

I'm sending the unit off for refurbishment, but need to remove it first. I'm fairly handy with cars etc, just wondering if anyone can give me some tips or a 'How To' guide. The person doing the re-firb, said it can be removed without taking apart the front end.

Thanks
 
Hi, this is my first post :)

My girlfriend has an Automatic 2011 Fiat 500 0.9 TwinAir. Recently, it keeps jumping into Neutral, and wont shift back into gear without turning it off and on again.

I believe it's a problem with the Dualogic Gearbox Actuator. I noticed the unit was leaking and very low on oil. I topped it up with the Petronas CS Speed fluid, but it's happening again after just 4 hours of driving.

I'm sending the unit off for refurbishment, but need to remove it first. I'm fairly handy with cars etc, just wondering if anyone can give me some tips or a 'How To' guide. The person doing the re-firb, said it can be removed without taking apart the front end.

Thanks
Look at the thread "The one and only dualogic failure thread "
 
It is certainly possible on a 1.2 Panda. No direct experience of a twin air 500, but probably very similar. Basic method:
5 bolts (one has an earth strap), I think 3 on top and 2 on front, but could be the other way round.
Quite a few electrical connections, including 3 at the back, a couple at the front and one at the side (which may have to wait until you have lifted it part way out.)
(On a Panda, drain coolant, disconnect bottom radiator hose, and remove rad fan frame to get a few extra mm of space, maybe not needed on 500)
Tilt whole unit in various directions to get it out upwards.

Not a particularly difficult job, using basic tools, spare pair of hands may help when lifting it out.

I've got it documented somewhere, but probably can't get to it until the weekend.

Pretty sure details are on ELearn, although possibly for a Punto if not for a 500. Same unit(-ish)
 
Thanks, going to give it a go tomorrow or Friday depending on the weather. Would be great if you can find your how to.
 
What’s an earth strap???
It's a fairly heavy cable (or a flat braided one, seen both) running from the gearbox to the actuator. Same size and material as your battery cables.
Not got a photo of it, but it'll be obvious when you get there.
I skipped a step though... remove battery and battery tray as first step. D'oh!
Found pics of front connections(pic 1) and top/rear connections (pic 2)
They kind-of fall naturally into the proper places, but worth either writing down/taking photos as you go.
Some have labels already on them, others either never did, or they've disappeared over time.
Don't forget, unless you've got an exchange unit to swap, it could be a while before you have to re-fit them.
Oh... you need some of the correct sealant. I think it is Loctite 510, but the refurbisher will know. Image%20(2).jpegImage%20(1).jpeg
 
I have the same problem with my car it’s a fiat 500 2015 low mileage, 36000 on the clock. Without any warning if stopped working. Gear stays in neutral. I called fiat customer service and someone misinformed me to take the car to main dealer cause it will only cost me £27 ?to have it checked as it’s still on low mileage. I waited 10 days to get an appointment with them, then it took them 2 days to get back to me, saying it’s the acid from battery that was leaking and it damaged the Dualogic unit and the connector, they quoted me with £2150 ?
The worst experience ever they got my car, and they care now whether to fix or just keep it there. I’m lost and can’t afford to pay all that money.
 
I have the same problem with my car it’s a fiat 500 2015 low mileage, 36000 on the clock. Without any warning if stopped working. Gear stays in neutral. I called fiat customer service and someone misinformed me to take the car to main dealer cause it will only cost me £27 ?to have it checked as it’s still on low mileage. I waited 10 days to get an appointment with them, then it took them 2 days to get back to me, saying it’s the acid from battery that was leaking and it damaged the Dualogic unit and the connector, they quoted me with £2150 ?
The worst experience ever they got my car, and they care now whether to fix or just keep it there. I’m lost and can’t afford to pay all that money.

That sounds like utter bs
I've not heard od any battery leaking acid for many years unless the casing has taken impact damage
 
That’s what main dealer told me that battery leaked and it’s not a manufacturer fault, however battery was replaced in December before I bought the car from the private seller, and the car broke down only end of June. I’m so annoyed about this and my car is there with them, not fixed or any thing.
 
Hello Kaykay, and welcome to the forum - I'm sorry it's in such sad circumstances.

I feel for you, I really do; it's most unusual for a battery to leak in this way and you have been dreadfully unlucky. My best guess as to what caused the battery to leak is that it was dropped heavily prior to installation.

Out of interest, what brand of battery was it?

Unfortunately I cannot think of any possible way for you to get any help from anywhere toward the cost of this repair. You have no claim against Fiat, and unless you could prove that the private seller knowingly sold it with this fault (and that would be well nigh impossible), no claim agains the person who sold it, either.

The dealer who currently has the car has the right to be paid a fair price for the diagnostic and any other work they may already have done, and if you leave it there for any length of time and don't have them repair it, they may also charge you for storing the vehicle. So you do need to do something; this isn't going to fix itself and noone else is going to help you with the cost. Sorry, but sometimes the truth hurts.

It's possible an independent garage may be able to repair it more cheaply, but the experience of others here suggests most such garages haven't got a clue as far as these transmissions are concerned. If the car can't be driven, taking it elsewhere for repair is fraught with difficulties and whichever garage you get it towed to will have you over the proverbial barrel.

Personally, I'd beg or borrow the cash, take the pain and get it repaired where it sits. At least you'll have a warranty on whatever they replace. If you absolutely can't afford it, then I don't see what option you have other than to sell the car as it is; to get a reasonable price for it, you'll likely have to pay what you owe so far and bring the car to a place where you can advertise it for sale - I doubt the garage where it's at will offer you much.

If you do nothing, then eventually the garage will just sell it to cover their costs and storage charges, and you'll likely end up with little, if anything.
 
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Did they provide any pictures or the damage it's possible it could of happen but would have to be quite rare and if it had leaked ammout of acid I'd have thought the battery wouldn't work very well either?
 
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