Technical Comfort-Matic Gearbox issues- 6 Months in Fiat Proffessional workshop

[BillModza]

Ok I just joined the forum as I am desperate & found no info on the forum so far so here is another winger.
I have a 2008 Fiat Ducato Motorhome, 160 Multijet, 3.0 litre diesel. The old "Gear unselectable". In a Sydney Fiat Professional workshop since October and still unable to drive ?. Changed the Hydraulic Unit, Slave cylinder, Gearbox ECU, Wiring loom, all four "4" Gearbox Solenoids, Gearbox was removed & clutch is good as it was changed about 15,000KM ago. Got them a donor gearbox for parts. They say the gear box is OK but the clutch will not move and drive. Any one had a problem similar to mine and got it fixed, if so how and where. Never get a FIAT DUCATO again.

 

[Seanwinder22]

Thankyou , I’ve been trying to work out which sensor it’s referring to , from what I can see it’s one of the rectangular type ones that’s sits upright on the front mesh ring the movement on the gear selector and this tallies with the loom as it’s labelled SPS “ shift position sensor “ however I’ve swapped it out for a known good one and it’s the same

If you swapped the gear sensor try the clutch sensor but again try mes look at data to see the current

 

[james999]

So the clutch sensor is actually at the bottom under the rectangle reservoir you have to take the bolts off the cage holding that reservoir it’s easy to do it don’t let it put you off

So I have also swapped this one out and no change, the odd but is it seems to be in a gear as like I say it will start but then releases the clutch and stalls all whilst still in neutral , it also will not select any gears with just the ignition on, like you can normally select 1st and reverse but it won’t do any of that either

 

[Seanwinder22]

When checking in parameters at solenoids the broke sensor will show 0ma and the others will show 925 or higher numbers of amp reading

This gear sensor you changed for a good one
Tomorrow pull the loom from
The senior if you have not got mes
Do it this way
Pull looms and turn on dash
Do not start the engine tho
See if you get a new code etc
Then try clutch position sensor loom

Has you could have any of the issue clutch sensor gear sensor or clutch actuator but the code you are getting and out of range is normal to a broke connection being sensor or snapped connector on the loom I’ve had to change pins before on the loom for the gear sensor

 

[Seanwinder22]

Don’t forget Reprogramming the robot because you changed sensors. The new sensor has different parameters. So now delete old programmed values and recalibrate the unit and you’re done.

 

[Seanwinder22]

When you change any sensor you need mes mate you can’t just change a sensor in the gear box maybe reason it’s still not working

 

[Seanwinder22]

You need to delete statistical data then service final calibration after changing any sensor mate wipe code and your done

When I had clutch issues etc on my 59 plate
I purchased gear sensor clutch sensor and EV1 solenoid
Changed old fluids gave a service
New accumulator and then did the rest and calibrated good has new
Remember could be the actual loom so inspect
Good luck

 

[Seanwinder22]

Sorry forgot to post this
Clutch sensor is under the master slave
I would be changing this has its the clutch not working to select gear while in neutral not the gear sensor but both can come in to play
Change clutch sensor then carry out in multiecuscan the flowing

 

[Seanwinder22]

It’s been a whole year since I’ve spoken about this issue sorry so few thing coming back
For the clutch / gear sensor it’s not in mes under clutch solenoid valve that’s the EV1 solenoid so ignore looking at that data

Do what I first mentioned unplug the loom to the clutch sensor see if any fault code appears and do the same for gear sensor or test with a multimeter both sensors and the loom

But has I mentioned even if you change the sensor to new and not program it won’t work has different parameters so needs calibration anyway that’s a must
So you may have sorted the issue but needs the reset and calibration

 

[james999]

It’s been a whole year since I’ve spoken about this issue sorry so few thing coming back
For the clutch / gear sensor it’s not in mes under clutch solenoid valve that’s the EV1 solenoid so ignore looking at that data

Do what I first mentioned unplug the loom to the clutch sensor see if any fault code appears and do the same for gear sensor or test with a multimeter both sensors and the loom

But has I mentioned even if you change the sensor to new and not program it won’t work has different parameters so needs calibration anyway that’s a must
So you may have sorted the issue but needs the reset and calibration

Appreciate all the info bud, I’ll have another look tomorrow and try the disconnect method , the other thing I did notice if the pump pressure sits around 36 bar I know it should be more like 42, I’ve check the feed and it does fire itself up but doesn’t always go to 42 more like 36 , I have over ridden it and taken it to 43 to see it it would let me select a gear but it didn’t , so unable to calibrate the box because isnt enough pressure also won’t do the clutch bleed procedure I’m assuming because of this , but no codes for pressure just the one single code for shift position sensor

 

[Seanwinder22]

Appreciate all the info bud, I’ll have another look tomorrow and try the disconnect method , the other thing I did notice if the pump pressure sits around 36 bar I know it should be more like 42, I’ve check the feed and it does fire itself up but doesn’t always go to 42 more like 36 , I have over ridden it and taken it to 43 to see it it would let me select a gear but it didn’t , so unable to calibrate the box because isnt enough pressure also won’t do the clutch bleed procedure I’m assuming because of this , but no codes for pressure just the one single code for shift position sensor

No mate pump pressure sounds fine mine sits at 35-40
if any issues with sensors like you have with the out of range it won’t let you carry out the kiss point until that part is changed everything you post is just sake I had on my very first issues with the robot
Reason I put a list is because over the space of 3 years another issue happened
First year I found the loom harness had a snapped pin on connector giving out of range issues so purchased new harness but because it was short circuit it damaged the sensor so then needed a sensor months later

Year later similar issue which was gear sensor but from my first short circuit clutch issue it had caused damage to the Ev0 solenoid has you have 4 in total red is gears blue is clutch The Red is clutch Ev1 is gears ev2 is gears ev3 reverse n 5 th ev0 clutch all these effect clutch operation mate your issue isn’t the pump or accumulator but because of the age of the van they become porous so after 10 years a change is needed easy swap


I changed both sensors and ev0 solenoid then eventually the accumulator and new oils etc your problem I would start with sensors then re program you have to wipe old data don’t just try to clutch kiss point
Read this forum on what I did on mes software after changing parts because at first it wouldn’t let me either you have a few options to do first