Technical Gearbox unavailable alarm

[Chrisnz]

Hi Everybody,
Chris here just newbie here , we have a Fiat Ducato from 2012 ( burstner motorhome) version ZFA250000# e3# DY2 engine F1AE3481D
hey just got few issues here with conformatic gearbox stuck on neutral with no access to gear , beside that had a few electrical issues lately like front deep beam light bulb blown , busing and clicking relays ( specially when connect to main power ) ,, conect diagnostic tools and replace T09 (P1850) relay , (please see pics attached) by chance anyone able to help here , kinda out of options here bit of learning will be good , really appreciated ,
Cheers
Chris

 

[varesecrazy]

Hi, that's a Long list..

At 12 years in service, the battery to Chassis Black Earth Cable may be failing.. They can rot internally

You can add a boostercable as a temporary measure

Are you saying that plugging the camper into mains electrics seems to be related..?

 

[Communicator]

Hi, that's a Long list..

At 12 years in service, the battery to Chassis Black Earth Cable may be failing.. They can rot internally

You can add a boostercable as a temporary measure

Are you saying that plugging the camper into mains electrics seems to be related..?

To avoid confusing Chris, may I suggest the alternative description of "engine block earth strap".
The one in the attached photo is not sheathed, so doess not merit being called a cable.
The negative connection at the battery can also suffer, but problems there are much less common.

Edit. Relays can fail, but such faults are rare. More often it is the connections to the relay that fail. In this respect the engine bay fusebox can have faults, particularly if water has got in there. Also check connectors for corrosion.

 

[jackwhoo]

@Seanwinder22

 

[Seanwinder22]

Hi mate honestly it would take me days to explain
The best thing to do is check my post on this issue I faced last year and again this year
Both times was wiring issues and sensors
But yes the gear box to chassis strap is a big one even if it looks ok it’s inside the corrosion starts
So take it off sand down the gearbox and chassis it sits on fit a new fat 35m2 260mm long cable
The selespeed harness disconnect it and clean everything all pins
Then before putting back in each sensor and plug clean that with contact cleaner plugging and unplugged a good few times to clean pins
Check my post I explain more things to do and check
Which just do everything it costs nothing
Then in multiecuscan start taking off connectors to each sensor one at a time seeing what fault codes you get

My issue this time not finding gear was the clutch position sensor located on the master slave cylinder bang below large transmission tank
Hard to get to so you have to remove light
Air box lid and fuse lid then 5 bolts on the gold bracket holding the reservoir on the gearbox takes 10 mins
Then you will see the sensor
It costs £40 but once on my codes went without clearing
Check the fuse and relay for the comfortmatic which I also show area on the thread
I am currently out and don’t have the information so take a look and read

 

[Seanwinder22]

Before anything tho get a hose pipe
Put some card on top of engine and turn hose pipe on to the windscreen watch if water gets in ?
The scuttle tray is a big issue so first need to stop this leaking otherwise everything won’t be drying out
If leaking seal the scuttle to the glass unblock any drain hoses

Then let’s begin unplugging the selespeed harness and cleaning and drying
Click on my names and posts and look for comfortmatic I posted on it today actually
Mine is all fixed
Misdiagnosed clutch bearing and slave wanted to fit full clutch kit £1500
It was wiring
Brake switch
Harness pin
And clutch sensor job done

 

[Seanwinder22]

Hi Everybody,
Chris here just newbie here , we have a Fiat Ducato from 2012 ( burstner motorhome) version ZFA250000# e3# DY2 engine F1AE3481D
hey just got few issues here with conformatic gearbox stuck on neutral with no access to gear , beside that had a few electrical issues lately like front deep beam light bulb blown , busing and clicking relays ( specially when connect to main power ) ,, conect diagnostic tools and replace T09 (P1850) relay , (please see pics attached) by chance anyone able to help here , kinda out of options here bit of learning will be good , really appreciated ,
Cheers
Chris

Just looking at all these codes I can see this is a wiring issue and not sensors etc
Leaking scuttle after heavy rain especially after so long taking in water will eventually get into the harness
All it takes is the rusty junction to rub and cause shorting out
Remove left headlight look at all harnesses and looms for nips in the insulation
Check for corrosion on contacts
Look in the engine fuse box for signs of wet
Remove negative cable from battery and check in the engine your Ecu make sure it’s not also soaked

Also try rule out just showing every fault code you have
Do a gearbox scan tell me what codes you have
Then engine tell me what codes you have
And last body computer codes and let’s start clearing codes one by one checking over each sensor each relay and harness
Check fuses

But this is what I would do check for a leak and fix
Then start removing the harness from each sensor and part and cleaning up but in stages had mentioned gearbox first
Then engine then bcm
Dry out plugs sensors etc or get rid corrosion
Look for splits etc and damage
It will take time but you will sort this

I would make a list for each code for gearbox and search for what it means then check that sensor or part and tick off a list otherwise you will confuse yourself with all these codes
So search them all make a note then clear the lot see what comes back
But to me this is wiring and sensor related
No way has all these parts got issues at once like this mate

 

[Chrisnz]

Hi, that's a Long list..

At 12 years in service, the battery to Chassis Black Earth Cable may be failing.. They can rot internally

You can add a boostercable as a temporary measure

Are you saying that plugging the camper into mains electrics seems to be related..

Hi, that's a Long list..

At 12 years in service, the battery to Chassis Black Earth Cable may be failing.. They can rot internally

You can add a boostercable as a temporary measure

Are you saying that plugging the camper into mains electrics seems to be related..?

 

[Chrisnz]

Hi there yes it seems like when house power is connected relay click ,buzz, and whistle, stop when disconect main power ,

 

[Chrisnz]

Hi, that's a Long list..

At 12 years in service, the battery to Chassis Black Earth Cable may be failing.. They can rot internally

You can add a boostercable as a temporary measure

Are you saying that plugging the camper into mains electrics seems to be related..?

Hi , ive checked the battery to chassis cable and it look ok

Hi, that's a Long list..

At 12 years in service, the battery to Chassis Black Earth Cable may be failing.. They can rot internally

You can add a boostercable as a temporary measure

Are you saying that plugging the camper into mains electrics seems to be related..?

Also chassis to gearbox look decent, please see attached pics, and thanks to all your annswer guys , still down atm but we will make it work
Cheers

 

[Chrisnz]

Just looking at all these codes I can see this is a wiring issue and not sensors etc
Leaking scuttle after heavy rain especially after so long taking in water will eventually get into the harness
All it takes is the rusty junction to rub and cause shorting out
Remove left headlight look at all harnesses and looms for nips in the insulation
Check for corrosion on contacts
Look in the engine fuse box for signs of wet
Remove negative cable from battery and check in the engine your Ecu make sure it’s not also soaked

Also try rule out just showing every fault code you have
Do a gearbox scan tell me what codes you have
Then engine tell me what codes you have
And last body computer codes and let’s start clearing codes one by one checking over each sensor each relay and harness
Check fuses

But this is what I would do check for a leak and fix
Then start removing the harness from each sensor and part and cleaning up but in stages had mentioned gearbox first
Then engine then bcm
Dry out plugs sensors etc or get rid corrosion
Look for splits etc and damage
It will take time but you will sort this

I would make a list for each code for gearbox and search for what it means then check that sensor or part and tick off a list otherwise you will confuse yourself with all these codes
So search them all make a note then clear the lot see what comes back
But to me this is wiring and sensor related
No way has all these parts got issues at once like this mate

Thanks Shaun thats really helpful,
so ive first found a water leak from windsreen plastic tube was disconected (see pics) leak was just above fuse , relay boxs ( got a good cover) and harness couldnt see any water seating but have cleaned with conector cleaner, inspecting,plugged and unplugged most of accesible harness ,fuse, sensor ( gearbox and engine from bottom ) couldnt find any tears or cut or splits on cable along the way , when start again message for gearbox still here , T09(main injection primary) and T20(thermal start valve) relay still click and buzz,
Just for info at time we have a fumes smells in the cabine on and off , i suspect also this blow by heater devices or sensor to it to be possibly faulty?
Yes i need to get again someone to come plug a diagnostic tool and go from there i guess i will share with you the results and hope we can start again from there ,
Thank you once again
Chris

 

[varesecrazy]

Hi , ive checked the battery to chassis cable and it look ok

Also chassis to gearbox look decent, please see attached pics, and thanks to all your annswer guys , still down atm but we will make it work
Cheers

The copper strands inside the cable can rot, making a green paste..

The cable Looks O. K., just doesn't conduct power effectively

 

[Seanwinder22]

All I can say mate is what I mentioned check the comfortmatic forums I did and read
I can only help with gear box codes comfortmatic the rest I’ve no idea sorry
But to me this is down to leaks and wiring
What I did was fix leak make sure it’s fixed by hose pipe and cardboard on the engine

Take negative from battery and remove all plugs and dry with air dryer
Tell me every gearbox code you have I definitely can help with gear box mate

I would even unplug the ecu which is near left headlight use contact cleaner
Set up multiecuscan and look at live data like I mentioned gearbox first then engine and bcm

While in engine parameters watch injectors and lambda sensor and egr and dpf thus is all you can do tbh to make sure everything is good enough

Test sensors and carry out adjustments in multiecuscan this is what helped me I had about 13 codes most in gearbox tho
A short circuit will throw many crazy codes

Did you actually take all tape off the harness and inspect ?
Also like I mentioned it’s no good thinking the gearbox to chassis strap looks ok
Test it …. Get a jumper cable and try it for a quick test

But that’s what I would be doing
Battery negative off
Unplug body computer which is near obd port
Test all fuses in there
Next engine bay test relays and fuses and clean up
Unplug the Ecu that’s under the rubber mount
Selespeed harness starts from on top of Ecu then to the gear box sensor and then clutch sensor to the speed sensor down near reverse switch front of gearbox face
The harness then goes to the back of the gearbox to some more plugs and the last 4 will be Evo0 to Evo3 all labelled with white taps and black ink

You will sort it I know you will hang in there and remember all this work saves big money
But I still got a auto electrician out to give me a hours check and help with some information checking continuity which they are great at
The rest you can do yourself
But yea …. Definitely wiring issue I think here with the codes
Send me all gearbox codes seperate to engine I will check
Then send engine
And body etc it stops confusing

 

[Chrisnz]

Hi, that's a Long list..

At 12 years in service, the battery to Chassis Black Earth Cable may be failing.. They can rot internally

You can add a boostercable as a temporary measure

Are you saying that plugging the camper into mains electrics seems to be related..?

Y

All I can say mate is what I mentioned check the comfortmatic forums I did and read
I can only help with gear box codes comfortmatic the rest I’ve no idea sorry
But to me this is down to leaks and wiring
What I did was fix leak make sure it’s fixed by hose pipe and cardboard on the engine

Take negative from battery and remove all plugs and dry with air dryer
Tell me every gearbox code you have I definitely can help with gear box mate

I would even unplug the ecu which is near left headlight use contact cleaner
Set up multiecuscan and look at live data like I mentioned gearbox first then engine and bcm

While in engine parameters watch injectors and lambda sensor and egr and dpf thus is all you can do tbh to make sure everything is good enough

Test sensors and carry out adjustments in multiecuscan this is what helped me I had about 13 codes most in gearbox tho
A short circuit will throw many crazy codes

Did you actually take all tape off the harness and inspect ?
Also like I mentioned it’s no good thinking the gearbox to chassis strap looks ok
Test it …. Get a jumper cable and try it for a quick test

But that’s what I would be doing
Battery negative off
Unplug body computer which is near obd port
Test all fuses in there
Next engine bay test relays and fuses and clean up
Unplug the Ecu that’s under the rubber mount
Selespeed harness starts from on top of Ecu then to the gear box sensor and then clutch sensor to the speed sensor down near reverse switch front of gearbox face
The harness then goes to the back of the gearbox to some more plugs and the last 4 will be Evo0 to Evo3 all labelled with white taps and black ink

You will sort it I know you will hang in there and remember all this work saves big money
But I still got a auto electrician out to give me a hours check and help with some information checking continuity which they are great at
The rest you can do yourself
But yea …. Definitely wiring issue I think here with the codes
Send me all gearbox codes seperate to engine I will check
Then send engine
And body etc it stops confusing

Hi mate thanks for your answer , so we did a scan today i let you have a look at the result , i feel like i make things worth but we will get there eventually,

All I can say mate is what I mentioned check the comfortmatic forums I did and read
I can only help with gear box codes comfortmatic the rest I’ve no idea sorry
But to me this is down to leaks and wiring
What I did was fix leak make sure it’s fixed by hose pipe and cardboard on the engine

Take negative from battery and remove all plugs and dry with air dryer
Tell me every gearbox code you have I definitely can help with gear box mate

I would even unplug the ecu which is near left headlight use contact cleaner
Set up multiecuscan and look at live data like I mentioned gearbox first then engine and bcm

While in engine parameters watch injectors and lambda sensor and egr and dpf thus is all you can do tbh to make sure everything is good enough

Test sensors and carry out adjustments in multiecuscan this is what helped me I had about 13 codes most in gearbox tho
A short circuit will throw many crazy codes

Did you actually take all tape off the harness and inspect ?
Also like I mentioned it’s no good thinking the gearbox to chassis strap looks ok
Test it …. Get a jumper cable and try it for a quick test

But that’s what I would be doing
Battery negative off
Unplug body computer which is near obd port
Test all fuses in there
Next engine bay test relays and fuses and clean up
Unplug the Ecu that’s under the rubber mount
Selespeed harness starts from on top of Ecu then to the gear box sensor and then clutch sensor to the speed sensor down near reverse switch front of gearbox face
The harness then goes to the back of the gearbox to some more plugs and the last 4 will be Evo0 to Evo3 all labelled with white taps and black ink

You will sort it I know you will hang in there and remember all this work saves big money
But I still got a auto electrician out to give me a hours check and help with some information checking continuity which they are great at
The rest you can do yourself
But yea …. Definitely wiring issue I think here with the codes
Send me all gearbox codes seperate to engine I will check
Then send engine
And body etc it stops confusing

 

[Chrisnz]

All I can say mate is what I mentioned check the comfortmatic forums I did and read
I can only help with gear box codes comfortmatic the rest I’ve no idea sorry
But to me this is down to leaks and wiring
What I did was fix leak make sure it’s fixed by hose pipe and cardboard on the engine

Take negative from battery and remove all plugs and dry with air dryer
Tell me every gearbox code you have I definitely can help with gear box mate

I would even unplug the ecu which is near left headlight use contact cleaner
Set up multiecuscan and look at live data like I mentioned gearbox first then engine and bcm

While in engine parameters watch injectors and lambda sensor and egr and dpf thus is all you can do tbh to make sure everything is good enough

Test sensors and carry out adjustments in multiecuscan this is what helped me I had about 13 codes most in gearbox tho
A short circuit will throw many crazy codes

Did you actually take all tape off the harness and inspect ?
Also like I mentioned it’s no good thinking the gearbox to chassis strap looks ok
Test it …. Get a jumper cable and try it for a quick test

But that’s what I would be doing
Battery negative off
Unplug body computer which is near obd port
Test all fuses in there
Next engine bay test relays and fuses and clean up
Unplug the Ecu that’s under the rubber mount
Selespeed harness starts from on top of Ecu then to the gear box sensor and then clutch sensor to the speed sensor down near reverse switch front of gearbox face
The harness then goes to the back of the gearbox to some more plugs and the last 4 will be Evo0 to Evo3 all labelled with white taps and black ink

You will sort it I know you will hang in there and remember all this work saves big money
But I still got a auto electrician out to give me a hours check and help with some information checking continuity which they are great at
The rest you can do yourself
But yea …. Definitely wiring issue I think here with the codes
Send me all gearbox codes seperate to engine I will check
Then send engine
And body etc it stops confusing

Hi thanks ,just did another diagnostic today please see pictures

 

[Seanwinder22]

Hi thanks ,just did another diagnostic today please see pictures

Ok thanks
You have wiring issue and a short circuit which can even come from sensors
I had a few sensors that the pin had broken in the sensor giving short circuits

I can see you have issues with brake switch
Very easy to change
Watch this also check other videos about comfortmatic issues all videos will help you

 

[Seanwinder22]

Hi thanks ,just did another diagnostic today please see pictures

I would even go has far to get the ecu scanned and tested looking at some data there you may need a update and flash
But first check fuses
Has mentioned on floor when remove battery cover look for the silver box and remove connector and clean
In the dash fuses remove plugs and clean test fuses

In engine bay test fuses and relay
100% remove ecu and clean pins and connectors and harness
Follow loom that run on the top at the back under scuttle tray
This harness goes into the bulkhead behind dash it can run on wiper motor and short out
Definitely remove brake switch this could cause all the gear box problems you get
Check the reservoirs for dot 4 near air box and fuse box 6mm from top the small reservoir needs to be
Large transmission reservoir needs to be filled half way