Technical How to check the Dualogic gearbox oil level and add oil

[jaahn]

Hi
We have just bought a 2013 500 POP 1.2 with Dualogic automatic. It sounds a bit whiny and I want to check the oil level and possibly put some additive in it. Hard to see where the fill plug is located. No leaks showing but worth checking after all these years and 75000KMs.
It goes Ok and I am giving it a full service and new belts plugs etc so it will be reliable for a few years more. Any hints accepted !
Cheers Jaahn

 

[skidbarth]

I had a lot of trouble finding information on the Dualogic gearbox. And then, it was pointed out to me that the Alfa 147 uses pretty much the same gearbox, and a search shows it has a lot more pages on its maintenance.

In particular, I found a gearbox oil change document that pretty much answers your question... but I can't post a URL! OK, search for "Alfa 147 gearbox oil change guide".

Now, I was searching in the context of an Abarth 500 (our car) - I do not know for sure if it's the same gearbox in a 1.2. However, the manual/"auto" on the Abarths is pretty much the same (just with or without the "robot"). And, I guess you'll see pretty quickly see if it's the same box in your car.

Good luck!

 

[rmjbn1]

We have just bought a 2013 500 POP 1.2 with Dualogic automatic. It sounds a bit whiny and I want to check the oil level and possibly put some additive in it.

Hi I understand there's a procedure for checking the Dualogic oil level as the system should be depressurised first.

Hopefully these threads are useful:
https://www.fiatforum.com/panda/449049-topping-up-dualogic-hydraulic-actuator-oil.html
https://www.fiatforum.com/500/425006-one-only-dualogic-failure-thread-19.html?p=4230950

 

[jaahn]

Hi
Thanks for the two replies.
To answer the second one first. I think you are referring to the automatic changing mechanism oil resevoir. Mine is OK and working ok !

What I wanted to do was check and add oil to the main gearbox itself. I did check my gearbox and can see the front level plug similar to the 147 box, but the auto change mechanism is in front of that and makes that option difficult. I did not want to remove parts from that to access it.
So after looking to see if there were any leaks and deciding that it was good I forced the breather cap on top open a bit and squeezed some gearbox additive into there. I had to remove the battery and holder tray to get to it. I will see if it makes the whine quieter ??
Thanks Jaahn

 

[rmjbn1]

Ah, OK Glad to hear the Dualogic is behaving itself

The transmission oil should be up to the level of the filler plug on the front of the gearbox, but if that filler plug is inaccessible that makes it a bit tricky.

If the gearbox oil level has been low, the input shaft bearing cage can quickly overheat and melt.

This causes play in the input shaft which results in the input shaft seal leaking - not uncommon on these gearboxes.

If you stick a finger in this inspection hole in the bell housing and it comes out oily, this would indicate a worn input shaft bearing:

 

[jaahn]

Hi
I jacked up the little Fiat and had a close look into the oil level plug location at the front of the gearbox. It does appear at first look to be impossible to get at but actually when you remove the cover from the actuator mechanism and look at the plastic oil container which is in front of the plug, you find that the container is moulded with a side cut away so you can access the plug. You need a 12mm hex bit and an extension several inches long. Not too long as the radiator is there in front. Very tight too.
So I selected some tools just the right length and removed the plug. The level was a bit down and hard to dip too. But using a thin tube from the top i put a bit more in till it overflowed. Possibly only added about 200ml in total. But I was happy I had done it to be certain of the level.
The gearbox still is noisy and sounds like a bearing is bad in first and second but for now it will do for a short run to work and back. I will look out for a good used gearbox I guess.
Cheers jaahn

 

[jaahn]

Hi
I jacked up the little Fiat and had a close look into the oil level plug location at the front of the gearbox. It does appear at first look to be impossible to get at but actually when you remove the cover from the actuator mechanism and look at the plastic oil container which is in front of the plug, you find that the container is moulded with a side cut away so you can access the plug. You need a 12mm hex bit and an extension several inches long. Not too long as the radiator is there in front. Very tight too.
So I selected some tools just the right length and removed the plug. The level was a bit down and hard to dip too. But using a thin tube from the top i put a bit more in till it overflowed. Possibly only added about 200ml in total. But I was happy I had done it to be certain of the level.
The gearbox still is noisy and sounds like a bearing is bad in first and second but for now it will do for a short run to work and back. I will look out for a good used gearbox I guess.
Cheers jaahn

Hi Well the gearbox top up and additive just put off the job of fixing the problem, I suspect the front input bearing is slack and the oil seal is leaking slowly and now the clutch is slipping under full throttle. The noise in the gearbox is there in first and second. Is this because those gears are near the worn bearing and are dropping out of mesh a bit.
What are my options, Easy first please. Can the bearing and seal be replaced by removing the box and then only the bell housing.
What are the required parts called, any part numbers available ! Is there a parts list.
No mechanics around here want to do the job so I might look into a replacement box or DIY the job.
How would i tell a used gearbox is not as bad as the old one ??
Cheers and please any suggestion read and considered.
Jaahn