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Comfortmatic gearbox - transmission not available

4421 Views 34 Replies 11 Participants Last post by  Malshadow
Hi all
Does anyone out there know of this issue - and more importantly a fix, please?
This relates to my 2018 Hymercar on Fiat Ducato Maxi chassis, 2.3 litre diesel 130bhp (remapped to 160bhp) and 40k miles otc.
It started as I was pulling up to some traffic lights, sudden ‘clank’ underneath like I’d driven over and thrown up a can or something, warning sound, red gearbox warning light on the dash, ’transmission unavailable’ message, loss of all power, engine still running ok, no gears forward or back.
So hazards on, switch off, restart, no problem, drove on and made it home 3hrs without further issue. it was a nice day weather wise, sun was out, no rain, no wipers.
Parked up for a couple of days, went to go out, started engine, red gearbox warning light again, ‘transmission unavailable’ message, unable to find gear to move from parking spot. Restart didn’t work this time.
Had to get recovery truck to transport camper van to Fiat Professional (FP) garage. FP decided ECU had ‘forgotten’ comfortmatic gear change capability so reprogrammed, re-taught ECU, took it for a test drive to check and that seemed to be that. I drove home happy, parked up for an overnight stay at the local body shop, picked it up the morning after and drove the four miles home no problem.
After two days on the drive the engine started fine but hey, guess what? Red light again, same transmission message and no gears!
And in the manner of intermittent problems, by the time the camper van has been flat-bed recovered and made it back to the FP garage for the second time, the warning light’s gone off and it starts and drives beautifully.
FP wants an OBD download of the now disappeared problem when the red light’s on and we’re now starting it every day or so, taking it for a drive and cannot reproduce the problem to catch it on diagnostic. It’s been at the garage a month now!
So we don‘t have a fix yet and I’m wondering if anyone in the Forum can offer any experience, enlightenment, answers or fixes?
Thanks and best wishes
Mike
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Initially The automatic gearbox with torque converter and manual gearbox were two entirely different concepts, they did not even look the same, manual gearbox basics consisted first motion shaft, main shaft, and lay shaft with a free spinning reverse gear which was mechanically pulled into position receiving transmission from a flywheel clutch disc and pressure plate. The automatic gearbox received transmission through a torque converter, solenoids and hydraulics enabled gear selection. The comfortmatic gearbox is basically a manual gearbox with robotic additions added it does require more Driver awareness so the Comfortmatic handbook plays an essential part in the understanding of robotic automatic transmission as it does not operate as a traditional automatic such as Borg Warner. Hope this throws a bit more light onto the subject folks.
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I'm having a wee chuckle to myself Malshadow! But I know there are plenty who do understand the various terms and scenarios. I wish I did as I have the Comfortmatic but definitely don't have a Comfortmatic handbook.
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Similar here Jean. I am constantly impressed at the levels of knowledge some folks amass and are able to help others with.
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Hi all Does anyone out there know of this issue - and more importantly a fix, please? This relates to my 2018 Hymercar on Fiat Ducato Maxi chassis, 2.3 litre diesel 130bhp (remapped to 160bhp) and 40k miles otc. It started as I was pulling up to some traffic lights, sudden ‘clank’ underneath like I’d driven over and thrown up a can or something, warning sound, red gearbox warning light on the dash, ’transmission unavailable’ message, loss of all power, engine still running ok, no gears forward or back. So hazards on, switch off, restart, no problem, drove on and made it home 3hrs without further issue. it was a nice day weather wise, sun was out, no rain, no wipers. Parked up for a couple of days, went to go out, started engine, red gearbox warning light again, ‘transmission unavailable’ message, unable to find gear to move from parking spot. Restart didn’t work this time. Had to get recovery truck to transport camper van to Fiat Professional (FP) garage. FP decided ECU had ‘forgotten’ comfortmatic gear change capability so reprogrammed, re-taught ECU, took it for a test drive to check and that seemed to be that. I drove home happy, parked up for an overnight stay at the local body shop, picked it up the morning after and drove the four miles home no problem. After two days on the drive the engine started fine but hey, guess what? Red light again, same transmission message and no gears! And in the manner of intermittent problems, by the time the camper van has been flat-bed recovered and made it back to the FP garage for the second time, the warning light’s gone off and it starts and drives beautifully. FP wants an OBD download of the now disappeared problem when the red light’s on and we’re now starting it every day or so, taking it for a drive and cannot reproduce the problem to catch it on diagnostic. It’s been at the garage a month now! So we don‘t have a fix yet and I’m wondering if anyone in the Forum can offer any experience, enlightenment, answers or fixes? Thanks and best wishes Mike
Hello Mike, Has this been resolved by your FP, as we have the same problem and ours are struggling to find the problem many thanks Helen
Hi Helen, Mike hasn't been about for a few months. I've dropped him a message to see if he can enlighten you.
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Hi Helen, Mike hasn't been about for a few months. I've dropped him a message to see if he can enlighten you.
Thank you, we have a huge problem with ours, so looking to see if his has been resolved and how, many thanks though Helen
Hi, all of the electronic controllers on a vehicle need to communicate with each other there are so many that is the reason Fiat Multiecuscan software for Ducato's is the only way to understand what is not communicating, items which one would not associate with a gearbox function may not be communicating, two examples would be the speed of the vehicles wheel rotation has to be correct for the gearbox to work as intended, the throttle pedal has a sensor attached if this is not communicating its correct position the gearbox may not know when to change gear all quite logical when explained, a garage or auto electrician with this software will be able to read the fault codes this is what is needed the next bit would be to interoperate those codes, the time consuming part is to check the connections to the suspect area of the DTC's one does not have to use a franchised workshop, the only thing you can do is to check that everything else is functioning correctly [ everything ] that would assist but you really need those DTC's [ Diagnostic trouble codes ] I have other posts on Multiecuscan for DIY if you felt confident, the codes are relatively easy to access the physical checking is what takes the time but you have to be looking in the area's of the code as they do give a description also, good luck.
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Hello Mike, Has this been resolved by your FP, as we have the same problem and ours are struggling to find the problem many thanks Helen
Hello Helen
No it’s not fixed yet. We spent four months trying to emulate the intermittent problem whilst it was still at the garage and we were desperate to provide Fiat with a photo of the dashboard with the warning light on and have the FP guys record the event live-time with their diagnostic equipment.
By a stroke of fortune this eventually happened and Fiat Tech UK advised it was probably a shot rivet on the clutch kiss plate and recommended a new clutch which is now fitted. But reprogramming the van didn’t work and Fiat Tech UK pointed to a sensor which was replaced and that didn’t work either. This leads us to consider it never was a mechanical problem but an electrical or electronic one and the FP have at last called in the Fiat big guns Tech who’s supposed to be investigating as I write now, over six months since our vehicle went in for a fix.
Various forums including this one have provided ideas which I’ve funded the garage to explore including loom check - we had a loom passing unprotected through the cab bulkhead in the past which caused shorting in the BCM, replaced for £900+labour.
One guy has said to check for faulty brake sensor.
So at the moment it’s a case of what we know it’s not rather than what it is. I’ll be happy to share news as it happens this week. I’d be interested to hear your story please.
Mike
Hi, all of the electronic controllers on a vehicle need to communicate with each other there are so many that is the reason Fiat Multiecuscan software for Ducato's is the only way to understand what is not communicating, items which one would not associate with a gearbox function may not be communicating, two examples would be the speed of the vehicles wheel rotation has to be correct for the gearbox to work as intended, the throttle pedal has a sensor attached if this is not communicating its correct position the gearbox may not know when to change gear all quite logical when explained, a garage or auto electrician with this software will be able to read the fault codes this is what is needed the next bit would be to interoperate those codes, the time consuming part is to check the connections to the suspect area of the DTC's one does not have to use a franchised workshop, the only thing you can do is to check that everything else is functioning correctly [ everything ] that would assist but you really need those DTC's [ Diagnostic trouble codes ] I have other posts on Multiecuscan for DIY if you felt confident, the codes are relatively easy to access the physical checking is what takes the time but you have to be looking in the area's of the code as they do give a description also, good luck.
Hi Jiwawa!
Our Fiat had no evidence of fault codes until we managed a live occurrence the despite my describing big red flashy lights on the dash and absolutely no control over gear change. To add insult to injury, when the vehicle was then lifted and transported by recovery truck it would start first time each time it arrived at the FP. If the codes has been stored it might have had a profound impact on our trouble shooting journey to get here today. I’ll keep the blog updated. Thanks for the email prompt. Mike
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Hello Helen
No it’s not fixed yet. We spent four months trying to emulate the intermittent problem whilst it was still at the garage and we were desperate to provide Fiat with a photo of the dashboard with the warning light on and have the FP guys record the event live-time with their diagnostic equipment.
By a stroke of fortune this eventually happened and Fiat Tech UK advised it was probably a shot rivet on the clutch kiss plate and recommended a new clutch which is now fitted. But reprogramming the van didn’t work and Fiat Tech UK pointed to a sensor which was replaced and that didn’t work either. This leads us to consider it never was a mechanical problem but an electrical or electronic one and the FP have at last called in the Fiat big guns Tech who’s supposed to be investigating as I write now, over six months since our vehicle went in for a fix.
Various forums including this one have provided ideas which I’ve funded the garage to explore including loom check - we had a loom passing unprotected through the cab bulkhead in the past which caused shorting in the BCM, replaced for £900+labour.
One guy has said to check for faulty brake sensor.
So at the moment it’s a case of what we know it’s not rather than what it is. I’ll be happy to share news as it happens this week. I’d be interested to hear your story please.
Mike

Hi Jiwawa!
Our Fiat had no evidence of fault codes until we managed a live occurrence the despite my describing big red flashy lights on the dash and absolutely no control over gear change. To add insult to injury, when the vehicle was then lifted and transported by recovery truck it would start first time each time it arrived at the FP. If the codes has been stored it might have had a profound impact on our trouble shooting journey to get here today. I’ll keep the blog updated. Thanks for the email prompt. Mike
Malshadow, thanks for your useful words
Hi, folks i have heard of the term no faults were recorded but the diagnostic print out with the VIN number of the vehicle and no diagnostic troubles codes found on all canbus systems message seems never to be presented to customers to endorse the findings of the report printing out the diagnostic results is standard practice. A MIL {malfunction indicator light } illuminates even when a stop lamp is not operating, and that fault is stored within the OBD along with how many times the fault has occurred and the time and that is only a simple stop lamp bulb. Trying to investigate trouble codes as people are experiencing can take an awful lot of time professional workshops included this I know first hand, and yes the causes can be of the simplest things not even component failure, but the time taken to investigate has got to be economically viable. If you were to post the actual symptoms people may be able to help in your dilemma.:)

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Here are four typical screen shots of an investigation into the comfortmatic robotic gearbox. 1 select model and type X290 DUCATO. 2 typical recorded faults one in the body controller, and one in the powertrain. 3 the actuators associated with the gearbox. 4 the adjustments this is into the professional territory. This may explain a little or confuse a lot, when a code PO68A-68 is stored it means that the engine / powertrain control module has detected a defect in the de-energizing procedure for the relay which supplies it with voltage. In this case the relay has de-energized too soon, again I am only trying to explain diagnostics and not trying to dishearten folk, having the diagnostic trouble codes can help with the diagnoses, extracting diagnostic trouble codes by a none franchised dealer will most likely effect any warranty, that is why obtaining a diagnostic print out is important. ;)(y)

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Looking at picture 3 it shows some info I really don't understand.
Engine RPM 9216
Gearbox oil 151°c
Battery volts 576 v
Also suggests, gear requested R and gear engaged 3
???
Hi, Every bus which there are up to five on the vehicle CANBUS has sensors which communicate with their appropriate controller which in turn communicates with the other controllers on different buses, the buse's have different speeds of data transfer, some are fault tollerent, some are not. The sensor's are many, ie pressure, speed, temperature, stability, position, [ gear selector ] they are everywhere all communicating. Lets say the sensor on the engine crank pulley or flywheel measuring the rpm of the motor has a resistance caused by a dirty or bad connection the signal or value that it sends to the Engine POwer Controller, code PO, is sent to the other controllers, they interpret that signal to perform their task, looking at this diagnostic print out would show that it would be highly unlikely for three of those sensor's to be faulty more likely to be something common to all of those sensor's GROUND CONNECTION from the engine's harness to the chassis on the Ducato there are rows of these ground points, the gear position sensor's signal looks correct, but the information that the transmission controller has received alters the pressure, or whatever else determines the physical selection of the gear, remember this is a robotic automatic gearbox it is basically a manual gearbox with solenoids, actuators etc which try to simulate the human element of depressing the clutch pedal, and selecting the appropriate gear at the appropriate engine RPM changing down when an incline is approached, the MAF airflow sensor determines the amount of air intake into the engine from the position of your foot on the accelerator drive by wire TPS throttle position sensor, the later Fiat Ducato has a 9 speed conventional automatic gearbox with Torque converter, hope this helps folks, quite logical when explained, if you were to get a puncture in a front tyre before OBD oh dear something not quite right here you feel the unevenness through the steering wheel the steering wheels becomes more difficult to rotate, the vehicle will dip on the corner that is punctured, with OBD the tyre inflation MIL, the ABS MIL, the stability control MIL, the steering angle sensor will all communicate that TPMS receives a signal from ABS the front wheel is not rotating at the same speed as the others as it rolling circumference has altered, stability controllers sensor detects the vehicle is not level , steering angle sensor detects you physically trying to correct the biased your speed may be restricted . I am i child from the analogue world, this is just a different way of thinking it is not rocket science:)
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So, a sensor or connection to a sensor will effect a system one would think has nothing to do with the gearbox, on a lighter note i have mentioned that putting your shopping on the passenger seat depending on the preset software data of the sensor will send a chime and message passenger seat belt not fastened, the body controller can not distinguish the weight of your shopping from that of your partner.
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Check out the updated Comfortmatic posting under the engine and gearbox heading for enhanced confusion :oops:
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