Technical transmission fluid top up Fiat 500 automatic and calibration after clutch replacement

[chrisstar]

Hi folks,
I cannot find any clear instructions on how to top up the transmission fouid after a clutch replacement on a Fiat 500 automatic with the Selespeed robot.
Is there a filler plug for the transmission fluid and if yes, where ? Maybe you can add a photo as well; would be lovely
I have replaced the clutch on that car and had the Selespeed robot undone as well.
Which calibration processes do I have to go through and in which order?
I have bought the official Fiat app.
Thanks for any advice,
Cheers
Chris

 

[puntodeltathema]

So there are two "fluids": regular gearbox oil (75W API GL4 or similar) which goes in the conventional filler/level hole behind the metal plug on the front face of the gearbox (accessible via the "cutout" in the white plastic bit on the actuator if the latter is back in place). Fiddly if you've got the actuator heatshield and front frame back on, but loosen all the heatshield bolts and you can just about move it enough (maybe with a bit of temporary bending) to get access.

That white plastic bit is the reservoir for the second fluid: the hydraulic oil for the actuator, which is completely separate. Fairly obvious how to fill it if you have the outer heatshield off. You must use Tutela CS Speed fluid for this - available from Fiat or (better) the likes of shop4parts online. Though generic Dexron III is acceptable as a second-best. May as well use the right Tutela stuff though, it's not expensive. There is usually a green mark on the reservoir - fill to that or the bottom of the neck.

The software procedures you need to do, in order, are as follows (using MES terms):

• "Clutch drain" - bleeds air from the system
• "Clutch self-calibration enable" - allows the system to "learn" the new clutch. You need to run the engine up to temperature before starting this one.
• "Production/service final calibration" - runs through all the gearbox functions to calibrate. (May be called "end of line calibration" or similar on other software).

Follow all instructions to the letter and don't attempt any gearchanges until it's all done.

 

[chrisstar]

So there are two "fluids": regular gearbox oil (75W API GL4 or similar) which goes in the conventional filler/level hole behind the metal plug on the front face of the gearbox (accessible via the "cutout" in the white plastic bit on the actuator if the latter is back in place). Fiddly if you've got the actuator heatshield and front frame back on, but loosen all the heatshield bolts and you can just about move it enough (maybe with a bit of temporary bending) to get access.

That white plastic bit is the reservoir for the second fluid: the hydraulic oil for the actuator, which is completely separate. Fairly obvious how to fill it if you have the outer heatshield off. You must use Tutela CS Speed fluid for this - available from Fiat or (better) the likes of shop4parts online. Though generic Dexron III is acceptable as a second-best. May as well use the right Tutela stuff though, it's not expensive. There is usually a green mark on the reservoir - fill to that or the bottom of the neck.

The software procedures you need to do, in order, are as follows (using MES terms):

• "Clutch drain" - bleeds air from the system
• "Clutch self-calibration enable" - allows the system to "learn" the new clutch. You need to run the engine up to temperature before starting this one.
• "Production/service final calibration" - runs through all the gearbox functions to calibrate. (May be called "end of line calibration" or similar on other software).

Follow all instructions to the letter and don't attempt any gearchanges until it's all done.

@puntodeltathema
Thanks a lot for all of the advice mate!
Very much appreciated.
Gearbox oil is in and evrerything came pretty much together.
HOWEVER: one cable (earth strap it seems) form the ESP or ABS seems disconnected and on all of the pictures that i have taken during the repairs, it doesn't seem obvious where it should be connected:

see picture
This question has been posted somewhere else but no answer was given
I've put it on the battery tray. When connecting the obd and wanting to do the calibrations, it does say that there is a problem with the brakes and thus cannot carry out the calibrations.
On the dash: obd, esp and hill starting problem; i guess it has to do with that earth strap??!

 

[puntodeltathema]

That earth strap goes to the ECU case - attach it to one of the screws holding the ECU on.

If the ESP etc errors persist (try clearing under the ABS bit of MES), you may have disturbed the multiplug to the ABS/ESP unit (with the cylindrical top) which is nearby.

 

[chrisstar]

That earth strap goes to the ECU case - attach it to one of the screws holding the ECU on.

If the ESP etc errors persist (try clearing under the ABS bit of MES), you may have disturbed the multiplug to the ABS/ESP unit (with the cylindrical top) which is nearby.

that was my first thought, ok the earth strap is back in place
I have checked every possible wire, cable and wiring loom with its connectors and they all seem properly connected without any visible damage

HOWEVER the dash still shows ABS, ESP and hill starter disconnected

I have the AlfaOBD app with a conventional OBD2 adapter and it allows me to do certain bidirectional operations

I have tries to clear the abs fault but it comes straight back
Do i need a specific app / tool with any of those Fiat adapters?

 

[chrisstar]

that was my first thought, ok the earth strap is back in place
I have checked every possible wire, cable and wiring loom with its connectors and they all seem properly connected without any visible damage

HOWEVER the dash still shows ABS, ESP and hill starter disconnected

I have the AlfaOBD app with a conventional OBD2 adapter and it allows me to do certain bidirectional operations

I have tries to clear the abs fault but it comes straight back
Do i need a specific app / tool with any of those Fiat adapters?

Update: the abs sensor seems damaged / broken. I have ordered a new one and will check again after that.