Al4 Transmission Solenoid And Firmware Upgrade

[Simple]

Hi,

I will be changing the two (infamous) solenoids within the AL4 Gearbox on my 2003 Citroen C8 2.0 HDi. This requires the upgrade of the Gearbox's ECU Firmware into a newer version. I don't know if my current Firmware is compatible with the Borg-Warner solenoids or not.

 

My current firmware details are:

 

Supplier: Siemens

PSA Reference: 8200302005

Software Reference: 9654868580

Supplier: 04

System: 92

Application: 08

Version: 1A

Version: 1701

Message System Number: 00

 

I have a Lexia clone, I know if I have a dealers log-in access, I would be able to update all the firmware on my car, but I don't.

 

How/Where can I download the various firmwares?

 

Simple.

[coastline taxis]

legal software updates are available form the dealers only. there are some bit torrent siteswere you can get software but you havnt got a clue what your uploading into your ecu and that coupled with a cloned lexia sound like it could go wrong big style.  Have you priced the dealers for the update

[Simple]

I don't like going to the dealers; competence is suspect. They try many things and charge you for them before giving up.<br /><br />I actually know a thing or two in software and hardware (over 30 years in IT). I would still like to do it myself and would appreciate if someone can pass me the link.<br /><br />TIA, Simple.<br />

[Simple]

I was informed that the Firmware on my Gearbox (listed in my initial post) is the latest, and is compatible with Borg-Warner solenoids.

[coastline taxis]

Glad your sorted. anymore info would be apriciated as software upgrade,s dont come onto the forum much.

[Simple]

I don't need to change the solenoids after all.

 

I came across a Malaysian site where a couple of users had problems identical to mine (namely, Gear fault in the first 10 minutes of driving and when the rev is above 2k, that does not happen again when engine is warm/hot), they solved theirs by flushing the oil and over filling by 0.5 liter.

 

So, whilst I am communicating with another source for the 2574.16, I decided to flush the oil for the second time, but this time I added half a liter more than the standard level...

 

Well, it has worked.. the gear is no longer failing and I don't need to change the solenoids...

[Simple]

I forgot to mention that the amount of oil overfill was 250ml (0.25 Liter or quarter a liter), the recommendation on the Malaysian site was overfill by half a Liter.

Also, I actually did buy the solenoids from China, but what I received did give the confidence to fit in my car.

[Simple]

To perform an accurate and scientific process, I reviewed all documents I could lay my hands on, including the French manual "RTA - CITROËN C8...pdf", and watched some YouTube videos.

The way I changed the oil is as follows:
# Precaution: Ensure that the filling plug is released before dropping the oil, you don’t want to end up with a gearbox that is empty and cannot be refilled.
1- Drove the car until operational temperature (90C) then parked it in the drive way. I jacked it up and ensured it was horizontal (using spirit level and laser gun).
2- Connected the Lexia device and kept it connected throughout, checked temperature and performed other tasks (preparations, diagnosis, deleted errors and waited) until Gear oil temperature was around 63C degrees.
3- With the Gear Lever in P, started engine, inserted a clean dry 5 liter container under the drainage point and opened the drainage nut (If oil level was high, it would spill the excess into the container until it trickles in drops; amount can be measured). In my case I got few drops, indicating correct or possibly low level.
4- Stopped engine (with temp at 66C) and removed the plastic insert (inside the drainage hole) using Allen key size 8. The oil gushed out until trickled, I started the engine few seconds and I got another spill. Total amount of drained oil was 2.77 Liter of reasonably good oil, since I performed first change 6 months ago.
5- Put back the plastic insert, replaced the drainage plug and filled in 3 Liters of Mobil LT 71141.
6- Started the engine, foot on brake and changed (all) gears very slowly until temperature is around 63C.
7- While Engine is on and gear in Park, opened the drainage plug and released excess oil in new dry and clean container (got a short spillage then drops). Now oil level is correct.
8- Replaced the drainage plug and added 0.25 Liter of Mobil LT71141, closed the filling plug.*
9- Drove the car under the same conditions few times now (previously, the error was easy to replicate under certain conditions), but the error has not occurred since.

* What actually happened here is that I overfilled by 0.45 liter, and immediately drove the car pushing it hard, when I kicked down (accelerator to the floor), I got a Lexia “Temporary fault, One-touch control signal†error template with no data. I assume this is either because I overfilled or the oil was full of bubbles and has not settled yet. Hence, the second day I removed all the excess oil (which came to be 230 ml only) and overfilled by only 250 ml (0.25 liter), and tried to replicate the error but it never occurred again.
There is no leakage in my gearbox, so the only explanations I have are that:
a- I assume that the oil did not fill all the holes and cavities it was supposed to occupy, and it took a couple of short trips and settling overnight to do so.
b- I have also noticed the presence of tiny bubbles when adding the clean oil, they may help to give a fake indication of the correct oil level, especially when they expand due to heat. Hence, I advise to overfill by 25 to 50 ml of fresh oil or you can close the nut when the oil becomes a thin trickle and not drops.
c- The “Temporary fault, One-touch control signal†may have been as a result of slippage due to the air bubbles (I could not replicate this error the second day, even before adjusting the oil level) or communication error between the main ECU and the Gearbox ECU.

d- Last time I obtained the Gearbox oil from the dealer "4HP20" at about 17.5 Euro a liter, this time I ordered Mobile LT71141 over the net (from France) at 7.5 Euro plus 10 Euro delivery to Ireland.

 

I actually took measurements of all activities (unlike first time I changed the oil) to ensure I would be in position to analyze the data if need be.

I hope the above may help someone..

Edited September 7, 2015 by Simple