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Home >> Fiat >> 2015 >> 500L Trekking, Automatic Trans >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 3 (Clutch System - 500L) >> Cylinder, Clutch Slave >> Removal >> DDCT, Odd Gears

DDCT, Odd Gears

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  1. Using the scan tool, perform the hydraulic circuit bleed procedure (Refer to ).
  2. Disconnect the battery tray. Refer to TRAY, BATTERY, REMOVAL .
  3. Raise the vehicle on a suitable hoist. Refer to HOISTING, STANDARD PROCEDURE .
  4. Remove the Left Hand (LH) front wheel. Refer to REMOVAL .
  5. Remove the LH front wheel house splash shield. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE, REMOVAL .
  6. Remove the belly pan. Refer to BELLY PAN, REMOVAL .
    Fig 1: Rear Cross Brace & Fasteners
    GC0158750Courtesy of CHRYSLER GROUP, LLC
  7. Remove four tunnel support brace bolts (1) and the tunnel support brace.
    Fig 2: Positioning Floor Jack
    GC0158934Courtesy of CHRYSLER GROUP, LLC
  8. Position the floor jack (1) under the transmission (2).
  9. Lift the transmission to relieve tension on the upper mount.
    Fig 3: Upper Transaxle Mount To Transaxle Bolts
    GC0159074Courtesy of CHRYSLER GROUP, LLC
  10. Remove the upper transmission mount bolts (2) holding the upper transmission mount to the upper transmission mount bracket (3).
  11. Lower the transmission until it rests just above the load beam to provide clearance for the odd gear clutch slave cylinder removal tool.
    Fig 4: Ground Cable Bolt
    GC0155599Courtesy of CHRYSLER GROUP, LLC
  12. Remove the ground cable bolt (1) from the transmission side cover and position the ground cable aside.
    Fig 5: Hydraulic Line & Clips
    GC0161700Courtesy of CHRYSLER GROUP, LLC
  13. Remove the odd gear slave cylinder hydraulic line fastening clip (1) and discard.
  14. Remove the odd gear slave cylinder hydraulic line from the retention clip (2).
  15. Remove the odd gear slave cylinder hydraulic line (3) from the slave cylinder, plug off the line with a rubber cap and position aside.
    Fig 6: Odd Gear Slave Cylinder Electrical Connector
    GC0161694Courtesy of CHRYSLER GROUP, LLC
  16. Disconnect the odd gear slave cylinder electrical connector (1).
    Fig 7: Odd Gear Slave Cylinder Bolts
    GC0161699Courtesy of CHRYSLER GROUP, LLC
  17. Remove the odd gear slave cylinder bolts (1).
    Fig 8: Dust Cover
    GC0161707Courtesy of CHRYSLER GROUP, LLC
  18. Remove the odd gear slave cylinder dust cover (1) by hand.
    Fig 9: Removing Odd Gear Slave Cylinder
    GC0161721Courtesy of CHRYSLER GROUP, LLC
  19. Turn the odd gear slave cylinder (1) clockwise (CW) 45°- 60°.
    multimedia:A supplement to the article is available.
    Fig 10: Support Posts
    GC0161728Courtesy of CHRYSLER GROUP, LLC
  20. Install the two (special tool #2012400210, Remover / Installer, CSC Valve) support posts (1) and tighten by hand.
    Fig 11: Hook Arm
    GC0161715Courtesy of CHRYSLER GROUP, LLC
  21. Install the (special tool #2012400210, Remover / Installer, CSC Valve) hook arm (1) in the upper bolt hole.
    Fig 12: Puller Tool & Hook Arm Fastener
    GC0161738Courtesy of CHRYSLER GROUP, LLC
  22. Install the (special tool #2012400210, Remover / Installer, CSC Valve) puller tool (1) on the odd gear slave cylinder by inserting the hook arm in its elongated hole, and install the support pins in the holes adjacent to the hook arm. Tighten the hook arm fastener (2) hand tight.
    Fig 13: Hook Arm, Fastener & Push Bar
    GC0161714Courtesy of CHRYSLER GROUP, LLC
  23. Install the (special tool #2012400210, Remover / Installer, CSC Valve) hook arm (1) and tighten the fastener (2) hand tight. Rotate the push bar (3) CW onto the support posts.
    Fig 14: Support Post Fasteners
    GC0161710Courtesy of CHRYSLER GROUP, LLC
  24. Tighten the (special tool #2012400210, Remover / Installer, CSC Valve) support post fasteners (1) hand tight.
    Fig 15: Puller Tool Bolt
    GC0161746Courtesy of CHRYSLER GROUP, LLC
    25. NOTE:

    Do not over tighten the puller tool bolt. 

    NOTE:

    To prevent personal injury do not place fingers between odd gear slave cylinder housing and the transmission case. 

    Fig 16: Plastic Shield
    GC0161718Courtesy of CHRYSLER GROUP, LLC
  25. Tighten the (special tool #2012400210, Remover / Installer, CSC Valve) puller tool bolt (1) CW until the bolt bottoms out on the washer or becomes tight on the odd gear slave cylinder piston.
    26. NOTE:

    To prevent personal injury do not place fingers between odd gear slave cylinder housing and the transmission case. 

    Fig 17: Handle
    GC0161724Courtesy of CHRYSLER GROUP, LLC
  26. Verify the plastic shield is recessed in the transmission case. If it is not, use a pick or equivalent, and move the black plastic shield (1) away from the odd gear slave cylinder housing and back into recess key in the transmission case.
    27. NOTE:

    To prevent personal injury do not place fingers between odd gear slave cylinder housing and the transmission case. 

    NOTE:

    For the clamp tool to fit correctly there will be approximately a 12.7 mm (0.5 in) gap between the odd gear slave cylinder and the transmission.

    Fig 18: Clamp Tool Fasteners
    GC0161701Courtesy of CHRYSLER GROUP, LLC
  27. Verify the odd gear slave cylinder has pulled off the transmission enough by using the (special tool #2012400210, Remover / Installer, CSC Valve) handle (1) end of the clamp tool as a gauge. If the handle fits loosely between the transmission and the odd gear slave cylinder proceed to step  22 . If the handle does not  fit, perform the following steps:
    1. Loosen the support post fasteners but do not remove them.
    2. Loosen the support posts approximately a half turn.
    3. Tighten the support post fasteners by hand.
    4. Verify the odd gear slave cylinder has pulled off the transmission enough by using the handle of the clamp tool as a gauge. If the handle fits loosely between the transaxle and the odd gear slave cylinder proceed to step  22 . If the handle does not  fit loosely, repeat above steps.
    28. NOTE:

    The clamp tool halves should come together until the handles almost contact each other with no more than a 2 mm gap.

    Fig 19: Puller Tool Bolt
    GC0161722Courtesy of CHRYSLER GROUP, LLC
  28. Install the (special tool #2012400210, Remover / Installer, CSC Valve) clamp tool halves and the fasteners, tighten the clamp tool fasteners (1) until tight with a wrench.
  29. Loosen the puller tool bolt (1).
    Fig 20: Support Post Fasteners
    GC0161710Courtesy of CHRYSLER GROUP, LLC
  30. Loosen the support post fasteners (1).
    Fig 21: Support Posts
    GC0161708Courtesy of CHRYSLER GROUP, LLC
  31. Turn the push bar counter clockwise (CCW) and remove the support posts (1).
    Fig 22: Puller Tool Bolt
    GC0161698Courtesy of CHRYSLER GROUP, LLC
    32. NOTE:

    Do not over tighten the puller tool bolt.

    Fig 23: Puller Tool
    GC0161706Courtesy of CHRYSLER GROUP, LLC
  32. Tighten the puller tool bolt CW until the bolt bottoms out on the washer or becomes tight on the odd gear slave cylinder piston.
    33. NOTE:

    The puller tool should rotate freely after the odd gear slave cylinder is broke free from the rod. If it rotates tight CCW then tighten the clamp tool fasteners more.

    Fig 24: Puller Tool & Odd Gear Slave Cylinder
    GC0161739Courtesy of CHRYSLER GROUP, LLC
  33. Remove the odd gear slave cylinder (1) from the transmission by turning the puller tool (1) CCW.
    34. NOTE:

    For installation, take note on how the puller tool is installed on the odd gear slave cylinder prior to removing the puller tool from the odd gear slave cylinder.

  34. Loosen the puller tool bolt, remove the hook arms and remove the puller tool (1) from the odd gear slave cylinder (2).
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