Citroen C4 Grand Picasso Part 18 - EGS gearbox actuator leak - FIXED!

I've been having a fluid leak for some time from the gearbox area so I decided to investigate. It turned out that I was losing the fluid for the EGS gearbox actuator (the bit that does the gearchanges). I traced the problem to a leaking return hose which is quite a common problem on the cars. It was replaced with a new one and it seems to have cured the leaking once I'd rectified an upside down seal for the fluid reservoir cap which I'd done when I topped up the actuator fluid prior to doing this job. It was an absolute pig of a job but I got there on the end.
I've had comments on other videos about not capturing every turn of every nut and bolt so I videoed as mush as possible and sped up the boring bits. I also show off my brand new Halfords axle stands.
PLEASE NOTE: I'm just a DIY mechanic. I try to do things correctly but sometimes I have to manage with what I have. Please treat this video as a "how-I-did-it" rather than a "how-to".
Link to Halfords axle stands:
www.halfords.com/workshop-too...
Twitter: / parknest
Google+: plus.google.com/u/0/
Intro & outro music: Sweeter Vermouth Kevin MacLeod (incompetech.com)
Licensed under Creative Commons: By Attribution 3.0 License
creativecommons.org/licenses/b...

[@marvcast2885]

Great job on this video. I have the same car (in Australia), and I believe the same issue has occurred to mine (took it to the mechanic for a service to get a call during the day to tell me major leak from the brains of the manual gear box (I am guessing he means the actuator), and also the gearbox, I was told to not drive it and get it towed to a transmission expert about 50Km from where I live, estimated cost 1500 to 2500 AUD!. I had no issues with gears prior to this, however I had seen a drip the night prior to taking to the mechanic for service and I mentioned this to him. I am no expert whatsoever, but last night I had look under the car and I can see oil around this unit, but not the rest of the gearbox. I am hoping to remove the air filter etc. to gain acces and hope it is the hose, don't know how I'll go sourcing a new hose as Citroen Aus.not very good at helping at all. By the way how do I go about checking the transmission oil level, I can't find the level hole.

[@Parknest]

I've not checked the gearbox oil level so I can't help you on that one. If you top up the actuator reservoir with the correct fluid it will be fine until you can get the return hose replaced. I just ordered the part from my local Citroen dealer without any problems. You should check out the C4 Owners website (www.c4owners.org). The forum on there contains a wealth of information.

[@marvcast2885]

@@Parknest Thanks, Did you show how to top up the reservoir? If not any tips on how to? What's the correct fluid.

[@technicaleventproductionse1900]

Really helpful, thank you. Just buying one of these cars and i'll triple check that.

[@Parknest]

The return hose is a common problem. The fix isn't cheap but cheaper than a replacement actuator.

[@jonathonmanxrusby7762]

Very helpful, thank you.

[@jmc216]

@Parknest, great video once again. When I changed the gearbox oil, I could see that the EGS reservoir was completely dirty with old oil and lots of dirty, so I thought that it could be that the HOSE PRESSURE POWER was broken as you comment in your video. However, after an exhaustive cleaning, I checked that the new hose (improved version) was installed and that the tank was at maximum. My suspicion is that before I bought it second-hand from a dealer (three years old) that tube was already changed due to a leak, but the work area was not cleaned ... could it be? If so, it seems unprofessional to leave the work area that dirty, in addition to making it difficult to see if there are losses after having done the work.

[@Parknest]

That's interesting. Shoddy workmanship doesn't surprise me though.

[@jmc216]

@@Parknest indeed !!! btw, Did you changed at any time the differential oil in the C4? thanks in advance

[@Parknest]

​@@jmc216 No, I didn't touch the gearbox oil (being FWD the gearbox and diff share the same oil).

[@hilalalsubhi9304]

Hello my friend I have a problem with the gear shift actoutor electric citroen grand picasso c4 mod 2011 Are you in Britain How do I contact you Do you have a phone number or email

[@hrhakbar]

Hi Ray. I was think of changing the actuator fluid in my G4 Picasso. Is easy enough to drain and refill? Would it need reprogramming?

[@adurrans]

Did you ever figure this out? I'm thinking about doing the same.

[@jaykent123]

Hi Great video, i have to do the same job soon, but was under the impression you needed a dealer service tool to release the pressure before putting fluid in the unit and then use the electronic dealer unit to prime it you didnt mention in your wonderful video what you did? regards Jay

[@Parknest]

You can just add the fluid and the EGS will self bleed as the fluid circulates. You might need Diagbox to clear any fault codes. The fluid is £40 for a litre from the dealer. You can get it cheaper from Fiat (they developed the EGS). My local Fiat dealer didn't have any in stock so I had to bit the bullet and go to the Citroen dealer. The pipe was about £60 from the dealer (an improved design). It was an expensive fix but it was cheaper than a replacement EGS unit. Glad the video is of help to you.

[@peterfoy7298]

@@Parknest I've found a cheaper oil supplier in the UK = £9.99, www.ravenol-direct.uk/ravenol-gha-f-fluid.html

[@philipkeogh748]

@@Parknest what fluid did you use W75?

[@Parknest]

@@philipkeogh748 I bought a litre of EGS actuator fluid from the dealer.

[@sossidgeboy]

Hi - I've replaced the pipe (reservoir end) but am having trouble getting it to push in, or even locate, into the top pipe. Do I need to remove the electronic box which is on top of the reservoir?

[@Parknest]

It should push straight in. I think I had to remove the ECU to get better access.

[@ribblefluke3261]

Awesome video, thanks. I refilled the empty reservoir and was then able to drive around for a mile before it broke down again. I then checked the reservoir and it was empty again and the fluid is dripping out. The return hose looks fine but the fluid is dripping out near the centre under the car, so I can't see the source - any ideas?

[@Parknest]

The actuator is bolted to the transmission so it could be from there. Get it all cleaned then you can tell where the leak is coming from.

[@neevisits2957]

Is there a minimum and maximum mark on the reservoir for the fluid? What fluid did you use to top it up?

[@Parknest]

I think there are markings on the reservoir. I used the EGS fluid from the dealer which was about £40 for 1 litre (expensive but cheaper than a replacement actuator). There are cheaper alternatives available.

[@richardfairclough8474]

Hi, Was the hose you replaced the actual cause of the leak or was it the seal on the cap ?

[@Parknest]

The fluid return hose was the cause. It had worn through causing it to leak. This was a known problem with the EGS actuator and Citroen had brought out an improved part to prevent this from happening again.

[@ultrasimplexdeuswhitescscope]

Hi. Can i ask your a question? Friends of mine selling the same car as you repairing here, the text he sent said 'fault with gearbox sometimes select Gear sometimes don't just flashes neutral'... Does that sound like the actuator or a duff gearbox? Thanks in advance.

[@Parknest]

It could well be the actuator. The gearbox itself is just a normal 6-speed manual with a clutch. The actuator is what does the actual gear changes and operates the clutch. The best way to find out would be to pull up any fault codes. A simple thing to check is the fluid level and to find any leaks. The return hose is a common problem and Citroen brought out an improved return hose because they're so prone to chafing and eventually leaking. The C4 Owners forum is a wealth of knowledge so it is worth checking it out.

[@ultrasimplexdeuswhitescscope]

@@Parknest thanks so much, thats very helpful. Fancy this car as looking at driving to Spain later this year, the idea of an automatic really appeals and it should return good economy too. I'll look at that forum you mention too. Once again, thanks really appreciate it.

[@undercoverdemonlover1025]

Hello, its a great video! I have a question about the transmission fluid. I have a 2011 peugeot 308 1.6 HDi. It has the same tranmission as your car. I want to change the tranmission fluid but I don't know which one would be better. Do you have any suggestions? I'm thinking about mobil atf, since i don't have many options.

[@Parknest]

I might be easier to change to a different car with the transmission you want. Changing to a different type of transmission is very difficult if not impossible because of all the ECUs involved.

[@undercoverdemonlover1025]

@@Parknest Ah sorry. I meant the transmission fluid, not the transmission's itself

[@Parknest]

Did you mean the fluid for the EGS actuator? I believe that Fiat sells the same fluid cheaper than Citroen. It was Fiat who developed the EGS transmission. There was somebody else in the comments who managed to source some fluid even cheaper.

[@undercoverdemonlover1025]

@@ParknestI have the fluid for actuator. Im looking for gear oil. There are total gear 8 75w80, motul and mobil atf but i am not sure which one should i pick. Some people says i need to put atf but since its an automated manuel transmission, im thinking gear oil like total gear 8 75w80 is a better choice. What do you think about it?

[@Parknest]

The EGS transmission is a manual gearbox with the actuator operating the clutch and doing the gear changes so you would need to use gearbox oil. The 75w80 is the right stuff. They're supposed to be sealed for life but changing the oil won't do it any harm. You would need 2 litres to do a gearbox oil change.

[@jmc216]

Thanks for the video, is very useful, could you provide us the full p/n of the pipe please? I cant find it online. Thanks in advance

[@Parknest]

I've just turned up the receipt and it lists the part number as 209038 A far as I can tell, it is only available from the dealer. It cost me £68.32 in July 2018

[@juanantoniomaroto4832]

@@Parknest many thanks, your video is very good and you have help us a lot. I've tried online a dealer but is out of stock. Do you have any link for the spare? thanks in advance

[@StandardGoose]

Hi, just seen your comment on another video of someone performing this fix. I've got a very very tiny leak, and would like to topup the fluid as a temporary stopgap until I can get it fixed properly. Is this doable? I am a complete novice, and this is the second time I've had an EGS fluid leak on this car. Last time I paid £550 to fix it :/

[@Parknest]

This job is definitely DIY-able as you can see on my video. The actuator fluid isn't cheap so better to fix it sooner rather than later.

[@stuartdrew3281]

hi parknest ive just bled my actuator and put more fluid in there wasnt a fill level that i could see so filled it to the top after i done that the bottle was dripping is there an overflow on the bottle incase it gets overfilled ? there was fluid init before i bled it so maybe theres s defect near the top of bottle? cheers

[@Parknest]

The lid has a seal. Maybe that could be the problem. Is the return hose leaking. I've since parted company with my C4GP.

[@stuartdrew3281]

@@Parknest hi mate do you no how much fluid a actuator tank takes?

[@Parknest]

It should be less than a litre...

[@lcs1603]

Have you had any problems with the ESP/ASR?

[@Parknest]

I've long since parted company with the C4GP. I never had any problems with th ESP.

[@dickhead2717]

I have a Citroen Grand Picasso automatic 2L HDi the gearbox has just started to make a whining noise in 3rd gear and above, and has now started whining in second gear. do you think this would be because of low transmission oil or low actuator fluid? im Not too sure what the actuator does

[@Parknest]

The actuator does the gear changing. Best to check all the fluid levels. It sounds like the bearings have worn. It is a known problem with the EGS transmission.

[@dickhead2717]

@@Parknest thanx for the reply, ill check all fluid levels

[@psgamer8321]

My citroen is a semi-automatic and is making a rattling/grinding noise in low gears. Any ideas on what it could be and advice on a temp fix or diy fix? Mechanics quoting me 1000 to fix.

[@Parknest]

Are there any fault codes? Did your mechanic tell you where your £1000 would be going.

[@psgamer8321]

@@Parknest either ecu gearbox or robot. And there were a few fault codes which my clever brain wiped 🤦‍♂️

[@psgamer8321]

@@Parknest also, there looks to be a transmission fluid leak

[@Parknest]

It sounds like the transmission is terminal. Such noises aren't a good sign. A known good used transmission is probably the most cost effective repair. The most common cause of transmisison leaks are usually the driveshaft seals.

[@psgamer8321]

@Parknest would topping up with fluid buy me time?

[@jamesdoolan1616]

Hi Ray think I've got a leak on my actuator pipe can you remember what the pipe is called and part number is please thanks for your help

[@stoymar]

209038 high pressure pipe

[@bobson5361]

@@stoymar can a leak in the pipe make the vehicle not change gears

[@stoymar]

@@bobson5361 Yes it can but only when the fluid is low

[@RAPZATOITZ]

Hi mate i have a warning ⚠️ coming out of my dash saying gearbox needs repair and doesn’t want to engage wen i put the lever to “A “do you have any suggestions where to start

[@Parknest]

Have you checked the fluid level. You might have the same problem as me. What fault codes do you have? The C4 Owners forum is a good place for help and advice.

[@StandardGoose]

This happened to me. For a couple if months it would occasionally slip out of auto into manual mode. Then one day it just wouldn't start and had the same warning you describe. The actuator was overheating because the fluid reservoir was bone dry. Cost me £550 to get a new tank and hose fitted.

[@Mad109R]

Hi there i know you don't have the picasso anymore but i thought you might be able to help me out with this. My picasso is 2009 1.6hdi EGS It started to act as if the clutch is dragging when coming to a stop (trying to pull the car forward) at the same time the gearbox wouldn't change from forward to reverse (all seemed ok on the display tho) then about a mile later it just wouldn't engage gear at all & i had to be recovered. The actuator reservoir is full so no leak there or i don't think there is. What do you think? Thanks in advance Jimbo.

[@Parknest]

Sorry, I haven't a clue. Lexia/Diagbox is probably the best way to diagnose it.

[@Phil-cj3ko]

I've got a similar problem on a Citroen Grand Picasso automatic. It gets stuck in neutral or reverse when one is changing gear. The Citroen garage say it's the gearbox actuator connected to the gear lever. They say the part costs £1100 and it'll be another £200 in labour. Ouch! Not sure what to do.

[@Parknest]

A used actuator would be a cheaper option.

[@Phil-cj3ko]

@@Parknest So is there only one actuator in the car, and that's the one connected to the gear lever? Also Citroen say the car has to be reprogrammed once the actuator has been replaced so it's a specialist job only they can do. Thanks for your help!

[@viorelcraiu895]

How do you change actuator oil and what kind of oil u need? I just changed gearbox oil today, but duno how to replace actuator oil

[@Parknest]

I just topped it up. The reservoir will need to be emptied to change the actuator fluid. I bought mine from the dealer which is quite expensive but there are cheaper alternatives.

[@viorelcraiu895]

@@Parknest do u have a video witj changing actuator oil? My picasso 16 ehdi 2011, work laggy when shifting gear on auto, i changed gearbox oil and i have same problem, so i dont know what to do next in order to change shifts normal. Thank you

[@Parknest]

This is the only video I made about the actuator. If the fluid is still clean than it shouldn't need to be changed. The only way I can see of changing the fluid is to extract it from the reservoir using a siphon or a syringe. I've no plans to change the actuator fluid. You may need to recalibrate your transmission with Lexia/Diagbox but a fluid change won't do any harm.

[@viorelcraiu895]

@@Parknest thank you. I will try this. I will come with results after that.

[@viorelcraiu895]

@@Parknest hello. i solved my problem when i change the gearbox clutch kit

[@juststuart]

Do you have an issue when in slow moving traffic in auto you give it a bit of gas and it clonks/jerks mine does and it's getting to me

[@Parknest]

Yeah, I've had that too.

[@ruwn561]

Stuart May hello. I have C4GP 2010 plate. My eggs actuator and cable went too. My car started lurching from idle, stationary. Then sometimes the gear would slip between N and A1. I think this is the start of it going. It cost me £230 to get repaired and done at Citroen garage.

[@Parknest]

Did you lose fluid like I did? The flexible return hose is a common problem. It chafes and will eventually wear through and start to leak. I caught mine just in time. It is now 100% fixed and it doesn't leak any more. It cost me over £100 for the hose (only available from the dealer) and a litre of the actuator fluid but it was money well spent and cheaper than a replacement actuator. Used ones are about £300 on eBay.

[@ruwn561]

Parknest hi, yes, I lost maybe a pint, maybe more. The hose was corroded and my gearbox had a TSB fault and needed reprogramming. It was done at the Citroen garage as I had not seen your video on how to do it, I probably could not have dont it myself as I had no idea what the issue was. The symptoms started a month ago. They were. 1. When engine cold the EGS would sometimes not go into A1 or R, would take several attempts. 2) at lights or stops etc the gears would flip between say A1/2/3 and manual 1/2/3 etc. 3) I spotted some fluid on ground, looked like oil but wasn’t, I could not determ8ne exactly whereabouts in engine it came from. 4) sometimes car would lurch from stationary when moving off, like a stutter. This was apparently the TSB? Reprogramming... that needed to be done.

[@LocalJunkRemoval2189]

Hi ray i have a c4 2008 model and its leaking oil from some where i checked the parts where u did urs in your youtube video and no leaks from it and now started to make a strange noise when u set off and but when ur driving down the road its gone

[@arfan245]

i am trying to find the oil presure switch on my c4 grand picasso any idea where it could be thnx

[@Parknest]

Which engine is it?

[@arfan245]

Parknest its 1.6 diesel

[@Parknest]

According to the Haynes for the C4 car, it should be next to the dipstick tube.

[@arfan245]

Parknest i have looked everywhere cant find it do you mean next to the engine oil dipstick

[@Parknest]

Yeah, it should be on the front of the engine next to the oil dipstick tube. You might have to get to it from underneath.

[@martinfoster1873]

I am having a problem where the gears slip from A$ to N leaving me going nowhere. I am disabled and can't do any DIY anymore, would it be very expensive for a garage to do it? I used to have motobility cars but the government took that and my benefits away. All because my wife works and I have " run out " of NI contributions.

[@Parknest]

You would be better off finding a Citroen/PSA specialist. They will have the specialized knowledge as well as the Lexia/Diagbox diagnostic software which will keep labour costs down. The C4 Owners website contains a wealth of information with a very useful forum. It would be worth joining the forum and asking for help.

[@martinfoster1873]

@@Parknest Thank you very much my friend, much appreciated

[@toolsmeca7004]

Egs6 oil gear box change please

[@Parknest]

I've no plans to change the gearbox oil or the actuator fluid.

[@johnbutler3654]

joe get yourself a big jack put the wheel under then big quarter sleeprs you are in danger with just axle stands as they are too small

[@Parknest]

I usually test it before I go underneath. A quick push on the car will determine if it is stable or not.

[@stuartdrew3281]

hi mate do you no wer i can get actuator fluid from ? i need a link thanks

[@Parknest]

I got mine form the dealer. Fiat sell the stuff as they developed the EGS transmission.

[@stuartdrew3281]

@@Parknest hi mate thanks for getting back to me could you tell me the name of the product so i can search for it im not really that good at looking for stuff online thanks mate

[@Parknest]

It is actuator fluid for the EGS transmission.

[@stuartdrew3281]

@@Parknest thanks mate keep the videos comin mate love them

[@stuartdrew3281]

@@Parknest sorry to bother you again mate ive been looking but im not sure what one is the best could you give me a make of one you use i dont want to put a wrong one in thabks parknest

[@punkeded]

What actuator fluid u used?

[@Parknest]

I used the genuine fluid from Citroen. It was £40 for a litre. I've read somewhere that Fiat sell the same fluid cheaper (it was Fiat who developed the EGS transmission). A replacement actuator will cost a LOT more than the fluid.

[@punkeded]

Thank u for the reply. Very expensive 😅looking for oem fluid saw Ravenol gha-f have it but if cannot find it may need use Citroen original then 👍

[@nasty_niff]

What the fluid part number? Tia

[@Parknest]

According to the receipt, it is 9979A4

[@phillipbrown7851]

Is this Johnny Vagas?

[@Parknest]

I don't look anything like him!

[@auraman1000]

Had Zara Picasso from new, reliable and trouble trouble free 1300,000 miles, then bought the Picasso C4 2008 what a terrible car shuddering clutch, indecisive gear box, engine loses power and cut outs without warning, how on earth have Citroen got the nerve to release this unsafe piece of junk on to the market.

[@Parknest]

There are a few issues but they're well known and most problems can be overcome without too much trouble or expense. Diagbox is very useful to have. Replacing the actuator return hose and buying fresh fluid does cost but it is cheaper than a replacement actuator. Mine has the 2.0HDi which is more bulletproof than the 1.6HDi that PSA developed with Ford. That has a reputation for lunching the turbo.

[@hilalalsubhi9304]

Hello my friend I have a problem with the gear shift actoutor electric citroen grand picasso c4 mod 2011 Are you in Britain How do I contact you Do you have a phone number or email

[@hilalalsubhi9304]

I’m from swindon

[@Parknest]

I no longer have my C4GP. Try the C4 Owners forum. It is a wealth of C4-related knowledge.

[@hilalalsubhi9304]

@@Parknest

[@andrewmorelli3274]

as is the norm from watching your videos, i'm no further forward to knowing how to fix my car. I'm starting to think this is a spoofsite 😅

[@Parknest]

The return hose is the most common problem with EGS transmission leaks. It is not necessarily the problem you have. Try scanning for fault codes. Diagbox is the best scanner if you have it.

[@petersomthing9508]

Hi is the gear oil 75w-80 or 75w-90 for simi Automatic

[@Parknest]

The EGS transmission is just a manaul gearbox with an electroinc actuator that does the gearchanges. According to Euro Car Parts it takes 75w-80