Fiat Ducato 2.5 5th gear Lubrication Tip

Discussion in 'Top Tips & Tricks' started by Tootles, Jul 8, 2014.

  1. Tootles

    Tootles Funster

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    I dont know if this has been posted before, however, if it has, I crave your forgiveness. :)

    The mechanic at my local garage was a fitter for Fiat. He has told me that removing the gearbox dipstick, measuring 20mm from where the stick comes out of its holder sleeve, and then marking with a junior hacksaw, will increase the gearbox oil capacity by some 60 ml once topped up to this level. No detriment to seals, says he. Apparently, this mod was issued to all FIAT agencies some time ago, and will reduce the occurrences of 5th gear failure, by ensuring a better oil splash effect.
    Not sure about other Fiat gearboxes with the same problem, he couldn't remember if it covered them all, however, he did say that they all pretty much conform to the 2.5 box.
     
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  2. Tootles

    Tootles Funster

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    Here is a photo of what I mean, reproduced from the public domain. gbox_dipstick.jpg

    Arrow pointing to the new mark.
     
  3. pappajohn

    pappajohn Funster Life Member

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    Neither of mine had a dipstick.

    2.5td and 2.8tdid with 5 speed gearboxs
     
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  4. Tootles

    Tootles Funster

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    Mine has John, even though it is a bitch to find. I thought they all had them.
     
  5. PP Bear

    PP Bear Funster Life Member

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    Blimey, there's a dip stick on the gearbox :cool:

    Where where where is it located (and yes I know the gearbox) but any pictures or ideas.

    I have the 2006 Autotrail with the 2.8JTD and 5 speed manual :)

    Thanks in advance Funsters
     
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  6. Snowbird

    Snowbird Funster Life Member

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    The best cure I found was not putting it into 5th until the engine had fully warmed up or at least 20 miles. 5th gear is very high and does not get a lot of oil, especially when the oil is thick due to being cold. All 2.5 diesels both turbo and non turbo had a dipstick on top of the box, its just to the right of the speado cable but am not sure about the 2.8 models. The gearbox has 2 chambers as 5th was an afterthought by Fiat. The best way to fill the box is remove the reversing light switch and fill the box through the hole. This will make sure both chambers are full.
     
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  7. Tootles

    Tootles Funster

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    Am now using semi-synthetic gear oil, much smoother change.
     
  8. pappajohn

    pappajohn Funster Life Member

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    To be honest, mine probably did...but gearboxs used to be a fill and forget item, unless they sprung a leak, with a combined fill and level plug.

    Never even gave a thought to it having a dipstick.....they were always the domain of auto boxs.
     
  9. Tootles

    Tootles Funster

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    service2.jpg

    Here you go. This is looking from the underneath, front LH side. 1 is the dipstick, 3 & 3 the drain plugs (2.5 TD) View attachment 37040
     
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  10. Snowbird

    Snowbird Funster Life Member

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    I would also recommend semi synthetic. Another problem is water contamination, due to the position of the heater vent and also running down the scuttle. It finds its way into the box via the dipstick or reversing light switch. Make sure the dipstick is a good fit and if possible make some form of cap from the top of an airosol.
     
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  11. Snowbird

    Snowbird Funster Life Member

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    That photo clearly shows the 2 chambers with 2 drain plugs. Thats why Fiat recommend filling via the reversing light switch.
     
  12. Tootles

    Tootles Funster

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    I dont seem to get that problem Checked it today, no contamination or emulsification on the dip stick.
     
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  13. pappajohn

    pappajohn Funster Life Member

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    My gearbox looked nothing like that......mine was manky and covered in muck.
     
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  14. pappajohn

    pappajohn Funster Life Member

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    Or fit the upgraded scuttle drain tube.
     
  15. dave newell lvs

    dave newell lvs Trader-Vehicle Services

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    Only ducatos on the old Talbot Express shape body had dipsticks on the gearbox. Express shape died out in '94 to be replaced by Mk2 (X230) Ducato/Boxer/Relay which ran till 2001/2 when the facelifted variant was brought in (X244), this version ran till late 2006 when the (X250) shape came in.

    D.
     
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  16. Rob and Val

    Rob and Val Funster

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    We have a 1994 TE with a Peugeot 2.5 non turbo engine. We were having problems with changing up to 5th gear. Our trusty mechanic did the alteration that Tootles suggests above. Result ... a much smoother gear change.
     
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  17. Tootles

    Tootles Funster

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    There you go!! I'm not totally useless after all!! (y)(y)
     
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  18. PP Bear

    PP Bear Funster Life Member

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    Tootles
    THANK YOUUUUUU (y):D:)(y):BigGrin:
     
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  19. ArcticKris

    ArcticKris Read Only Funster

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    Great topic,Thanks to Tootles for this,out of interest we use only synthetic oils in our cars,MH and equipment,we find it a lot easier on machinery in our very cold winters,talking - 35/40 in January

    Kris
     
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