Fiat Ducato 2.8TD swap for 2.8 JTD (1 Viewer)

reynardracer

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We have been looking for a new motorhome to replace our current Hymer B544. This is primarily because of the 'old' 2.8 engine and gearbox combination. We love the vehicle and its layout but when towing the poor gear ratios are not only apparent but down right frustration and makes driving a real effort.

We have looked at many motorhomes over the last few weeks but cannot find anything within our budget, and to be honest have been very disappointed with the standard of vehicles we have looked at.

Therefore does anyone know if it is possible to swap out the 2.8 TD engine and replace it with a 2.8 JTD engine. I know it sounds a drastic step to take but it will alleviate the breaking 5th gear problem experienced on the earlier 'add' on 5th gear on my 2000 model.

Thanks
Peter
 

pappajohn

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You possibly could make it fit but you would need all the electronics wiring and ECU fitting as well which would be a cost prohibitive and monumental task to say the least.
The old TD is mechanically injected, the JTD is all electronic.
 
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Not long enough!
Unless you can do it yourself it would cost a bloody fortune, even then it would eerrrm cost a fortune:confused:

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Jaws

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There is an old saying in the custom motor world.
Anything will fit anything if you throw enough beer tokens at it..

And what you would like to do will involve an AWFUL lot of beer tokens and require, as well as mechanical skills, a very good auto electrician to marry the old with the new
 

The Nomad

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Technically? Yes. It could be done.

You could get a nitrous 4 litre V8 in there if you were prepared to pay a specialist automotive engineering company to do the work.

Utterly enormous amounts of money and time and grief though. Probably the wrong side of 5 grand at the very least.
Plus consequent insurance and registration issues.

In the real world it's a total no no. Its NOT an unbolt the old lump and just drop the different one in jobbie. The control systems, electronic injection rather than mechanical will all be different. Wiring changes will be a big issue.
And then even on the JTD's, at least up to the facelift, they still had the 5 speed box with the added-on 5th in it's own added "cupboard" on the end of the box........but at least that does mean that in the actually very very very very rare event of 5th ever breaking, you can very easily replace the cog without having to take out and strip the whole box.

Just enjoy what you've got. Drop down a gear whenever you're slogging the engine, and chug about smiling at the scenery.

If you really are finding 5th consistently too high a gear and you are unhappy about chugging in 4th, I seem to recall reading somewhere that there's a slightly lower ratio'd cog you can bung in instead......others may have more info on this.
 
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reynardracer

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It was a question more in hope than anything else. Didn't really think it could be done but worth asking the question. The 5th gear problem is most prominent when towing. The engine has the power to pull the vehicle along but as we know the 5th gear is an 'add-on' and quite weak and ultimately breaks. Already done one in first year of ownership. Don't like revving the engine to anymore than 3000 rpm in 4th and that is what you have to do otherwise when you drop it into fifth it drops to under 2000 rpm.

Thanks to all the replies, as usual much appreciated.

Peter

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We had a 2.8 Tdi change to a 2.8 jdt on a later van.
Tdi was a lot brighter pulled better did three more miles to the gallon
And it was on a bigger van .
should have keep old one.:(
Good piece of advice every time we change a van we always spend another ÂŁ1,000 plus bringing it up to our standards.
And it doesn't get any better how much money you spend on your next van.
Quite often if you spend a grand on your old van you would be more happy.
Only problem is you don,t now till you do it (y)
 
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It was a question more in hope than anything else. Didn't really think it could be done but worth asking the question. The 5th gear problem is most prominent when towing. The engine has the power to pull the vehicle along but as we know the 5th gear is an 'add-on' and quite weak and ultimately breaks. Already done one in first year of ownership. Don't like revving the engine to anymore than 3000 rpm in 4th and that is what you have to do otherwise when you drop it into fifth it drops to under 2000 rpm.

Thanks to all the replies, as usual much appreciated.

Peter
I have a feeling that there are three different 5th gear ratios available. If you research it you'll solve at least that problem at minimal cost. On the subject of rpm: I cruise at 65mph in my 2.8jtd Hymer. At that speed the engine is turning at 3200rpm in 5th.
 

Jaws

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On our previous van fitted with the 2.8JTD lump, we pulled 2000 rpm at 52mph.. Canna remember any other speed/rpm ratio as that is the speed we sat at most of the time..
But that equates to 2300 rpm at 60

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Badknee

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I have a feeling that there are three different 5th gear ratios available. If you research it you'll solve at least that problem at minimal cost. On the subject of rpm: I cruise at 65mph in my 2.8jtd Hymer. At that speed the engine is turning at 3200rpm in 5th.
:Eeek::Eeek::Eeek:
3200rpm? Is that a sausage finger moment you had there Tony? Ours is 2200rpm (n)
 

Geo

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Hymer had a special 5th gear ratio made specificly for Hymer conversions
Chassis No to Esanjay in Poole. will resolve your problem
he will ask questions like what revs are you cruising at in 5th at 60 etc
he will do that to try and confirm you "still have" the original 5th gear or have the alternative presently fitted
Two main variants one best suited for towing and one best suited for lower RPM cruising sounds to me like you have the cruising gear fitted
costs circ ÂŁ500 +vat from the last one we did inc new gears
Geo
 
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It was a question more in hope than anything else. Didn't really think it could be done but worth asking the question. The 5th gear problem is most prominent when towing. The engine has the power to pull the vehicle along but as we know the 5th gear is an 'add-on' and quite weak and ultimately breaks. Already done one in first year of ownership. Don't like revving the engine to anymore than 3000 rpm in 4th and that is what you have to do otherwise when you drop it into fifth it drops to under 2000 rpm.

Thanks to all the replies, as usual much appreciated.

Peter
3000rpm in 4th, is that just on hills or won't it pull 5th on the level? All gearboxes up to 2006 have the "bolt on" 5th gear, modified a bit in 2002 when reverse changed to left and forward as opposed to right and back (if you know what I mean).

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Last edited:
Aug 6, 2013
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:Eeek::Eeek::Eeek:
3200rpm? Is that a sausage finger moment you had there Tony? Ours is 2200rpm (n)
Nope - that's what it's doing. The speed is satnav because the van thinks that at 65 I'm doing 72. I tow a Smartie on a trailer and as you can imagine I never need to change down on the motorway.
 
Aug 6, 2013
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Hymer had a special 5th gear ratio made specificly for Hymer conversions
Chassis No to Esanjay in Poole. will resolve your problem
he will ask questions like what revs are you cruising at in 5th at 60 etc
he will do that to try and confirm you "still have" the original 5th gear or have the alternative presently fitted
Two main variants one best suited for towing and one best suited for lower RPM cruising sounds to me like you have the cruising gear fitted
costs circ ÂŁ500 +vat from the last one we did inc new gears
Geo
I think I have the towing version fitted! To make matters worse Hymer fit 15" wheels (it's a Maxi chassis so should have 16" - which I'm considering fitting now the tyres need changing).
 

Jaws

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Nope - that's what it's doing. The speed is satnav because the van thinks that at 65 I'm doing 72. I tow a Smartie on a trailer and as you can imagine I never need to change down on the motorway.
In that caseyou def do not have a standard ratio.. Someone must have changed it post manufacture..

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Jaws

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Just had a VERY rough work out.. even changing 16" wheels down to 15" would only give about a 1/4 of that error..
 

Forestboy

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@reynardracer

My Hymer is a 2002 2.8 jtd 5000 kgs gross but running at 4800 kgs 7.5 metre tag axle on 16" tyres.
Cruising at 2200 revs is between 58mph and 60 mph depending on terrain and returns 24mpg never go over 3000 revs usually change up just as it approaches 3000.
Had to replace 5th gear this year at 65000 miles.
Mechanically it's only real weakness is the ridiculously small clutch.
Spent a few thousand on it this year doing some refurb work as it was cheaper than replacing, especially as we couldn't find anything even half as good.
(y)(y)
 

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