Ducato 2.5T slipping clutch (1 Viewer)

[gavzz]

Hi all, never done a forum before but hoping I might get some help with what seems a major problem!

We have recently bought a 93 Hymer B694 with a Ducato 2.5T and have had a string of clutch problems and are now desperate to find the solution before heading off to Europe and hopefully Morocco. This may be a bit lengthy and I apologise in advance but shows why we need help!

A new clutch was fitted before heading to Scotland, after 150 miles it broke down with severe slipping. RAC garage said it had wrong clutch cable and couldn't fix it as they couldn't source a L/H drive cable. I sourced one from Coastal Motorhomes and garage who fitted clutch replaced cable and told me to test the clutch to see if everything was working OK as clutch was new and perhaps didn't need replacing again so soon.

Tested it on a few short day trips then headed off to Scotland again. It broke down AGAIN in Northumberland with same slipping problem. Second RAC garage discovered the clutch had an LUT friction plate fitted with a Galeo pressure plate and guessed this may have been the problem. They fitted a complete LUT clutch kit and gave me a 12 month guarantee.

Thought that was problem solved, however, while we completed our tour of Scotland the clutch still had a tendency to slip in 4th gear at high revs or in 5th gear again at high revs. We encountered several very steep hills (15 and 16%) and I thought it was bound to fail but made it every time with no slip at all, albeit in 1st gear and 5mph! The clutch also seems to burn a bit when setting off in first gear and shudders as it fully engages. It also shudders sometimes when in a higher gear and under load going up a hill.

The engine seems to have plenty of pull despite its 150k miles but the clutch seems to be the weak link and has an effect on travelling speed. A hill will bring it to a crawl very quickly with the tendency to slip even though there seems to be a reserve of power, I have to change down into fourth or even third to get up any long slope and speed drops down to 35 or even 30 mph which on a motorway feels positively dangerous!

So my questions to anyone still awake after reading all this are:

Is it possible to get an uprated clutch (bearing in mind the gross weight of around 5 tonnes) and who might be able to do it?

Could it be a flywheel problem?

Should I get a new engine and gearbox fitted as the original garage recommended (he suggested swapping Fiat engine with a Transit 2.4T - is that even possible??? sounds off the wall to me)

Is a Fiat dealer my best option?

Should I cut my losses and sell it?

Any advice gratefully welcomed.

Thanks!

 

[Barclaybasher]

I have a !991 Eriba with a 2.5 non turbo diesel and the engine pulls great - but my van weighs 3 tonnes

My previous van a 2004 Burstner 3.5t had a 2.8 turbo diesel - again well matched power to weight

2.5 non turbo pulling 5 tonnes? - It's asking a lot

Hopefully someone with a similar van will give an opinion - good luck anyway

 

[tonyidle]

Check the surface of the flywheel for blued patches and overall 'flatness'. A problem with either will cause judder. The amount of slip you are experiencing suggests maladjustment - can you move the clutch operating arm (under the bell housing) back and forth by hand a small amount? Adjustment is made in the same location using the nut(s) on the cable outer. Bear in mind that unfortunately your clutch will require replacement again - slipping overheats the friction plate and will have carbonised the linings.

If your engine isn't burning oil and runs smoothly I wouldn't consider changing it. Similarly if the gearbox is quiet and has working synchromesh on all forward gears it's OK.

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[TheBig1]

sounds like a warped flywheel or a missing spacer reducing clutch contact area

 

[ivorantony]

if at some time the flywheel has been skimmed then the centre plate will not have the same pressure exerted on by the cover assembly which can promote slipping, also I think you mean LUK clutch kit, if you do they have a two year guarantee, so you may have some comeback their,
is the thrust bearing sliding smoothly and not sticking?

 

[gavzz]

Thank you everyone for your input, a lot of good points to note. I think I will have to find a good clutch specialist who hopefully will get to the root of the problem, fit an uprated clutch and hope the engine is good for another 150k !!

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[wigster]

No need for new engine and gearbox just find someone who knows what they are doing to fit clutch +flywheel if necessary . You will get estimates but no good mechanic will give a real price till hes cracked the gearbox off and can see whats going on . I need mine doing so if you find a good one give me a heads up

 

[gavzz]

No need for new engine and gearbox just find someone who knows what they are doing to fit clutch +flywheel if necessary . You will get estimates but no good mechanic will give a real price till hes cracked the gearbox off and can see whats going on . I need mine doing so if you find a good one give me a heads up

I think you"re right. Most garages will just replace the clutch with same spec but I think the power to weight ratio (in my case) needs looking at and uprated if necessary. 5 tonnes is a lot to pull ! I'll let you know if I find someone good and maybe if you find one first you could do the same.

I did find a clutch specialist on line called TruckFix who seem to know what they are doing but they are in W Yorkshire so a long way to go with a dodgy clutch. I'm looking for someone near London outside the emission zone.

Cheers!

 

[ivorantony]

the one problem you may encounter is the clutch diameter is usually fixed and cannot be increased easily, most Manafactures fit the largest clutch they can,
if you can source a flywheel that has been modified to take a larger clutch make sure it will fit inside the bellhousing, but that can also cause other problems with Starter motor/ clutch fork/thrust bearings and so forth, so be careful!

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[JockandRita]

@gavzz, ask local haulage or coach operators, who does their servicing and mechanical repairs.

They'll have the the proper hoists or pits to do the job properly. Commercial repairers are more geared up for the heavy jobs, than car type workshops.

HTH,

Jock.