Ducato Windscreen Scuttle Leaks

Nov 8, 2020
120
321
Harpenden
Funster No
77,551
MH
Auto Trail Comanche
Exp
1998
Hi Everyone
Thought I would do a little thread on the Fiat Ducato X250 and its windscreen scuttle leak problem, as I have been asked about it a few times. The problem is in fact THREE problems. I will go through them in turn.

1) Blocked drains in the scuttle which really is a maintenance issue. Keeping the drains clear is imperative and I know it’s a pain especially in the autumn. There are three in all. Two small ones at either end of the scuttle around the wiper spindles. They are very small and block very easily. Make sure the pipe on the back is not knocked off when you clean them as water will drip onto the back of the headlights. (Bad). If left unattended the drivers side wiper spindle will seize up. (Bad). The third hole is much larger and is easier to clean out. Located just in front of the driver next to the off side wiper. Once again make sure the drain pipe on the back does not become detached or broken.

2) Leaking at the joint of the two halves of the scuttle in the centre. This was intended to be joined with some stupid tape that always perishes. I have designed a drip catcher to overcome this problem by diverting the inevitable flow of water to a more non destructive position in front of the engine, rather than into the engine injectors. (Bad and expensive).

3) Water dripping onto the air filter casing and into the heating intake duct. This comes from the vent in the bonnet on the passenger side. The water seeps from the grilles in the bonnet down into the vent and accumulates around the rubber seal on the leading edge of the duct. This is pretty easy to deal with. Drill a hole behind where the rubber seal is, to allow the water to escape and drip onto the air filter casing. It will not harm the casing and just looks worrying, but its OK. When drilling the hole, make sure you drill it over to the right so the water doesn’t drip onto the wiring loom below. (Bad).

Hope this has been of help, as I am sure most people are unaware that there are three leaks as apposed to one. Some pictures are below hopefully giving you a visual feel to my ramblings.

Paul and Chrissy
 

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Sep 12, 2016
1,850
3,605
Chesterfield England Tellus 3
Funster No
45,091
MH
Lunar Roadstar 800
Exp
10000 miles and 300 nights in 3 years
Were you not aware this is NORMAL they all bloody leak until you fix them yourself

At least our main drain problem was easy to unblock some Walter had let a standard wine cork get stuck down the thing a piece of flexible fibreglass rod soon popped it out, the secondary drain on the nearside was a little more difficult as it's a lot smaller but a large drain syringe blasted the rubbish out
 
May 23, 2008
2,035
2,546
Near Durham City
Funster No
2,787
MH
Carthago
Exp
Since 1984
I had this problem in 1998. The manufacturers denied it was an issue then. Hey-ho and 22 years later its still with us.

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TheBig1

LIFE MEMBER
Nov 27, 2011
14,497
27,585
Dorset
Funster No
19,048
MH
A class
Exp
many many years! since I was a kid
You missed out another issue caused by the scuttle drain hose dripping onto the gearbox and seeping into the oil ruining the gearbox. Easily rectified if caught in time by fitting a longer hose to drain on the floor.

The central scuttle draining onto the top of the engine has a couple of approved fixes. An engine cover and a water diverter that fits to the 2 bolts already there
 
Dec 6, 2011
6,514
9,525
South Wales
Funster No
19,136
MH
Coach built Adria
Exp
Since 2007
the other thing to watch is even the diverted water onto the front of the engine runs down into the starter motor electrics.

i have placed a simple small butyl rubber sheet from the scuttle center point across to the slam panel takes all the water completely off the top of the engine.

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TheBig1

LIFE MEMBER
Nov 27, 2011
14,497
27,585
Dorset
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MH
A class
Exp
many many years! since I was a kid
Oh also flooded fuse and relay box on the nearside wing, which can be protected with a rubber floor mat
 
Sep 26, 2013
2,884
2,639
Market Rasen
Funster No
28,295
MH
Self Build
Exp
Since 2003
The earlier X250 did not have 3 holes as you suggest, in fact there was only one and there are quite a few posts on how to put in the extra ones at each end. The solution to the leak on the centre of the two piece scuttle is to reseal it using Sika 512 or similar.
 
OP
PaulandChrissy
Nov 8, 2020
120
321
Harpenden
Funster No
77,551
MH
Auto Trail Comanche
Exp
1998
Were you not aware this is NORMAL they all bloody leak until you fix them yourself

At least our main drain problem was easy to unblock some Walter had let a standard wine cork get stuck down the thing a piece of flexible fibreglass rod soon popped it out, the secondary drain on the nearside was a little more difficult as it's a lot smaller but a large drain syringe blasted the rubbish out
We know it’s normal, that’s why I was trying to help people that are not in the no. It may be normal, but it doesn’t make it acceptable. 😊

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Sep 12, 2016
1,850
3,605
Chesterfield England Tellus 3
Funster No
45,091
MH
Lunar Roadstar 800
Exp
10000 miles and 300 nights in 3 years
We know it’s normal, that’s why I was trying to help people that are not in the no. It may be normal, but it doesn’t make it acceptable. 😊

The problem is the scuttle is a multipart item and the twisting of the chassis causes the part to separate over time but also it's poorly designed with parts sticking up on the drain side can be fixed but takes a lot of doing
 
OP
PaulandChrissy
Nov 8, 2020
120
321
Harpenden
Funster No
77,551
MH
Auto Trail Comanche
Exp
1998
Thanks for this. You mentioned X250. How much is still applicable to the X290?
Not sure about X290. The problem vans were the ones with 2 minute drains on the left and right. The newer versions have 3 healthy sized drains that work much better.

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Sep 16, 2010
2,649
2,240
Bungay Suffolk
Funster No
13,734
MH
C Class
Exp
Since 2010
Ref the small drain holes each side, I drilled the holes big enough to accept a nozzle from the sort of tubes of silicon or decorators filler.
I pushed them down each hole and sealed the tops. Then pushed some garden hose up from underneath onto the 2 nozzles and led the hoses down into the wheel arch area.
Job done.
Mitch.
 
OP
PaulandChrissy
Nov 8, 2020
120
321
Harpenden
Funster No
77,551
MH
Auto Trail Comanche
Exp
1998
And here is the solution
View attachment 441561
A Polar thermal windscreen cover by Minster.
Available for Ducatto's, Sprinters, etc.
If you get the 'long' version it covers the scuttle and the vents.
I’ve got one of those. It works a treat. 👍

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Feb 18, 2017
975
2,046
Greenwich, London, UK
Funster No
47,382
MH
Hymer MLT 570
Exp
1986
I’ve got one of those. It works a treat. 👍
So have I.

For those looking to clear out the drain holes manually, the solution I found was XL Pipe Cleaners.
Available in any craft or hobby shop, they are like conventional pipe cleaners (bits of coated wire for cleaning tobacco pipes), but a lot bigger
 
Sep 9, 2019
223
617
Runcorn
Funster No
63,956
MH
Autotrail Apache 632
Exp
Since Sept 2019
Take a tip from the MX5 owners club crew, all MX5’s get blocked drain holes for the soft top. Long ago in a galaxy far from here someone discovered the ideal fix for this..... wait for it...... wait for it...... A trombone cleaning brush! It’s absolutely perfect for the job!

Here’s one from Amazon.....

Cheers! Russ

FA4D68CA-781D-485C-A369-F774E0647FCC.jpeg
 
Last edited:
May 15, 2008
5,636
10,737
Europe
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PVC
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30+ inc camping & caravan
Jan 8, 2013
4,835
5,776
Dronfield - Derbyshire
Funster No
24,202
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Burstner Lyseo 690G
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Happy FLT since 2011
Water dripping onto the air filter casing and into the heating intake duct. This comes from the vent in the bonnet on the passenger side. The water seeps from the grilles in the bonnet down into the vent and accumulates around the rubber seal on the leading edge of the duct.

Its not a problem. It might look bad but that water will run into the bottom of the plastic box and drain away under the van.

A Polar thermal windscreen cover by Minster.
Available for Ducatto's, Sprinters, etc.
If you get the 'long' version it covers the scuttle and the vents.

I'm not happy with the long windscreen covers that covers that vent - its needed to allow fresh air into the van to keep it aired
 
OP
PaulandChrissy
Nov 8, 2020
120
321
Harpenden
Funster No
77,551
MH
Auto Trail Comanche
Exp
1998
Its not a problem. It might look bad but that water will run into the bottom of the plastic box and drain away under the van.



I'm not happy with the long windscreen covers that covers that vent - its needed to allow fresh air into the van to keep it aired
Hi
im trying to develop a grill cover that will stop, or at least greatly reduce the water coming in through the vent while still allowing ventilation. Working on it at the moment. It will be 3D printed in either ABS or ASA plastic.

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Jan 27, 2018
585
501
Northampton
Funster No
52,151
MH
Rapido & Bongone
Take a tip from the MX5 owners club crew, all MX5’s get blocked drain holes for the soft top. Long ago in a galaxy far from here someone discovered the ideal fix for this..... wait for it...... wait for it...... A trombone cleaning brush! It’s absolutely perfect for the job!

Here’s one from Amazon.....

Cheers! Russ

View attachment 452851
As a bongo owner i got a trombone brush. Used for leaf detritus in scuttle and wing gaps. Then used wide cable ties to jiggle up and down the drainipe whist travelling.

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