Fiat Ducato 2.5 5th gear Lubrication Tip

Tootles

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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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Tootles

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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.
 
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Tootles

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PP Bear

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

Snowbird

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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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Tootles

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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.

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

pappajohn

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Mine has John, even though it is a bitch to find. I thought they all had them.
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.
 
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service2.jpg
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


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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Snowbird

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

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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Tootles

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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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pappajohn

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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.
Or fit the upgraded scuttle drain tube.
 

dave newell

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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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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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Tootles

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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.

There you go!! I'm not totally useless after all!! (y)(y)
 

ArcticKris

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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
 

Vespita

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Hallo

Just did the some on my Ducato from 1992, before something more serious hapandes.

Many thanks from the tips that I learned and I special thanks to Tootles
Thank You.

CxH4Tsx.jpg


iedE3I7.jpg


wAsQ4Lf.jpg


Here with the oil

hsEHNj4.jpg


I aplied regural mineral 80w90 and put an adictive to help the changing the gears from STP. Here were I live in Portugal didn´t find a syntetic 80w90 oil.

TEtFs90.jpg


xofvxzk.jpg


Best regards
 
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Can anyone say for sure whether the 2.8JTD (2006) 5 speed, has a dipstick please?
If the answer is..no,I will try to top up through the reverse gear switch,but haven't got a clue where that is.......help please!
Thanks.

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Feb 21, 2016
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Do these pictures help.

Fill up through the breather on the 2.8JTD.

Also look on YouTube as lots of help there too:)
View attachment 187768 View attachment 187769 View attachment 187770 View attachment 187771
Great help,thanks PP Bear,I'll take a look in the morning.Never really understand it when gearboxes are "filled for life" seems a silly thing to me,but then I'm from the time when you changed the engine oil every 3000 miles,as well,as the gearbox and rear axle regularly.
I'll take a look at that new fangled U tube thingy too!
Thanks again.

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dave newell

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Can anyone say for sure whether the 2.8JTD (2006) 5 speed, has a dipstick please?
If the answer is..no,I will try to top up through the reverse gear switch,but haven't got a clue where that is.......help please!
Thanks.
Podney, by 2006 the gearbox was totally different to previous versions. It will not need topping up unless there is a leak, if there is a leak then that needs sorting out first.

D.
 

Emmit

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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.
Unless you own a Hobby who seemed to have an inexhaustible supply of X244 2.8's that didn't see the light of a DVLA Reg Plate until September 2007:whistle: I know, we have one.
 
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Whilst your down there...

I was advised and I think its standard policy now, to overfill the box by an extra amount as the 5th gear is (on our 2005) is only splash lubricated. For that reason I try hard not to load the 5th gear until the engine is fully up to temperature. The other thing is that the scuttle drain pipe has a habit of dumping its waste water onto the gearbox breather! and also this affects the gearchange linkage at the bottom, so this needs to be kept oily. At least thats what my very experienced van garage told me.

So far (777000m) no problems

Mike & Ann
sorry that should be only 77,000 miles!

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Oct 2, 2008
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The other thing I would highly recommend is to fill with a full synthetic oil . RED LINE OILS do all kinds of gear oils . It is not cheap but is a major improvement . Proved their oils in the extremes of Australia . I have no involvement with Red line other than as a user and also sold and installed it in Australia.
 
Nov 18, 2011
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To fill my gear box I filled it through the reverse switch
I used a pressure brake bleeder to pump the gear oil in this is a old one I use just for that job it works well
Bill
 

Silas

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Can I just be clear about this, you are putting less oil in the gearbox?

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