Fiat E350 BESSACARR GEARBOX ISSUES

[Paul Chubb]

Hi All,

In need of help if possible please, I have a fiat Ducatto 10 E350 BESSACARR motorhome (2002), the issue is due to water ingress into the gearbox from the front windscreen scutter panel.
I have been given a price of £2500 - £3K to repair the existing gearbox with new internal parts and clutch etc, but have been advised to get the water issue beforehand as it will only have the same problem again if not resolved.
Looking under the bonnet below the windscreen scutter panel there is a pipe that has detached and the reason being is that the hole that held the pipe in originally has rusted out and now far to big for it to fit back in etc.
I am by no means a mechanic and would like some advise on how to sort this out before I spending a lot of money out on the gearbox refurb.?
Many thanks in advance for any suggestions
Paul.

 

[Figaro]

I think you just need to fabricate something that will carry the water off the scuttle and down past the engine to drain underneath.
I don't think it matters much how it's done.

 

[Captain Yoghurtpot]

Just a quick question on the gearbox issue.
Is the problem on gears two and three " crunching" on selection, and difficult to change down from 3 to 2, with occasional difficulty engaging 1st gear?
Asking because I have had this problem on a 2000/2001 fiat gearbox, have had it refurbished and a new clutch fitted, and it's still not much better and still can crunch.
Water ingress was a potential factor of cause, but the biggest issue was sourcing synchro gears for a gearbox which is obsolete now.
If this is relevant, please check if parts are available, as said, fiat do not have parts for these.
If not relevant, please ignore me.
But, £2500 to £3000 is a lot of pennies IF parts are not available for that age of gearbox.

 

[Paul Chubb]

Just a quick question on the gearbox issue.
Is the problem on gears two and three " crunching" on selection, and difficult to change down from 3 to 2, with occasional difficulty engaging 1st gear?
Asking because I have had this problem on a 2000/2001 fiat gearbox, have had it refurbished and a new clutch fitted, and it's still not much better and still can crunch.
Water ingress was a potential factor of cause, but the biggest issue was sourcing synchro gears for a gearbox which is obsolete now.
If this is relevant, please check if parts are available, as said, fiat do not have parts for these.
If not relevant, please ignore me.
But, £2500 to £3000 is a lot of pennies IF parts are not available for that age of gearbox.

Hi Cptn
You’ve pretty well hit the nail on the head with the gearbox issue on my 2002 model
I have sourced a local gearbox specialist that has managed to get hold of parts from Italy (been waiting over 3months)
The cost is made up of £1500 to refurbish the gearbox £400 to remove and replace then new clutch complete £200 +oil+ the dreaded VAT !
What was the outcome for you in the end please ?
Regards
Paul

 

[Captain Yoghurtpot]

Not as much as that in price, but.............
Had to " import" a 2nd gear from Germany after an extensive search with fiat UK for parts, of which only 1 European stockist could be found with parts needed due to gearboxes of this ilk being obsolete.
Managed to track down syncro gears from Coastal Motorhomes in the UK that were needed, and then motorhome went to one specialist garage who could fit the motorhome in due to its height, who removed gearbox and then it went to a specialist for repair, and was returned back to the garage to refit, along with a new clutch.
All told about 3 weeks from start to finish and gearbox was smooth.
Then after about 6 months, same problem returned, but less severe.
I now drive it extra carefully, and can overcome the crunching to a minimum in 2nd and 3rd, and 4th and 5th are excellent.
Have resigned myself to the fact that , after much searching, there just are no parts available now for MY make and model of gearbox, but yours may well be a different story and model variation.
My consideration is to replace my 1.9td engine with a 2.3td engine and gearbox combination ( but used and working and probably of a higher mileage than my current engine) of a newer model that will comparably fit from a reputable supplier, and the cost is coming in sub £1500, but I have to be ABSOLUTELY sure the new " doner" parts will fit, and I am still checking this.
The age of the motorhome is such that I am reluctant to spend too much, as there comes a point where it is uneconomical, and If I sell it, with this known fault/ quirk, it will still sell.
And I can still drive it, albeit carefully.

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[CAB96]

I think PaulandChrissy 3d print a solution.

 

[PaulandChrissy]

I think PaulandChrissy 3d print a solution.

My Ducato drain kits are for 2006on, but if I can be supplied with pictures and dimensions I can make any design pipe outlets needed. If anyone lives in the North Hertfordshire area with this age van, I can come and measure up to make something suitable.
PaulandChrissy

 

[headlight]

I just cable tied my scuttle drain pipe out of the way so that it doesn't drip on the gearbox on my 2006 Ducato.