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Old 06-03-2010   #1
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57 reg xlwb brake/clutch problem

Hi, I have got a 57 plate xlwb ducato maxi and a few weeks ago I lost all pressure in the clutch pedal. After taking it to the dealers(waste of time, but that's another story) I had it repaired at a local garage. They replaced the full clutch and the cylinder that is inside the gear box and I thought that my problems were solved. However a week later the clutch pedal started to sink to the floor on its own when I was applying the brakes and I was having to pop it back up by putting my foot underneath the pedal and manually flicking it up. The garage then replaced the cylinder behind the clutch pedal in the cab and lo and behold 5 days later the clutch is sinking to the floor when pressing the brake pedal!! I am not leaking brake fluid and the brakes have been re-bled and I am now at a total loss as to what to do. I have just started my own business and this van is my livelihood, any help here would be very much appreciated.

By the way, the van has only covered a touch over 24,000 miles!!!
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Last edited by odinjay; 06-03-2010 at 20:57.
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Old 07-03-2010   #2
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Re: 57 reg xlwb brake/clutch problem

what's a 57 reg mean ?
can't help unless you define the model exactly
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Old 07-03-2010   #3
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Re: 57 reg xlwb brake/clutch problem

It is the DUCATO 35 MAXI 120M-J LWB!! 2,287cc

Hope you can shed some light for me
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Last edited by odinjay; 07-03-2010 at 12:10.
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Old 07-03-2010   #4
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Re: 57 reg xlwb brake/clutch problem

Quote Originally Posted by odinjay View Post
It is the DUCATO 35 MAXI 120M-J LWB!! 2,287cc

Hope you can shed some light for me
2007 year X250 Lebesset mate.
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Old 08-03-2010   #5
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Re: 57 reg xlwb brake/clutch problem

Can only be a hydraulic issue really
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Old 08-03-2010   #6
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Re: 57 reg xlwb brake/clutch problem

Well whatever it is it seems to have got the mechanics at my local garage completely stumped. I have found another Fiat dealer nearby though and have taken it there today and left it with them. They also say that it is something that they have never come across before so I can only hope that they find something. It even pulls the clutch pedal down when you brake and it's not in gear! I tried it going down hill approaching traffic lights.
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Old 08-03-2010   #7
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Re: 57 reg xlwb brake/clutch problem

I guess it could be a crazy pedal box problem? lol

Let us know what they find!!
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Old 09-03-2010   #8
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Re: 57 reg xlwb brake/clutch problem

Brake and clutch are hydraulic.
Do they share the same resiovour and or casting for the master cylinders ?
If they do, logic says the problem should be in that area. Pressure being back fed thru the resovour or a casting fault in the master cyl.

Just a guess, I've hardly lifted the bonnet on mine yet so not familier with the system.
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Old 09-03-2010   #9
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Re: 57 reg xlwb brake/clutch problem

Well, the Fiat dealers phoned me to say that they are pretty sure that it's the master cylinder that's knackered! I have told them it was replaced only 5 days ago but they say it could be a faulty one so they are going to replace it and see what happens. I will update in a few days to let you know because so far everytime it has gone in to the workshop it has gone back in within 3-4 days. I shall not hold my breath!!!
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Last edited by odinjay; 09-03-2010 at 22:37.
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Old 09-03-2010   #10
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Re: 57 reg xlwb brake/clutch problem

Quote Originally Posted by odinjay View Post
Well, the Fiat dealers phoned me to say that they are pretty sure that it's the master cylinder that's knackered! I have told them it was replaced only 5 days ago but they say it could be a faulty one so they are going to replace it and see what happens. I will update in a few days to let you know because so far everytime it has gone in to the workshop it has gone back in within 3-4 days. I shall not hold my breath!!!
The clutch master cylinder is connected to the brake vacuum servo so could be the problem. Maybe they replaced the cylinder without replacing the servo previously. Though they are only available as a unit from fiat I think.

The vacuum is to assist with depressing the clutch pedal so if your clutch master cylinder was faulty maybe the vacuum would be enough to depress the pedal. Maybe with air in the clutch system the pedal would be soft enough for the vacuum to depress it.
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Old 11-03-2010   #11
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Re: 57 reg xlwb brake/clutch problem

Corkman, are you saying the brakes and clutch are servo assisted ?
Never seen this before but sounds like a smart idea.
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Old 22-03-2010   #12
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Re: 57 reg xlwb brake/clutch problem

Well it has been over a week now since I got the van back and I'm pleased to say that there has been no bother with it as yet!!!
The mechanics at the main dealer were all scratching their heads and eventually came to the conclusion that the master cylinder that I had just had replaced was a faulty one. They say that they will give me a refund on the faulty cylinder as it was bought from them but I would still have to pay for labour. So at the moment all is well and once again it is a pleasure to drive and is allowing me to work away without worrying about it.

The main dealer that i took it was NORTHERN COMMERCIALS in Brighouse if any of you need to know. and they are open 24 hours for dropping off your vehicles.
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Old 11-04-2010   #13
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Re: 57 reg xlwb brake/clutch problem

What did they charge you for the labour out of interest?
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Old 10-08-2010   #14
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Re: 57 reg xlwb brake/clutch problem

Guys New here so I will be very brief our works van has had the vey same problem as stated above with the clutch pedal sinking to floor the dealer has said this to be a sevo problem and not covered by the warranty its a 57 plate also a Ducato pre registered 29 sept 07 but bought on july 2008 so are they correct saying its not covered
Regards Derek
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Old 10-08-2010   #15
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Re: 57 reg xlwb brake/clutch problem

I should also say that only two weeks ago it had a service which required the front brake pads replaced and it never felt 100% afterwards I have been on holiday for a week after the service so hadnt been used for that time could this have something to do with it .
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