Register Login
endrop - for all your online needs
Reply
 
Thread Tools Search this Thread
Old 24-02-2008   #1
Join Date: Feb 2008
Posts: 2
Thanks: 0
Trader Rating: 0
Walkthough: Ducato 2.0 Hdi Gearbox Removal & Clutch Change

Here we go if this helps everyone, just done this today and what a tw@t of a job!!! Thanks for Torq's instructions on here were almost correct for the HDI 2.0, heres my amendments. Hope they help anyone.

1. Jack up van and remove passenger side wheel, Put van on axle stands, but under body not axle.

2. Remove air filter lid and filter, then remove bolts inside the filter to remove filter box.

3. Jack up gearbox side, remove nut that holds gearbox end mount to chassis, it's near the air filter.

4. Strip down turbo pipes and remove diesel pipes. Undo fuse box and lift out the way to the inner wing.

5. Jack up engine slightly and support with concrete blocks and a bit of timber.

6. Drain gearbox oil, lever off gear change cables (half ball joints pop off), disconnect speedo drive and reversing switch. Unbolt brackets holding gear change cables.

5. Remove starter, crawl under van and remove rear gearbox mount. I had to remove the rear main box mount and the bracket onto the gearbox to get it to slide back.

7. On passenger side suspension, remove 4 bolts that secure the bottom ball joint, you may need to turn the wheel to get at the bolts. Remove the steering rack bolt too.

8. The hub will now pull the driveshaft out of the gearbox on the passenger side whilst being bolted into the hub so you don't have to strip out disc and pads. Put something around the end of the shaft to protect it.

9. Support gearbox and remove 4 nuts and bolts that hold gearbox end mount and lift out mount. You have to remove the entire mount of the engine otherwise there is no clearange.

10. Remove the 8 to 10 bolts that hold the box to the engine. You will have to remove a plastic covering at the bottom of the flywheel with 2 allen keys. There are 2 bolts behind there.

Once they are all out lever the gearbox off the engine, it will free from the clutch and the drivers side inner cv joint.

11. Drag it out from under the van and say donald duck that was a right pain in the neck!

Putting it back in is just the reverse procedure. It's also a good time to check track rod ends, cv joints and ball joints.

Slightly different to the 2.8 but not too much! Hope that helps anyone. Cheers to Torq for the initial guidelines
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

AceeJon is offline Reply With Quote Quote 
Old 24-02-2008   #2
Forum Moderator
 
T14086's Avatar
Join Date: Sep 2004
Location: Preston
Posts: 29,985
Thanks: 1066
Trader Rating: 0
T14086 has donated!
United Kingdom 
Re: Walkthough: Ducato 2.0 Hdi Gearbox Removal & Clutch Change

dont suppose you took any pics so can make it into a guide?
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

T14086 is offline Reply With Quote Quote 
Old 24-02-2008   #3
Join Date: Feb 2008
Posts: 2
Thanks: 0
Trader Rating: 0
Re: Walkthough: Ducato 2.0 Hdi Gearbox Removal & Clutch Change

Yeah got a few Will do.
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

AceeJon is offline Reply With Quote Quote 
Old 24-02-2008   #4
Forum Moderator
 
T14086's Avatar
Join Date: Sep 2004
Location: Preston
Posts: 29,985
Thanks: 1066
Trader Rating: 0
T14086 has donated!
United Kingdom 
Re: Walkthough: Ducato 2.0 Hdi Gearbox Removal & Clutch Change

Excellent good stuff:

This will be of help;

https://www.fiatforum.com/guides/435...e-new-how.html
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

T14086 is offline Reply With Quote Quote 
Reply
Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump
Similar Threads
Thread Thread Starter Forum Replies Last Post
(T) Rear disc conversion arc Cinquecento / Seicento 206 16-08-2008 14:02
(G) 2.0 jtd 2004 gearbox oil change wanderer Ducato 3 07-10-2007 19:00
(T) marea 1.6 clutch change fionamark Marea 1 31-01-2007 21:15