Hi All
Interested in your experience of this and the pitfalls to watch out for.
I had a Peugeot Expert which was a real nightmare getting parts for, I ordered stuff online and it was all the wrong stuff,Aux belt etc, in the end after I had returned the the parts I was no better off, that going down to the local auto factors and buying there.
Guy was talking about three notches on the head gasket as I would have to get the head off first to work out which head gasket I'll be ordering.

All this for the 2.0 turbo engine.
Clutch 3 piece £76 (41-105)
Cam belt kit inc water pump £89.98 (59-90)
head gasket set £47
head bolts £26 (67-90) (all in headgasket set inc bolts)
Aux belt £10.98

Air filter £11.98
oil filter £5.98
fuel filter £8.38
cabin filter £7.5

Brakes
pads £23
discs £57.73
drums £84
shoes £26.98
My plan of attack is to do the clutch first.
Then get the van to its mot in march.
People have been telling that the rules have changed, and it will fail on an oil leak?
The rocker cover is leaking and last time I came across this it was the head gasket. But I have no idea now to check this on a diesel engine. Last time I swapped the rocker cover gasket out first and it did not solve the problem and so I swapped out the head gasket and job done. the vehicle ran for two years with this minor leak, before I got sick of looking at it.Fiat punto 1.2

I can buy the parts cheaper on ebay, car parts are dear in Milton Keynes, when compared to Leicester or Peterborough.

I was quoted to do theses jobs.
£650 Clutch
£400 Cam belt
£1000 Head gasket

So £300 on parts sounds like a bargain. I do like bolting new bits on to my old vehicle, I also like driving around with a good idea of the general condition of the vehicle.

I bought the van to save on rental. which I worked out that I would need about £1000 worth. I paid £1000 for the van.I damaged the clutch release bear in the snow we had, trying to get out of the drive. Its worth £220-280 scrap, or about £400 on gumtree. But never normally scrap vehicles I always
Try to repair them first. But these vehicles are insanely complex, and this job scares the hell out of me. Anyway thanks for reading, climbing under my van now....

For peugeot and citroen you can signup at servicebox and check exactly the parts you need from vin number. For fiat theres eper up to 2014 or fiatdalys

Jacked it up today, put it on axle stands.
Took passage side wheel off.
Got air box out pushed electrics back.
I have bought an engine support beam, but at the minute I cannot see how I can fit it. I am worried at the minute about supporting the engine on the sump as its a heavy engine and my sump is alloy. I would not a second though about putting my 2 ton jack with a block of wood, if the sump was steel.
I'm going to make a solid flat block the same size as the sump and hopefully this will do the job of supporting the engine without breaking the sump.

I took the starter off, Clutch hydraulic Slave Cylinder off.
Have discovered a nasty, the metal tube to the slave has been routed though a metal bracket which has been rubbing and slowly cutting the brake line in half.

The CLUTCH RELEASE FORK is wobbling around in the bell housing, so its looking like the casing in the bell housing has failed. But I will not know this until I pull the gearbox off.

I replaced a clutch on a 1989 Talbot and my recollection is that I jacked the engine up on the gearbox (obviously before removing bellhousing bolts) in order to raise and support the nearside of engine; I didn't remove the offside mounting and used a piece of timber and rope to support the engine rather than the proper equipment however the Talbot did have a conveniently placed bulkhead ledge normally used for supporting the spare wheel.

The job was *eventually* successful but the memorable difficulties were removing and refitting driveshafts and pulling the gearbox in the last inch or so; this probably due to a slightly misaligned pressure plate, and yes I used a made-up tool for this as well

Good luck!

For my reference

See previous posts
https://www.fiatforum.com/ducato/174...e-bearing.html

https://www.fiatforum.com/ducato/189...-54-plate.html

I've done a few clutch in my time, like you do...
Sometimes they just pop on and sometimes they are a complete pig.
In Both instances I've used a clutch centering tool. When I first did a clutch It was eyed in.
Usually the sumps have been made of steel which where supported with a block of wood and a trolley jack.This method allows you to move the engine around during gearbox installation. But unfortunately my sump is alloy. So I purchased and engine support beam, which is designed to support the engine from the top of the engine bay. I just cannot see how I am going to use this kit as my front end is very sharp and theirs lots of expense components blocking me from using the engine support beam. I have been looking at the under chassis type aswell.
Normally I would just take the lot out but I've lost my workshop. So I am doing this on my parking bay. I've built a little temp garage, constructed from cls, Bolt Down Post Shoe x2, tarpaulin sheet and screws / washers to secure it all together . I fixed the Bolt Down Post Shoes with red raw plugs and screws washer. Fixed the top to the roof rack, so it super secure and keeps the weather off me .
So van is on axle stands leveled off and gearbox is loose waiting for me to decide how I will support the engine when the gearbox is removed.
So I scratching my head on this one at the minute and would like your wisdom, on the matter.

just a thought as I have never done this job !! why not drop the sump if you can and then support the engine by means of the solid engine block base. just an idea and oh !!! yes you can stop laughing now.

Yes, would be a good idea in theory.But in practise?
I'd have to make a base strong enough to do the job.
Then its outside and theirs a risk of water and dirt getting into the engine.
Changing the clutch is enough work on its own without adding more work to the equation.
I'm going to try and use the engine support beam, as I first planned.
If I can get it to work it will be cool. But I'm taking the risk that someone might remove from the vehicle while I'm at work or at night etc.
I been buying 1/2 inch sockets to replace the stuff 'missing or wrecked after my 750 cooling system bust, drowning the socket set sitting under neath it.

Had to replace the Right Tie Track Rod End as the nut was sized on. and the threaded rod broke. after I had hack sawed it off did I discover the Allen key slot at the top.:yuck: I've been working in the evenings and the track rod is pointing downwards so difficult to see unless you know its there.
Thought easy I order a new one on ebay.. They are asking for the OEM number of the part?:bang:
If my reg number not good enough? I'm afraid that deal is screwed.

I will have to do this the old fashioned way take it off and take it to the auto factors

Took half day yesterday, undid the final bolts holding the gearbox on, took two hours just to get the turbo pipes off!
When it stops raining I will be back out there, got to check that I got all the gearbox bolts before attacking...

Re: Buying parts "clutch up date"

Checked the gearbox for bolts and job done so I started easing it off and the Gearbox fell off... I had made a gearbox support for the 3 ton trolley jack, so that broke the fall.
One of the Tx bolts holding the clutch housing twisted up , so I managed to break the clutch housing off and get the mole grips on it twist it off.
The clutch plate looks brand new, (measured it and its 230mm), as did the clutch housing. Doh
The clutch release bearing was toast, the clutch housing metal tabs are damaged, release fork has wear. CLUTCH GUIDE is destroyed .
I think I need to replace the seal on the lay shaft the keeps the oil in the gearbox off the clutch as I have an oil leak.
Managed to check the reverse switch in the gearbox as well. Removed it and plugged it in and tested it, seems to be shot as well. Will test it at work tomorrow with a multi meter.
I noticed that the turbo has been leaking a little oil so will have to remove this and replace the gasket. Has any one else done this or do you just let the experts do this job? I have a complete spare unit so maybe just easier,to swop out. But I have no idea of the condition of my spare.
Just got to these parts replaced and get it back together. So I will be bagging it all up and going down the auto parts place. Next weekend as you well know is bank holiday week...Looks like its going to rain baby rain...

Got a quote at the dealer today. Though Id have a laugh...Needed to know what parts I needed.
Clutch kit 318.37
Clutch fork 44.52
Fork ball joint 3.91
Fork ball joint shell 38.11
Guide bush 20.38
Also asked about turbo seals, they only do a few external seals..
That lot came to £434.75.
I was quoted £650 for the garage to repair the van.


I've sourced lots of the parts, that I'm interested in from various places. But I'm looking at spending about 100/150 ish depends upon the cost of the clutch. Local parts factor can supply it for £78 (three piece set).


Was thinking today maybe the oil leak on the turbo is something to do with the oil leak on the rocker case cover gasket.
But I will not know until I swop it out.

Been rummaging though my parts bin..
Oh look I've got a turbo, head lights, mirrors, One of my gumtree finds, bought a hole bunch of stuff of a guy because their was a fuel sender unit. My dash read 1/4 full when its full. I plugged the spare in and it did the same thing..But I got spares galore, pump, injectors, injector pipes, various electrical parts boxes of them, rear bumpers, you name it. Been sitting at work now for nearly a year. My NSF headlight is working fine but, the bonnet latch is broken off.My NS mirror is wobbling around on its housing (some kind foll broke it while it was parked at work) Gearbox switch is faulty,Oh and my turbo is leaking oil. So I will replace.
Just got to find the gaskets at the local auto factors and job done. The turbo is easy to get to now the gearbox is off. Also got a bucket load of bolts which is always really handy, if your me and can never find that one bolt you stored safely.

Clean the turbo off with carb cleaner and check where exactly the oil is coming from, could just be a copper washer on the banjo bolt or the return hose, check the intake hose for oil - oil could be from pcv.

Ordered the clutch tonight (Paid £76), bought other bits I needed off ebay so waiting for them.
I jumped under the van tonight and start unscrewing bolts.
It stopped raining and the sun was out???
One left on the exhaust manifold. bracket needs to be removed first.
rounded off a bolt on the exhaust joint, so will be cutting that off.
Found a guy round here remanufacturing turbos, so hoping to get the gaskets off him..juicy tenner....
I'm going to chuck my spare turbo on... Because I've got an over pressurised rocker gasket leaking oil. I need to start crossing off items off the list of potential fault's that cause this particular problem.

corcai said:

Clean the turbo off with carb cleaner and check where exactly the oil is coming from, could just be a copper washer on the banjo bolt or the return hose, check the intake hose for oil - oil could be from pcv.

Click to expand...

Their was a drip on the underneath. their is oil in the air side, other than that
its realty difficult to work out where the leak is coming from due to the location of the turbo

Have been attacking the turbo last two days..
First a 10mm nut rounded off on the exhaust spring clamp. So I had to cut it off. managed to find replacements on eBay £2.15 per bolt. Locally they want £35 for clamp set. 4 nuts between manifold and turbo housing "11mm spanner". Got three off, but one is obstructed by a bracket bolted on the exhaust manifold bolt and the back of the turbo. Think its Tx, but managed to round that one off.. got the manifold side off.. but bracket will not move.
So attacked the bracket underneath the turbo got bolts out into the engine casing. When I tried to remove the nut & bolt on the turbo rounded off.
So then I removed the manifold bolts and cant identify the to fasteners connecting the manifold to the PFi ?
So in a right old pickle at the minute, ordered a set of crowfeet spanners off ebay in the hope that I can get the last bolt off. I can get at the last manifold bolt maybe I can bend the bracket out of the way. I have tried to bend it but the engine was moving around so its a strong bracket.
Will plod on tomorrow.

Better news on the product front.
Bought an inspection lamp from Aldi for a fiver.. very like a £40 model, but its the mutts nuts.. I've chucked it, dropped it forgot it was left on.. Its tough and very bright. Its got three mods full power half power and spot lamp. Its been covered in oil washed a few times now and its been rained on a few times now. You can angle it and its got a few sets of magnets in the right places so job done, also get a handy hook. So very at getting light where you need it when your working...
I also order a maplin's solar powder battery charger, just plug it into the cig lighter and leave where it will get some sun. Even works during cloudy days, which is just as well at the minute. I'm taking so long one this job the mot has run out and the battery will be flat..so may be a good buy..