I have a 1992 Fiat Dance 903 5 speed. I have two questions here;

A few months ago i ventured to top up the gearbox oil level up. I managed to undo the plug and I expected to have to top up a little oil since it is a closed system. I was surprised to have to top it up significantly before the level was clearly visible and oil was oozing out. I guess the oil had not been topped up before but I was surprised to see how much oil I had to pour in. (no sign of any leak) Any advice/diagnosis? If I wish to drain the gearbox oil and replace it what volume should I expect to drain/refill it with?

2) At high revs and at low speeds the car is less responsive and I think the clutch is slipping. Without replacing the clutch can I do anything to further diagnose/fix this problem? How easy is it/expensive to replace the clutch?

I am still looking for a second hand replacement Windscreen in the London area.

Thanks

The gearbox holds a bit over 2 litres - it depends how empty it was, as you can only get so much out through the drain plug, and a bit more if you change the driveshaft boots.
I think the maximum is approaching 2.4 litres.

A common cause of oil loss is the drive shaft boots splitting - you loose nearly all the oil over a period of weeks or days, then the gearbox breaks due to lack of lube.

It's possible your clutch slip and oil loss are related problems - if you've got oil contamination on the clutch.


First, see if you can get someone to press the pedal for you while you watch to see if the actuating arm travels fully - you might have a frayed clutch cable which isn't letting the clutch engage fully.

Then check the adjustment of the clutch:
"Haynes" says pedal depression is 127mm plus or minus 5mm
"Porter" says clutch pedal is 8 to 12 mm lower than the brake pedal
take your pick - adjustment is at the end of the cable, gearbox end.

Then find a quiet flat bit of road with a 40 limit or greater, do a steady 40 in 4th gear, accelerate, dip the clutch a bit and then bring the clutch back up again sharply - see if the engine speed comes back down.
If the engine continues to race with the clutch pedal back up, you have clutch slip.

I couldn't say how long it takes to do the clutch, as I've not done one yet.
But taking the gearbox out while dismantling a Panda took me while on my own (with a hired hoist).
The gearbox is quite heavy, and there are some 10mm bolts at the bottom which don't look like they need to undo - but they do.

A comfortable days job for two, with suitable tools, I'd guess.
Do the inboard boots while you're there.

Anyone done this lately, and know the going price for a clutch kit??

I know that you are currently 'focused' on the clutch and gearbox;
but have you totally eliminated the carb and timing as sources ?