Technical 1.9td gearbox

[BessyGrandma]

Good morning. The gearbox has failed on our 1998 1.9td Ducato campervan. I know this is a major problem and parts impossible to find. So help please! Is it possible to adapt another gearbox to do the job? Or has someone found a way round this. The campervan is far too good to scrap. Any advice/ideas welcomed. Many thanks.

 

[bugsymike]

99.99 % Clutch not releasing fully
Garage should identify if this is the case very quickly.
I don't know off top of my head if clutch cable operated or hydraulic, if cable then possibly just an adjustment required or a new cable.

Is it a faulty self adjusting clutch cable if applicable?
Oil on clutch or a faulty clutch?
Hopefully your local garage will advise.
Seems very unlucky to have water ingress twice in a short time.
Not been parking at the bottom of the slipway in the harbour?

 

[BessyGrandma]

Is it a faulty self adjusting clutch cable if applicable?
Oil on clutch or a faulty clutch?
Hopefully your local garage will advise.
Seems very unlucky to have water ingress twice in a short time.
Not been parking at the bottom of the slipway in the harbour?

No but we are in an exposed area. Hopefully just clutch problem although only a few weeks old

 

[Communicator]

The clutch pedal pressure seems normal. Clutch was only fitted late November so is there another part that might produce this problem? Thanks for responding and I will certainly update the post when we eventually find the solution.

Possibly yes, but I am not familiar with the x230 mechanical clutch operation. To assist in explanation I am attaching a copy an eLearn diagram for x244 hydraulic operation - only one that I can access quickly.

Ignore the top half of the diagram with clutch pedal etc. Look at the slave cylinder (3), which pushes on the forked clutch withdrawal lever. A cable operated clutch will pull on a similar lever but from the other side. If the lever pivot pin breaks or is not in correct position it is possible that some movement of the clutch will be lost. The clutch cable is like a big bicycle brake cable with inner and outer parts which must both be correctly located.

I had a similar failure too many years ago when in Ardnamurchan Scotland, on a then twistier single track road. Extreme difficulty in changing gear. On investigating found that a linking (clevis) pin which connected a slave cylinder to a crank and release lever had broken but was still in place. Clutch movment reduced, hence problem when changing gear.

 

[porta]

If worse comes to worst and need replacement…
There are a number of specialist van breakers who test/drive before they sell
There are a few just down the road from us in Leeds/Bradford area that always have the Fiat/Peugeot/Citroen/Talbot from all eras in (and iveco)…they all advertise on eBay as well as their own sites

 

[BessyGrandma]

If worse comes to worst and need replacement…
There are a number of specialist van breakers who test/drive before they sell
There are a few just down the road from us in Leeds/Bradford area that always have the Fiat/Peugeot/Citroen/Talbot from all eras in (and iveco)…they all advertise on eBay as well as their own sites

Thanks. Do you happen to have any names please? Keep googling for Fiat breakers but no luck. Obviously asking the wrong question! We are in Northumberland so Leeds definitely within striking distance.

 

[BessyGrandma]

Possibly yes, but I am not familiar with the x230 mechanical clutch operation. To assist in explanation I am attaching a copy an eLearn diagram for x244 hydraulic operation - only one that I can access quickly.

Ignore the top half of the diagram with clutch pedal etc. Look at the slave cylinder (3), which pushes on the forked clutch withdrawal lever. A cable operated clutch will pull on a similar lever but from the other side. If the lever pivot pin breaks or is not in correct position it is possible that some movement of the clutch will be lost. The clutch cable is like a big bicycle brake cable with inner and outer parts which must both be correctly located.

I had a similar failure too many years ago when in Ardnamurchan Scotland, on a then twistier single track road. Extreme difficulty in changing gear. On investigating found that a linking (clevis) pin which connected a slave cylinder to a crank and release lever had broken but was still in place. Clutch movment reduced, hence problem when changing gear.

Thanks. If this rain ever stops (!) I’ll go and have a look for that. Really appreciate your efforts to help. Just so do not want it to be the gearbox again

 

[porta]

Thanks. Do you happen to have any names please? Keep googling for Fiat breakers but no luck. Obviously asking the wrong question! We are in Northumberland so Leeds definitely within striking distance.

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yorkshirevanbreakers.co.uk

https://a1vanbreakers.co.uk/ (in bury)
If you look on eBay, most of the recon-boxes have 12mth warranty, so I would have expected yours to be!
There is one closer to you in Newcastle where I got an o/s driveshaft for our 1998 2.8 ducato about 6 years ago, but I can’t remember the name…these are all general van breakers but stock the ‘gang of four’ Fiat based vans as, by volume, they’re the most popular if you take all the marques numbers together

 

[BessyGrandma]

High Quality Used Van Parts & Spares | Yorkshire Van Breakers Ltd

Yorkshire Van Breakers supply high quality used van parts and spares with next day delivery available across the UK.

yorkshirevanbreakers.co.uk

https://a1vanbreakers.co.uk/ (in bury)
If you look on eBay, most of the recon-boxes have 12mth warranty, so I would have expected yours to be!
There is one closer to you in Newcastle where I got an o/s driveshaft for our 1998 2.8 ducato about 6 years ago, but I can’t remember the name…these are all general van breakers but stock the ‘gang of four’ Fiat based vans as, by volume, they’re the most popular if you take all the marques numbers together

Thanks. Yes the gearbox does have 12 months guarantee- except in the case of water damage. Which is my fear. Nothing to be done until next week but just wondered what the alternative would be if it is that. This particular gearbox is just about impossible to repair now - no parts. But appreciate your response and it is certainly a route we will explore if the worst happens. Thanks.

 

[porta]

If water has got in in a such a short space of time I’d be more inclined to think bad firmest! Considering that there are reconditioned and rebuilt gearboxes for sale then someone is obviously able to get the bits from somewhere…like a lot of things, brexit hasn’t helped, but there’s always the ‘sharp intake of breath’ that is a precursor to ‘ain’t seen one of those in a while, I doubt we can get the bits’ when, for some oldies at least, there are plenty of bits but many who would like to profit from ‘alleged’ scarcity