Technical 2006 Ducato 2.3 manual gearbox oil change & CV boot replacement.

[Georgeducato]

Hi folks,I hope this post will help the next person who wants to change their 2.3 litre 5 speed ducato gearbox oil because when I searched this topic I found so much waffle!!
1. I bought three litres of Smith & Allen's gearbox oil in one litre bottles with pop out spouts.(ask for their own brand of Tutela 75w 80 fully sunthetic gearbox oil) £6.50 + vat per litre.
2. Drove the Ducato around to heat the gearbox oil up.
3.Drained the oil then refitted sump plug after cleaning any metal filings off the sump plug magnet.
4. Locate the speed transducer, undo the one 10mm bolt which secures it into the gearbox, unclip the multi plug and pull the transducer out. (rear of gearbox, i.e furthest away from the front bumper)
5. Refill gearbox through this hole, between 2.5 and 2.9 litrs should do it.
6. Refit transducer and job done, dead easy!
Difficult if you dont have a pit or a ramp!!
CV boot change;
1. remove wheel trim
2.slacken drive shaft nut after tapping the two lock tab parts back. You will need a breaker bar!
3. Remove road wheel.
4.Remove track rod ball joint nut & free the ball joint from where it passes through.
5. Undo the lower anti-role bar nut, washer and bush.
6.Unbolt the bottom ball joint from the hub (4 bolts).
7. Jack up the hub assembly whilst levering the wishbone down over, will lower with some resistance.
8.Push/tap the drive shaft out from inside the hub bearing.
9. move the drive shaft to one side to work on, i used a neoprene stretch boot kit to replace my split CV boot.
10. Refit and done!
*If you pull the drive shaftbout of the gearbox by even 1/4 inch you will loose some gearbox oil, hence why I decided to just drain & refill mine.
Not a novice job and you need a few tools including CV boot band crimpers to do the job correctly. Two me about 1 3/4 hours to complete!
Hope this helps!

 

[robin123]

Filling gearbox oil though transducer/speedo cable hole that's a sod to get too , have you not got a reverse switch on top , a bit of tube and funnel does the job

 

[CDK]

3 Years ago I had a wheel bearing replaced by a garage on this island. Primitive baboons, they had dropped the shaft and installed it with a large gash in the CV boot that splashed grease on the inside of the wheel and tyre.
As an emergency repair I cleaned the damaged area with acetone and glued it with Henkel flexible superglue. The van has covered almost 40 K miles since then!

 

[Georgeducato]

Filling gearbox oil though transducer/speedo cable hole that's a sod to get too , have you not got a reverse switch on top , a bit of tube and funnel does the job

I am
lucky enough to have my own inspection pit at home, so undoing one 10mm bolt and lifting the transducer out is so easy and takes no time at all and you dont spill a drop!

 

[windyjools]

Easy enough to refill the gearbox via the breather on top of the gearbox, length of tubing makes it pretty easy, no spanners or pit needed!