General Ducato 2.3 2009 clutch problem

[Jase666]

Hi all any info on my problem would be grateful
I have a ducato 2.3 multijet 2009 my problem is I keep losing pressure on my clutch pedal. I have checked around gearbox to see if slave cylinder leaking and don’t seem to be also checked all pipe work and master cylinder, no leaks but do seem to be losing small amount of fluid. The peddle slowly works it’s way down until the peddle starts to stop down, when I back bleed it it’s fine for a few miles then back to the floor. I have noticed the fluid is quite cloudy and not clear but have now replaced all fluid but no better. Also I have a slight crunch when changing to 4th gear unless I double clutch the peddle and goes in fine then !
Just need to pinpoint the problem
Please help

 

[whine0]

Common fault thrust bearing fail bet when you first did first clutch bleed the fluid was black , the seal failing in bearing causing pedal to drop, sounds like the gearbox needs a repair too 3rd and 4th synchro and new 4th gear, no kind words gonna fix it you best see how much on the money tree!

 

[rayc]

I had a problem of the clutch pedal falling to the floor whilst touring Germany. I could see no fluid leak from the combined clutch/brake reservoir.
I hand pumped the clutch pedal about 20 times and pressure restored. I then did about 100 foot depressions and the pedal was returning between presses. I then had no further problems.

 

[Jase666]

Thanx for info guys and yes whineo 1st bleed fluid was black but if fluid was leaking inside gearbox wouldn’t there be some signs like slipping clutch or fluid leaking from bottom of gearbox ?
I was thinking of changing clutch master cylinder before taking gearbox off do you think give it a try or am I wasting my money and get the box off ??*??*??*??

 

[whine0]

I see clutch release bearings fail intermittent or complete pedal drop on Ducatos we get vans recovered on back recovery trucks with no pedal yes Iv bled systems to get the pedal back but you think I’d give back to customer and see how they go with chance it fails again? NO ?iv stripped the clutch bearings down on failures there’s a black seal inside that holds the pressure ,and when fluid really black could be the seal causing fluid colour Iv changed master cylinder too to save that contaminating system but not had master cylinder fail on ducato ,am I throwing to many bits at at job ?No fix first time that’s why my repairs don’t come back if your on tight budget then different but you run the risk of failure again

 

[syldale]

hi . it sounds like the release bearing to me as well if it was me i would put a full clutch kit in while the box was out . i had clutch slip on a 2008 & when we took the clutch out the plate was like brand new ( 28000 miles only ) it was the pressure plate springs had gone weak with age its only just over half a day job for 2 people Fiat Ducato | Clutch Kits | Car Clutch Replacement Parts | Euro Car Parts

 

[Jase666]

Hi syldale did u replace clutch urself ? If so was it a easy job only asking as I been told they have a pull clutch system instead of a push system and are quite awkward
Thanx

 

[whine0]

The 244 have pull clutch and can be tricky to remove gearbox because a rod has to be removed out gearbox that connects thrust bearing lever to this rod ,they can be seized in,on the 250 versions it’s a push clutch with hydraulic thrust bearing that’s comes off without the trouble of removing this rod however the clutch pressure plate does have a worm gear inside that’s a self adjusting system and your supposed to use the correct Tool to push clutch pressure plate onto fly wheel which I use but I can guarantee most people won’t use and won’t have problem if you tighten pressure plate evenly

 

[syldale]

Hi syldale did u replace clutch urself ? If so was it a easy job only asking as I been told they have a pull clutch system instead of a push system and are quite awkward
Thanx

hi . yes i was the gofer for the fitter because its a 2 handed job & what this guy doesn't know its worth knowing by the way it was a x250 different from yours . jud

 

[Jase666]

Thanx guys
I have now changed my master cylinder as it’s the easiest option at the moment and supposed to be goin Belgium end of month so not enough time to remove box get it reconditioned and back together. Took her out for an hr last night and didn’t seem to lose alot of peddle pressure, gonna try again today ??still crunch in 4th (obviously) but can live with that till get back ?
Can anyone advise on a decent gearbox oil to help with the crunching 4th gear
Thanx

 

[syldale]

hi jase666. don't know where you are in the country but i use a top gearbox specialist
in Lincoln very reasonable . Jud

 

[Jersey Trev]

The 244 have pull clutch and can be tricky to remove gearbox because a rod has to be removed out gearbox that connects thrust bearing lever to this rod ,they can be seized in,on the 250 versions it’s a push clutch with hydraulic thrust bearing that’s comes off without the trouble of removing this rod however the clutch pressure plate does have a worm gear inside that’s a self adjusting system and your supposed to use the correct Tool to push clutch pressure plate onto fly wheel which I use but I can guarantee most people won’t use and won’t have problem if you tighten pressure plate evenly

Hi, Just joined up and saw your post. i am in a campsite in Newport Gwent. as i pulled into the site i had to stop suddenly and did not put my foot on the clutch. the motorhome stalled. when i re started the engine i went to put my foot on the clutch pedal and it had flopped down i lifted it by hand and tried again but it just went straight down with no resistance? it feels as though the linkage has failed but i cant see anything? its a 2013 fiat ducato 2.3 only miles on the clock 2700 dont know what to look for or try. any advise would be appreciated. thanks

 

[Crossingkeeper]

Whin0 will hopefully be along to advise you but from having owned the various models I can confirm that yours does not have a mechanical linkage but a hydraulic system; even worse the slave cylinder is inside the bellhousing.

The only check that you could easily make is that the clutch pedal is still connected to the master cylinder. (and that the hydraulic pipe isn't damaged)

 

[whine0]

Look under gear box at clutch side of gearbox is it wet? Showing any signs that thrust bearing leaking you will see a wet patch at bottom of gearbox at the back where the clutch fluid weeps out bell housing and collects