Technical Ducato motor home 1.9td 5 speed gearbox info please Year 2000

[Rodney 2000]

Speedo drive shaft bolt worked loose and the cable popped out on a recent trip. Lots of gear oil was lost but I was at a campsite so no harm done. I now want to drain the gearbox, replace the missing speedo drive bolt and fill up with fresh oil. Can you help with the following questions please…?
What tool do I need to undo the gearbox sump plug ( see pic)
What size is the speedo drive bolt?
How much oil should I put in and of what type?
Is there a way to check the oil level?
And lastly how do I get oil into the gearbox?

Thanks for your help

Rodney

 

[jackwhoo]

That looks like a Peugeot/ Citroen gearbox to me , type BE3
If you have the Peugeot Citroen xu diesel engine then it almost certainly will be a Peugeot Citroen gearbox.

The drain is the round plug at bottom that takes a square key to remove, 7mm square?

 

[jackwhoo]

The fixings are all metric on that box .
Speedo drive retaining bolt either m6 or m8.

 

[jackwhoo]

Total BV 75w80.
The filler/ level plug is in pressed metal end plate ,19mm plug.
Inital fill volume is 2 litres, though it retains quite a bit when drained.
I found filling easier by unscrewing the black plastic breather on top of gearbox and using breather hole, but that was on a Peugeot 205.

 

[bugsymike]

Is this any help . By the way this is the genuine Peugeot/Renault tool and measures 8mm square, I expect the speedo drive retaining bolts to be M6 standard. there should be a filler on the side with same square. Don't know why the bolts were loose , we always used to pull the rubber plug /pin out to remove speedo cable when dropping gearboxes.

 

[jackwhoo]

Good one bugsy,
i see the book specs 75w90 synthetic but the be3 box is happier with total brand bv 75w80 .
Cheers
Jack

 

[Rodney 2000]

That looks like a Peugeot/ Citroen gearbox to me , type BE3
If you have the Peugeot Citroen xu diesel engine then it almost certainly will be a Peugeot Citroen gearbox.

The drain is the round plug at bottom that takes a square key to remove, 7mm square?

Thanks for this….how can I confirm the engine and gearbox type? I’ve look hard and can’t see any markings. The gearbox was reconditioned recently so I wonder if the bolt was not tightened or locked?

 

[jackwhoo]

What Is Best Oil For Gearbox ? Be3

hey, done some search but cant find anserw-- what can be best oil for gearbox. I changed it some mounths ago its Shell SF5288 thats the oil what is even Peugeot 205 users manual. When oil is cold then gears goes very well but if its going warmer its little harder to change gears? I found that lot...

www.205gtidrivers.com

 

[jackwhoo]

 

[jackwhoo]

If the gearbox end cover looks like that then it is be3 and the level plug is indicated.

 

[Rodney 2000]

That looks like a Peugeot/ Citroen gearbox to me , type BE3
If you have the Peugeot Citroen xu diesel engine then it almost certainly will be a Peugeot Citroen gearbox.

The drain is the round plug at bottom that takes a square key to remove, 7mm square?

Hi Jackwhoo,
Can you help me further…I have attached pics of the gearbox and engine…can you work out what we have please? Thanks

 

[Rodney 2000]

View attachment 420215

Not sure that is what I have…but thanks for sharing

 

[Rodney 2000]

Total BV 75w80.
The filler/ level plug is in pressed metal end plate ,19mm plug.
Inital fill volume is 2 litres, though it retains quite a bit when drained.
I found filling easier by unscrewing the black plastic breather on top of gearbox and using breather hole, but that was on a Peugeot 205.

Not sure I have one of those

 

[jackwhoo]

Good pictures thank you.

It does not look like the be3 box I was thinking of .

So going forward :- use gear oil spec shown in @bugsymike photo of autodata in column for your vehicle.

I am sure the plug with square hole at lowest point is the drain plug.

Drain all the oil out , refit plug, remove reverse light switch from top of box , slowly fill through reverse switch hole with 2litres of correct oil, refit reverse light switch, celebrate a job well done.

Best wishes

Jack

 

[bugsymike]

Some of those similar gearboxes fitted to Peugeot/Renault had the square plug that I showed the tool for, as a level plug on the side of the axle as well as used at bottom for drain plugs, however it is probably safest to drain the oil and then refill the correct amount as has mentioned through the breather at the top of gearbox until it runs out of axle level plug. I think???
By the way the tool measures 8mm square, before acquiring the tool at a Renault garage auction I used an old 3/8th adaptor ground down, they can be quite tight!

 

[jackwhoo]

Don't worry if you don't find a level plug..... some boxes don't have them and the only way is drain completely and refill with correct volume and spec.

 

[Rodney 2000]

Good pictures thank you.

It does not look like the be3 box I was thinking of .

So going forward :- use gear oil spec shown in @bugsymike photo of autodata in column for your vehicle.

I am sure the plug with square hole at lowest point is the drain plug.

Drain all the oil out , refit plug, remove reverse light switch from top of box , slowly fill through reverse switch hole with 2litres of correct oil, refit reverse light switch, celebrate a job well done.

Best wishes

Jack

Thank you Jack

 

[T MAN]

Pretty much what everyone's said, I have the same 1.9TD engine and ML5TU box and just did mine. Drain is a 8mm square bolt at lowest point of box below where the left side axle meets gearbox, mine had a copper crush washer which should be replaced. Have been advised to overfill with 2.3L of semi-synth 75w-90 (plus whatever remains in the box after draining) by a gearbox specialists who refurbish these and they fill with 2.5L from empty.

Fill through reverse switch on top of box using cheap funnel set from amazon, snip the end of tube so it can fit in where the reverse switch was, all accessible through engine bay. While you're there add some tape around the switch to seal where it meets the black plastic cable cover to prevent possible water ingress.

This is your reverse switch here in the top-left of your photo:

https://www.fiatforum.com/attachments/23969703-e1ab-412a-9089-d2d70bc6c765-jpeg.420218/

 

[Rodney 2000]

Pretty much what everyone's said, I have the same 1.9TD engine and ML5TU box and just did mine. Drain is a 8mm square bolt at lowest point of box below where the left side axle meets gearbox, mine had a copper crush washer which should be replaced. Have been advised to overfill with 2.3L of semi-synth 75w-90 (plus whatever remains in the box after draining) by a gearbox specialists who refurbish these and they fill with 2.5L from empty.

Fill through reverse switch on top of box using cheap funnel set from amazon, snip the end of tube so it can fit in where the reverse switch was, all accessible through engine bay. While you're there add some tape around the switch to seal where it meets the black plastic cable cover to prevent possible water ingress.

This is your reverse switch here in the top-left of your photo:

https://www.fiatforum.com/attachments/23969703-e1ab-412a-9089-d2d70bc6c765-jpeg.420218/

Thanks…just finished this but may go back to add another . 3 litre of oil as you have suggested

 

[Rodney 2000]

The fixings are all metric on that box .
Speedo drive retaining bolt either m6 or m8.

After a bit of investigation I have deduced this is an M7.