General Ducato x244 2.0 JTD clutch

[lydecker777]

Hi,

Last year I bought a Borg and beck clutch kit as the clutch I had fitted a couple years ago was failing , along with the gear selector arm seizing up? The clutch was 75% worn after 25k>>

After fitting the new clutch , it's still not right, the bite is quite high which is common on these apparently, however the gear changes are clunky and not smooth , and it occasionally pops out of gear ?

When it's in neutral it's almost as if there's still a bit of drive to the gearbox as it's rattling ?

Now I've read about the thrust bearing that clicks into the pressure plate , my clutch kit didn't have this , and it wasn't fitted to the previous clutch?

Would this be the problem or would adjusting the gear cables help?

I've attached the photos of my gearbox after 2 years that the garage did , and a photo of the thrust bearing I think I need?

 

[lydecker777]

Hi,

Found the issue ... One of the retainers on the gears has broken ..it's a common fault ..

Going to pull gearbox off now and take it from there .

See pic

 

[bugsymike]

Hi,

Found the issue ... One of the retainers on the gears has broken ..it's a common fault ..

Going to pull gearbox off now and take it from there .

See pic

The plot thickens.

 

[lydecker777]

Yeah definitely, Its the gear baulk ring I think ..so unless I take gearbox apart I won't know for sure , however I do also think the clutch was ever so slightly misaligned too...

So I think it's a combination of the two..

With the baulk ring like that it would jump out of gear and with the clutch misaligned it would drag too.. so going to have a bit of a research now on how to replace the ring ?

 

[bugsymike]

Yeah definitely, Its the gear baulk ring I think ..so unless I take gearbox apart I won't know for sure , however I do also think the clutch was ever so slightly misaligned too...

So I think it's a combination of the two..

With the baulk ring like that it would jump out of gear and with the clutch misaligned it would drag too.. so going to have a bit of a research now on how to replace the ring ?

At least you are getting there.

 

[lydecker777]

Yeah will do, thanks for your reply, I will get it off this weekend and report back..

 

[lydecker777]

Took it off the weekend, split the gearbox and multiple baulk rings broken , amazing how the box still operates...

I think I'm going to have to get a refurbished gearbox , as replacing the baulk rings is £50 but then the servos and gearing are worn too, so by the time I've bought parts it's just easier to buy a refurbished gearbox ?

 

[bugsymike]

Took it off the weekend, split the gearbox and multiple baulk rings broken , amazing how the box still operates...

I think I'm going to have to get a refurbished gearbox , as replacing the baulk rings is £50 but then the servos and gearing are worn too, so by the time I've bought parts it's just easier to buy a refurbished gearbox ?

Sadly these days it quickly becomes unviable to repair anything much.

 

[lydecker777]

Sadly these days it quickly becomes unviable to repair anything much.

Definitely..the costs and time outweigh the risk of saving a couple quid really ...2nd gearbox is 500/600 which could have the same issues...

Parts to buy separately are roughly 860/900

So a refurbished box with a years guarantee for around 1200/1400 isn't that bad

 

[bugsymike]

Definitely..the costs and time outweigh the risk of saving a couple quid really ...2nd gearbox is 500/600 which could have the same issues...

Parts to buy separately are roughly 860/900

So a refurbished box with a years guarantee for around 1200/1400 isn't that bad

In the old days we always rebuild all make of gearboxes in the different cars that came in using new parts, sadly we became undercut on price by local companies offering cheap rebuilt boxes.
We found we couldn't compete as they were using parts of scrap gearboxes, gears, hubs, reusing gaskets, seals and bearings etc. The warranty of 3 months wasn't worth the paper it was written on, but as people buy on price alone in many cases these days, there was nothing we could do about it, apart from refusing to fit them as when they failed the customer would come back to the person who fitted it.

 

[lydecker777]

In the old days we always rebuild all make of gearboxes in the different cars that came in using new parts, sadly we became undercut on price by local companies offering cheap rebuilt boxes.
We found we couldn't compete as they were using parts of scrap gearboxes, gears, hubs, reusing gaskets, seals and bearings etc. The warranty of 3 months wasn't worth the paper it was written on, but as people buy on price alone in many cases these days, there was nothing we could do about it, apart from refusing to fit them as when they failed the customer would come back to the person who fitted it.

If I could get a decent kit, then I probably would do it , but it's hard to find a complete kit