General 1.9TD Gearbox

[NdL]

Hi.
I'm struggling with bad syncro in my gearbox on my 1998 1,9TD.
It is only on 2nd gear. All other works fine.
The gearbox is marked 20KE22.

Questions.
Is there any syncros available to this gearbox?
Will other gearboxes fit? Like 20KE01?

Thanks.

 

[NdL]

No response for this?

Will a;
20KE01
20KE02 box fit on mine?

Or is it better to change the synchro myself?
Where can I find the correct synchros?

Thanks.

 

[cid]

Hi NdL, I own a 1996 1.9td and have done for 17 years. About 5 years ago my van developed the same problem as you describe. I drove it for a year avoiding second gear but, eventually, I decided to have it repaired. £1300 later the job was done. All was well for about 15 months then 2nd started crunching again. When the first repair was done, the gearbox repairer did say that Fiat 2nd gears were impossible to find but he could obtain a replacement gear for my particular box from a different maker. My repairer is used by many garages in the city of Leeds and has an excellent reputation but is only as good as the parts he can get. Since the recurring fault started, I decided to follow some advice from an older driver ( I'm 71). He said," when driving vans , he always started in 2nd gear unless it was on a hill and impossible to do so." I started doing this and it works perfectly. You, quickly, get used to doing it and it becomes quite natural. When slowing down, come to a stop using brakes then go into 2nd ready to start again. It is amazing how 3rd gear will pull from a very low speed as it has very good torque. So I would suggest you give it a try and see how you go. It will give you time to try and find the correct part, if you must, or save you a lot of money if you don't bother. All the Best, Ian

 

[bugsymike]

To increase your search pattern, what engine is yours, Fiat or Peugeot/Renault/Citroen flavour.
I know this sounds stupid, but some didn't use Fiat engine and gearboxes.
I can't guarantee, but I think the non Fiat versions had a speedo cable held in the gearbox drive with a rubber bung/mushroom from memory.

 

[cid]

Hi again NdL, I notice that it was nearly six months between your 1st and 2nd posts
. When it comes to gearboxes fitted to Fiat flagged vehicles the topic is complex to the extreme. I, too, am baffled by the different types and identity numbers etc. However, if you are going to make progress it is essential to maintain a dialogue with the people trying to help you. There is no point in coming onto the forum, asking a question and then disappearing. People are willing to help, if they can, but our time is precious too. All the Best, Ian.

 

[NdL]

Hi.
Thanks for your answers.
I just bought a 20KE02 gearbox
Guess I’ll find out if it will fit.

 

[cid]

Hi again, The very best of luck. Sometimes you just have to take a leap of faith so I hope it works out for you. In any event
, please let us know the outcome if only so we can pick your brains. All the Best, Ian.

 

[NdL]

Thanks. I guess we will find out pretty quick if it works.
But one thing that came to my mind was;
Last summer I changed the clutch.
I saw that the bushing in the flywheel was really worn.
It was like 2mm bigger than the shaft on the gearbox.

Do anyone know if there is any new bushing to fit?

 

[bugsymike]

In the 60s we were often replacing those bushes, we used to pack them with grease and use a tight fit punch or an old clutch aligning tool to drive them out by hydraulic lock principle.
I would have thought most small engineering shops or someone with a lathe could soon turn one up out of bronze/phosphor bronze, then lightly oil or hmp grease it. It doesn't need to be too tight as that will cause a noise when you dip the clutch, which is actually the only time it gets any load on it.
Most modern cars don't even support the first motion shaft in the flywheel, the shaft ends with the clutch spline.
Having said that the 1.9 05 Doblo I had with 220K miles had the front bearing fail in the gearbox and it took out the gears inside it was wobbling so much when I bought it. Luckily at the time I got a s/h gearbox that had been reconditioned and only cost me £70.