Technical change ducato 2.5 engine gearbox for later model

[Eccles]

Hi There, I impulse bought a motorhome with a 1996 2.5TD 5 speed manual gearbox KM20KM. I now find I may have gearbox problems and after looking on this site I see this 5 speed gearbox is a bit notorious for 2nd and 5th gear issues. I may be lucky and have overfilled it with oil and it seems to be running ok. BUT when speaking to recon places all over the UK the general message was that due to the issues these gearboxes are getting rarer and rarer to source - or stupidly expensive. I was also told that you can't mate any other gearboxes onto engine if its the 5 speed manual diesel. Is this true? will any other 20KM versions that would work?

Therefore, and this is the key bit I wonder if anyone can advise on.......... Is it possible to take a later 6 speed 2.8TDi engine or just TD engine and fit it into the 1996 Ducato chassis? Does it fit? are driveshafts too different? Anyone done this? is it a straight fit or too complicated? Are there any known alternatives? Am very concerned if gearbox goes bang at a later time I will be stuck with a stationary expensive wendy House! Aaaarrggh! Help! Cheers

 

[jontee61]

hi eccles. read your posting with interest; firstly you describe motor as 1996 2.5td as the td was only fitted to the citroen jumper or puegeot boxer which was the psa engine and the Fiat was fitted with the Iveco 2.5tdi engine. with regard to the gearbox as long as driven correctly ie double de clutching and drive without placing unnecessary torque it should be fine, if its the 2.5tdi Iveco engine its a high revving engine so change gear at the top of the revs so placing no drag on gearbox DO NOT crawl about at 40--50 mph in fifth just leave it in fourth. my tdi drives like a dream and I drive it hard.

 

[Eccles]

Cheers Jon, that sounds positive, just out of interest where can I check to see if its an iveco engine / gearbox? Is it actually stamped on the engine? and if so whereabouts? slightly embarassed but v5 says its a 2.5TD but noticed yesterday the badges on the wings do say TDi - Doh!

 

[jontee61]

Cheers Jon, that sounds positive, just out of interest where can I check to see if its an iveco engine / gearbox? Is it actually stamped on the engine? and if so whereabouts? slightly embarassed but v5 says its a 2.5TD but noticed yesterday the badges on the wings do say TDi - Doh!

hi eccles. you may find going to Wikipedia fiat ducato and following all the links will find confirmation on info, lots of history of the mk your engine should be the 8140--47 direct injection with INTERCOOLER the ONLY 2.5tdi used from 94 to 98 was the IVECO engine there was a 2.5 tdi model with CAT my v5 says the same also top of engine cover will say FIAT but still IVECO. I know its confusing but the more you learn and research the clearer the picture becomes. loads of info available on the SOFIM ENGINE on fiat ducato Wikipedia hope that helps....ps/ my motors done 106000 mls and gearbox clean as a whistle and we do the alpes and pyrenees every year following the t/d/f so plenty of hard work there for the gearbox!!!!!!!!!!

 

[Eccles]

Hi Jon thanks for getting back to me - have now found the 8140.47 code so that's another step forward!! will get onto wiki and have a look cheers steve