Technical Ducato 2.8 JTD 2004yr Clutch Replacement.

[Riviera181]

Hi all,
I have a 2004 Fiat Ducato Motorhome fitted with the 2.8 common rail Diesel engine, that seems to have developed a clutch problem/slip.
When changing up a gear and accelerating the clutch slips between approx 2500-3200 RPM (I presume this is when maximum torque is produced??). If you back off the accelerator the slippage stops. If you accelerate oh so gently by barely resting your foot on the accelerator it doesnt happen.
Its only covered 27,000 miles which I dont consider a great deal

I going to get the gearbox off and have a look to see if there is another cause - i.e oil contamination and replace the clutch.
As I have limited space it needs to be done fairly quickly. Before I start I have a couple of questions.

1. I have read on here about extracting the release bearing pivot pin before being able to seperate the engine & 'box. Do these come out easily or does the pin normally seize/corrode into the alloy casing? How many of you have had success removing the pin or not?

2. I understand that the release bearing can be split. Has anyone used the method of giving the clutch arm a firm smack to split the bearing and then enabling the engine & 'box to be seperated?

3. How is the release bearing assembly fitted during refitment of the new clutch? Is the release bearing and clutch arm fitted to the clutch cover/diaphragm as one unit before the gearbox is refitted and then the pivot pin attempted to pass through the arm/lined up/refitted last?

and finally, lol
4. I have tried to download the e-learn manuals off here (onto a 4.7GB disc) but with no success. Is there a procedure that needs to be followed/installed to alllow these to be saved/read?
I presume mine is the X244 model, as is has 244 in the chassis number (but no X?).

Any help gratefully recieved.

Many Thanks.

 

[corcai]

You can inspect the clutch without removing the box by removing the starter or lower bellhousing cover and using a lamp an a mirror.

 

[Riviera181]

You can inspect the clutch without removing the box by removing the starter or lower bellhousing cover and using a lamp an a mirror.

Hi,
Thanks for the advice. As the clutch is slipping I think the bottom line is that the 'box will have to come out.
Do you have any advice on the removal of the gearbox?
Thanks

 

[corcai]

Hi,
Thanks for the advice. As the clutch is slipping I think the bottom line is that the 'box will have to come out.
Do you have any advice on the removal of the gearbox?
Thanks

You can make a tool to remove the fork like so this also links to other guides:
https://www.fiatforum.com/ducato/294652-ducato-2-8-jtd-gearbox-removal.html?p=2970057

The other alternative is to drill the other side of the housing and drift the fork out with a punch.

 

[FreeSpirit]

Hi,
Thanks for the advice. As the clutch is slipping I think the bottom line is that the 'box will have to come out.
Do you have any advice on the removal of the gearbox?
Thanks

Hi
Have you removed the gearbox as yet, I remember somewhere seeing a video of the removal & replacement procedure of the gearbox on a Ducato, but it was in Spanish ? or something. Will see if I can find it, even if you can't understand what he is saying you can at least watch the procedure. - I remember the :-
quote:
"(used the method of giving the clutch arm a firm smack to split the bearing and then enabling the engine & 'box to be separated?)"
Cheers

 

[Riviera181]

Hi
Have you removed the gearbox as yet, I remember somewhere seeing a video of the removal & replacement procedure of the gearbox on a Ducato, but it was in Spanish ? or something. Will see if I can find it, even if you can't understand what he is saying you can at least watch the procedure. - I remember the :-
quote:
"(used the method of giving the clutch arm a firm smack to split the bearing and then enabling the engine & 'box to be separated?)"
Cheers

Hi,
No not yet, I was going to wait for an extra pair of hands to help lift the 'box out ( I am doing it on my back at home), but decided today to have a go on my own.
Yes I saw the video on Youtube, that's why I asked about giving the arm a good smack.
I tried the good smack method to day but couldn't get enough swing in the engine bay to achieve success.
I have made a tool to pull the pivot pin, but when I look at my 'box, the (what I think is the) location for the pin , the pin seems to stand proud already and there is no (M6) thread in it to screw the 55mm bolt into??

 

[Riviera181]

Hi
Have you removed the gearbox as yet,

This is what the top part of the pivot pin/gearbox casing looks like

 

[Riviera181]

OK, got the box out in the end.....
I went down the route of one of the other guys that have posted on here and undid the x6 allen bolts that hold the clutch cover to the flywheel, through the square inspection hole on the underside of the bell housing.
This meant that the 'box and clutch assembly came out together.
I had to cut a small part off the 6mm allen key that I used to enable access.
x2 of the bolts rounded internally and I ended up starting them by knocking them round with a chisel.


How have people in the past assembled/re-fitted the clutch onto the flywheel during the gearbox refit?


TIA

 

[Riviera181]

Late Update, lol. After finding some pictures on my mobile reminded me to come back and report back.
There was some gear oil residue in the bell housing so I took it to a gearbox specialist to take a look at it.
While it was there they drilled the casing to the pivot pin can be drifted out in the future should the need arise (fingers crossed not) .
Pictures available


It says give the clutch arm a firm smack to get the release bearing to engage.
Me and a mate had to get half a trolley jack handle behind it to get it engage, there just isn't the room to swing a good sized hammer around.
After much swearing there was a small click and it was in.