Technical How to change gearbox oil on a Fiat Ducato 2.8 idTD

[Washburn]

I was supposed to change the gearbox oil on my Fiat Ducato 2.8 idTD based Frankia A700 motorhome. I noticed there were a few tips on the net but I couldn't find any guide with pictures showing the reverse switch on top of the gearbox. So while doing the job I've taken some pictures and hope anyone can have som help from this.

This guide applies to the Fiat Ducato type X230, mine is model year 2000, second generation, pre-facelift. The 2.8 litre diesel engine is called “idtd” (Injection Direct Turbo Diesel), non-common-rail, mechanically driven fuel injection system. Engine type code 8140.43 (Sofim).

Open attached PDF to view this guide. Enjoy!

 

[EuraDan]

Congratulations, your pdf guide looks very good, particularly with the use of photographs to support the written information.

I have a motorhome with the same specification engine on which I am about to carry out a gearbox oil change, and have been trying to establish how much oil to use.
I have found various volumes from 2 to 2.7 ltrs recommended, but yours at 3 ltrs is the most. Did you get advice from a Fiat dealership/service station with regards to both the volume and substitution of 75w/90 GL4 specification in place of the specified 2litres of 75w/85 GL5 .
From the information I have gathered on line, I believe that the fifth gear is lubricated by means of splashing of the oil by the other gears in the box. I am concerned that if too much oil is used that it could submerge the gear train mechanism reducing the splashing and reducing the resultant lubrication, if you compare it to whipping a bowl of cream with an electric whisk, when you hold the whisk below the cream surface it all keeps in place but lift it out a bit and you can splatter everything within range.

It would be great to hear from anyone that has definitive information regarding this subject!

 

[Washburn]

EuraDan, you got a good point. Before doing the change I was also reading a bit trying to find out the correct amount and type, and it's true the original spec states to use 2.7 litres of Tutela ZC 75 75W80 SYNTH which is rated GL-5.

As for the type of oil, my personal opinion is that the the Red Line 75W90 fully synthetic should be just as good, it's a modern oil. You could of course use something else like for example the Trans Castrol Syntrax which says GL4/5. As for the GL-4 and GL-5, it's worse putting in a GL-5 in a GL-4 spec gearbox than the other way around. But I admit it's not the original spec, and I have no Fiat advice on that, I guess they would say to put in the original spec again.

As for the amount, I measured what came out and there was 3 litres in the box when I drained it. So I suppose that at the previous change they have put in 3, because there was no water in the oil either, no milky colour. So instead of the 2.7 litres I had planned to put in, I put back the same amount.

The camper has been rolling 74.000 km so far, without trashed gearbox.
I only use 5th gear when I'm above 90 km/h, and otherwise use 4th gear a lot and the engine is happy revving. So I hope my oil change will give me a lot more, if I would notice any trouble using this type and amount of oil I will update this post to share the experience.

 

[merovingian]

Well, I left the gearbox to drain for 2 days and refilled with 3 litres of Fuchs gl5 with a funnel via the breather hole, the Russek guide says it will take 2.8 litres if the box is completely empty, can't see that an extra 20cl will do any harm we're not making a victoria sponge here lol
Don't use fifth until the engine is up to temperature.
Incidently it's a 2.8jtd 2004 and I stuck a couple of whiteboard magnets on it for good measure.
PS this is the same oil that a lot of manufacturers use for the sealed for life box's

 

[golfcarmad]

Thank You

 

[Billysailing]

I know it's quite an old thread but Thankyou for the excellent write up, looking at the drain plug picture there is a similar looking plug to the left at the top of the row of bolts, I can't tell properly from pic but wondered if that could be the official filler plug rather than removing reverse switch sensor to refill ? I'm about to do the oil change , my van is 20 years old and speaking with previous owners I don't think it's ever been changed.No issues with box- so far ,50,000 miles.

 

[Washburn]

Hi! From all that I've read and found out in real life I do not think there is a regular filler hole. The bolt you refer to is most likely holding the box together. After this writeup I sold the camper but a few years later I bought another one model year 2001, last summer I changed gear oil using the same method and it's really easy once you get through the steps as outlined. The reverse switch is easy to get loose. This time I used another lubricant: Omega 690 (75w90), read a lot about it and I can really recommend it. It's double the price but worth it! The box is smooth like new, after 20 years.
Omega 690 is not easy to find but you can probably find a web store, I did and bought 3 litres. Put in 2,8 litres, everything working fine. More info at https://sovereign-omega.co.uk/omega-690-super-ep-gear-oil/

 

[Billysailing]

Hi thanks for the further update re which type of oil , Iv seen lost of conflicting views on using Gl4 or Gl5 as per original oil which is partly why I haven't done the job as all seems well but I can't help thinking it really should be changed after so long ! I will refill through the reversing switch as per your pictures .
Thanks again and happy travels

 

[corcai]

They're not really conflicting views, some of the older boxes had bronze parts. If your box has bronze parts and you want to go for a gl5 oil it has to be one that's compatible with bronze. If you're not sure and want to upgrade then there are lots of so called gl4+ oils you can use that are backwards compatible.

 

[maxoujmr]

Thank You