Q Can I repair my Fiat Ducato gearbox?

We have a 2001 Fiat Ducato 2.4D (not turbocharged), owned for six years, which has only done 70,000 miles.

There’s always been an issue

(crunching) with the synchromesh on third gear and, following a couple of postlockdown trips, it’s now happening changing up to second gear.

I’ve been told that parts for this box are no longer available, and therefore cannot be repaired or reconditioned. If the parts really are unobtainable, do I have any realistic alternatives to keep her going?

Jack Vaughan

AI am going to assume you actually have a 2.8 non-turbo Ducato. Parts for these gearboxes have been hard to obtain from Fiat and now Peugeot sources for some time. Peugeot used the

same gearbox on its 2.8 HDi and the same box was used on the 2.8JTD Fiat.

There are specialist gearbox remanufacturers who have either a stock of parts or a source of pattern parts available that are not widely known of. These specialists are out there and but take a little tracking down.

The economics are fairly simple. To remove, strip, repair and replace a gearbox will take at least 10 hours. At even as little as £50 per hour, you already have £500. Then, you will require a couple of synchromeshes and at least one gear cluster plus a seal kit as a minimum. That will be between £300 and £500. Add VAT to that and you are over £1,200 at least.

A quick look at eBay resulted in several hits on parts, but also fully reconditioned gearboxes with guarantees for £1,200 to £1,500. This would appear to be a bargain, but you still have to pay someone to swap it for you and you will also need a new clutch kit.

There are options and so I would be hopeful that the old girl is salvageable.

You will need to make sure that you get the right gearbox. While the 2.8, 2.8JTD and 2.8HDi use the same box, there are two versions of it. The one fitted to the Maxi van (3,500kg) that had the larger

16in wheels has different gear ratios to the lighter 15in wheel variant. This is important. Check the GVW plate under the bonnet has 3,500kg, which means it is a Maxi.

If you can find a specialist that will undertake the whole job, this would be best. You have some research to do but I am certain that it can be done.

Jack contacted me a few days later to say that he had made some calls and found a reasonably local firm that was prepared to give a worst-case quote for removing, repairing and refitting the gearbox. I hope to be able to give an update when it has been done.

Nick Fisher