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gear box clutch help ( not scirocco but i'm stuck!)

Posted: Thu Dec 09, 2010 1:54 pm
by Mike the Founder
Hi all
bit of off topic i know - but have tried the fiat forums with no response... and i know some of you guys are mechanics / tinkerers like me who may have come across or fitted one.. :-)
we have had trouble with a 95 fiat ducato van clutch for a while.
its a bit back to front being a pull clutch i.e the cable is fixed to the gearbox - the sleeved pulls a fork that pushes the clutch. this is fitted after the box is on by means of a pin that goes thru the belle housing thru the fork ( as a pivot) and into bushes.
this pin has come out on more than one occasion meaning a loss of clutch.
The garage who fitted the second hand box and clutch back in january keep hitting it back in ( they said thats how it worked ) eventually i told em to get the box off after total loss of clutch ( after it going back 5 times ) turns out the casting inside that holds the pin was broken - tried some engineering shops no repair to be done. got a gearbox rebuild with a second hand bell housing and bushes that the pin sits in.
After seeing it myself - the pin slides thru into a plastic bush insert /seat, so hammering it in is wrong as would break the seat - which is probably what they did - enabling the pin to move about too much and put pressure on the casting at an angle and eventually rub thru and break. This time he pushed it in with his finger so the top is flush with the gearbox.
My concern is what the turnip does keep it in? there is no top or anything i could see to stop it.
i cant work it out at all and am worried about it . we cannot afford to have it off the road again it has cost us too much money in lost business / stress and bills. you cant see it to check on it cos its in a dumbass place on the back of the box down a bit of a hole.
The specialist mechanic at the garage ( yeah right!) didnt have a clue - and it had too go back there as obviously they will not be billing me.. :-) cos its there cockup ( although i am having to pay for the gearbox rebuild as they are not admitting having broken it - but that it must have been cracked in the first place but hey ho... some liability is better than none)
Local fiat garage dont know and cant be arsed to find out.
fiat forums have not responded.
so i am hoping someone on here may have done one of these ( there are plenty about after all and the relay and boxer are mechanically similar and may work something like the same)
so here is my last hope ob1 :-)
thanks all...
Mike.
:-)

Re: gear box clutch help ( not scirocco but i'm stuck!)

Posted: Thu Dec 09, 2010 9:39 pm
by duncancallum
any pics mate?

Ill ask my lads in the workshop tomorrow

Re: gear box clutch help ( not scirocco but i'm stuck!)

Posted: Fri Dec 10, 2010 3:43 pm
by Mike the Founder
cheers ,matey
sorry no photos - its all in now and fitted, just worries about it coming out, being where it is you cant see it too check it,...

Re: gear box clutch help ( not scirocco but i'm stuck!)

Posted: Sat Dec 11, 2010 1:41 pm
by Mike the Founder
reet,.,, update for you...
clutch dropped a bit.
on getting it checked this pin was working its way out again! new casting / bushes ( sleeves) all sorts.
Tania actually was passing the fiat dealers today and went into the garage section and asked. found a friendly bloke who came out looked and had a chat too her.
The pin needs hammering in normally and cant be pushed in to the sleeves with your fingers ( unlike ours), we couldnt get brand new sleeves, the ones in our original one were non existent ( something else the garage should have spotted on fitting and advised) but the gearbox refurb company found some that looked almost new.
he couldnt work it out either - without removing the box again - and investigating he was stuck.
he did advise tho given the sleeves on our original were gone and the issues we have had - it may be the pin could be slightly worn - or even misshaped. Given that the pin is only £20 odd we have ordered one. and will manufacture something to keep it in i guess if it is still lose.
unusual to find a helpful soul at the dealers... :-)
i had rung before but could never get past the receptionist...:-)