Cost to repair 2nd gear syncro on 3.0 X250 - Motorhome Forums, Motorhome Discussion, Motorhome Chat

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post #1 of 31 (permalink) Old 08-07-2014, 23:14 Thread Starter
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Cost to repair 2nd gear syncro on 3.0 X250

Hi there,
I am experiencing an issue changing down from 3rd to 2nd. I believe it to be the syncro.
The symptoms are as follows:
I have no trouble going up the gears or changing down when going extremely slowly (say under 10 mph). Anything above that and I crunch the change down to 2nd.

My question is how much would I expect to pay to have this work completed, I assuming it means removing the gearbox etc.

Secondly would it be a cheaper alternative to get a full re-conditioned gearbox fitted rather than getting my own repaired.

I assume a gearbox specialist is a better bet than going back to Fiat, the van is a 2008 3.0ltr

Lastly anyone suggest a good company in Ireland that could carry this out for me

Regards
Raymond
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post #2 of 31 (permalink) Old 08-07-2014, 23:26
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This is the first time I have heard of a problem with a Ducato gearbox on any post 2001 model.

My advice would be to take it to a Fiat dealership first. They should be the experts and will give you some idea of what is involved (you don't have to book it in with them).

It may not be a gearbox failure as such. It could be a badly adjusted linkage (from new) which happens and shows up when there is a bit of stretch in it. It could even be the start of a worn clutch plate.

Don't jump to any conclusions until you get more info. You could also ask the question on the Fiat forum.

http://www.fiatforum.com/ducato/

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post #3 of 31 (permalink) Old 09-07-2014, 08:22
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I can't believe it is the gearbox. X250 gearboxes are rock solid and are designed to last for at least 200000 miles. The problem is more likely to be related to the clutch.
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post #4 of 31 (permalink) Old 09-07-2014, 09:56
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My nephew has a 2007 ducato, 2.3, at 5000 miles syncro has gone on 2nd gear, confirmed by Fiat, who dont want to accept any liability, this only occurs when changing up, ie 1st to 2nd, hope yours is just an adjustment,

Best of luck Eric
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post #5 of 31 (permalink) Old 09-07-2014, 10:44 Thread Starter
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All,
Thanks for your replies so far and just to add some more information

The van has only 18k miles on the clock, but has had a new clutch fitted by the previous owner. Bearing in mind that it is a 747 and very heavy, I was not that suprised by that.

I am not sure that the gearbox is as rock solid as some believe as I have searched this forum and came across two threads of issues relatively similar both were believed to be caused by water ingress into the gearbox through the breather pipe.

Could the issue be a badly fitted replacement clutch and if so how would I diagnose this?

Also why would it only affect 2nd gear as other than that the gearbox is perfect and again why is the issue only on the downshift

I did visit a Fiat dealer , who on hearing the symptons, believed it to be the syncro, hence the reason for my original post

Thanks for all your help

Raymond
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post #6 of 31 (permalink) Old 09-07-2014, 10:47
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(unhelpfully) learn to double declutch
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post #7 of 31 (permalink) Old 09-07-2014, 11:45
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On our 2008 3.0 Kontiki with 14k miles on the clock, there's many a time when 3rd is nigh on impossible to find when coming down from 4th to 3rd. Have to wait until the road speed drops right off, by which time I need 2nd gear.

I can live with this for now but will get it looked at in early January 2015 when the vehicle & hab services are due together with the MOT.
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post #8 of 31 (permalink) Old 09-07-2014, 12:34
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Its usually the third gear synchro that causes trouble not second.

The cause is repeated rushed downchanges. Basically a synchro hub is a a device that synchronises the speed (hence the term synchro hub) of two gear wheels that are rotating at different speeds so they will engage without graunching, the faster you try and change gear the harder the syncrho hub has to work, and they do wear out !!

You MAY find that if you slow your gearchanging down CONSIDERABLY ( try SLOWLY counting, "one thousand" as you come OUT of third gear, pause for "two thousand" with the box in neutral and THEN say "three thousand" as you select second gear) the problem may ease, also try not to let the engine revs drop off as you change down, in fact they actually need to INCREASE slightly, (try not lifting your right foot when changing down, or just lift it SLIGHTLY) it all helps to keep the gear whels rotating at similar speeds which means the synchro hub doesnt have to work too hard. each gearchange SHOULD take you in the region of two to three seonds to complete smoothly. You should aim not to feel any gearchange up or down. It can be done trust me, in fact if you get the engine revs matched correctly to your road speed you can change up and down WITHOUT using the clutch at all. (except for pulling away from rest)

Any repair is going to be expensive because of the labour time involved. It will be cheaper to have yours repaired than fit a new (or recon) one !!

I have a 3 Litre with 29K on the clock and the gearbox is like silk up and down. I would suspect that the previous owner had no finesse at all when changing gear.

If you can find someone to teach you how to double declutch that will alleviate the problem greatly (an old time truck driver will certainly know how to do it!!)

Its not the destination that matters.

It's who you share the journey with (even if like me, itís in a caravan!)
I am very fortunate to have Mrs Plodd to share mine with
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post #9 of 31 (permalink) Old 09-07-2014, 12:59
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Quote:
Originally Posted by thieawin
(unhelpfully) learn to double declutch
That is not unhelpful at all.

I drove my Skoda Roomster for 2 years due to a similar problem when changing up from 1st to 2nd. It just becomes a habit after a while and I sometimes do it while driving the motorhome.

As has been said, change DOWN slowly and match the revs to suit the lower gear. It means you can still use the van.

I would change the gearbox oil anyway if there is a risk of water in it. The cost of oil is negligible compared to a gearbox overhaul.

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post #10 of 31 (permalink) Old 09-07-2014, 13:55
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