And with that, another job is ticked off the list for TLC with Bertha, as today she has had a transmission fluid change. Regular readers of this site will know I commented before on the issue of a leak with the gearbox oil. This had been topped up so many times, no one was quite sure how much oil was in there. As such, I took the executive decision to drain and replace it.
Key Numbers;
Gearbox Oil Capacity: 2.9 litres
Gearbox Oil Specification: 75W-80 GL4 Synthetic Gear Oil
Sump Nut Size – 8mm tool required to remove
The process
Unless you are incredibly thin you will need to jack the van up to improve access. Make sure once you have done this you secure the van on a suitably rated axle stand to reduce the risk of injury Remember depending on how it is loaded you van likely weighs in the region of 3 tonnes.
To complete the oil change for the transmission you will need 3 key tools;
- A 8mm sump key to undo the sump plug
- An oil collection pan to drain the oil into
- A long necked funnel or better still one with a plastic tube attached
Once the vehicle is raised and secured on an axle stand you can go underneath. The first step is to drain the old oil. As with any engine change this is easier if the oil is warm (but not too hot!). Locate the gearbox sump nut as shown in the picture below. Insert your tool and turn anti-clockwise to release.
You will be able to turn the sump plug quite a long way before the oil starts to flow. I personally recommend you wear gloves to do this, as especially if you are working on the ground with the van jacked up, you have limited chances to avoid covering your hands in used oil when you release the sump plug.
If your sump plug has a magnetic end, be sure to clean the end of it before going to refit later. Mine had quite a few bits of what looked like iron filings stuck to it. This is a job you can easily be doing while the oil drains.
Time to refill
Once all the oil has finished draining, you are over the messiest part of the job. Make sure you have cleaned the sump plug up and refit it, turning it clockwise to secure.
The easiest way to refill the gearbox with fresh oil is through the breather hole in the top of it, as shown in the picture below. To do this I use my funnel with a hose attached to reduce the risk of spillage.
A bit of patience is required with this, ensuring not to pour too fast or you run the risk of spilling oil all over the gearbox. As with all work we have done on Bertha, we recommend using Liqui Moly fluids when changing them. The provide a good quality of consumable at a reasonable price and have never let us down yet. Probably why their tech is trusted in race cars. You can buy the correct spec of gearbox oil for this age of Fiat Ducato easily here on ebay.
Once you have refilled the gearbox with fresh oil, it is time to replace the breather cap. At this stage I always go back underneath to make sure the sump plug was done up tightly and has not started dripping. Also, it is a good time to have a quick spray round with either brake or parts cleaner and get rid of any spilt oil by wiping away with a rag.
Test Drive
After doing any such service work it is always wise to take the vehicle for a quick test drive. This will help establish all has gone well, and you can discover any residual issues in a controlled manner hopefully. Not flying down the motorway at speed. Having changed the gearbox oil, I would recommend taking it gently for the first few miles, enabling the fresh oil to get around the gearbox and lubricate all parts before you starting pushing your Ducato too hard.
Lifetime service
Fiat state the gearbox on the Ducato is a lifetime service item and shouldn’t ever need a fluid change. However given Bertha is now 17 years old with 180k+ miles on the clock I figured it would help even if not needed. Early evidence post change suggests the transmission is now quieter and smoother.