gear FIAT DUCATO 244 2005 3.G Service Manual

201TECHNICAL SPECIFICATIONS
Version 15
Chassis cab long wheelbase crew cab Camping Car
Truck long wheelbase crew cab
Transport ambulance medium wheelbase
Panorama medium wheelbase
Panorama medium wheelbase automatic gearbox
Panorama Autonomy
Combi 6 seater medium wheelbase
Combi 6 seater medium wheelbase
Combi 6 seater medium wheelbase automatic gearbox
Combi 6 seater medium wheelbase automatic gearbox
Combi medium wheelbase
Combi medium wheelbase high sided
Combi medium wheelbase automatic gearbox
Chassis cab short wheelbase special Camping Car
Chassis cowl short wheelbase special Camping Car
Chassis cab medium wheelbase special Camping Car
Combi medium wheelbase high sided automatic gearbox
C
hassis cab with load bed short wheelbase low roof Camping Car Special automatic gearbox
Chassis cab with load bed medium wheelbase low roof
Camping Car Special automatic gearbox
Chassis cab with load bed long wheelbase low roof
Camping Car Special automatic gearbox
Chassis cab short wheelbase special Camping car automatic gearbox
Chassis cab medium wheelbase low roof special Camping car automatic gearbox
Chassis cab long wheelbase low roof special
Camping car automatic gearbox
Chassis cab 4050 wheelbase special Camping car automatic gearbox
Chassis cowl short wheelbase special Camping car automatic gearbox
Chassis cowl medium wheelbase low roof special Camping car automatic gearbox Engine
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTDEngine
code
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43SBodywork
version
244BPARB 17
244BPARB 17B
244BPMFB ZX
244BPMNB ZX
244BPAFB ZX
244BPAPA 32
244BPMAA BXC
244BPMBA BXC
244BPMAB BXC
244BPMHG AYC
244BPMHG AX
244BPMHG AXC
244BPADG AX
244BPMDG AX
244BPMDG AY
244BPMGG AX
244BPANB ZX
244BPACA BXC
244BPACB BXC
244BPACC BXC
244BPAAA BXC
244BPAAB BXC
244BPAAC BXC
244BPAAG BXC
244BPABA BXC
244BPABA BXC

202TECHNICAL SPECIFICATIONS
Engine
code
8140.43S
8140.43S
8140.43N
8140.43N
8140.43N
8140.43N
8140.43N
8140.43N
8140.43N
8140.43N
8140.43N
8140.43N
8140.43N
8140.43N
8140.43N
8140.43N
8140.43N
8140.43N
8140.43N
8140.43N
8140.43N
8140.43N
8140.43N
8140.43N
8140.43N
8140.43N
8140.43NBodywork
version
244BPABA BXC
244BPABA BXC
244BZMFA AY
244BZMFA BY
244BZMFB AY
244BZMNB AY
244BZMNB BY
244BZMNC AY
244BZMNC BY
244BZMDA AY
244BZMDB AY
244BZMDC AY
244BZMDG AY
244BZMGG AY
244BZMGB AY
244BZMGC AY
244BZMBA AY
244BZMBA AYC
244BZMBB AY
244BZMBB AYC
244BZMBC AY
244BZMBC AYC
244BZMBG AY
244BZMBG AYC
244BZMBA BYC
244BZMBB BYC
244BZMBC BYCEngine
2.8 JTD
2.8 JTD
2.8 JTD POWER
2.8 JTD POWER
2.8 JTD POWER
2.8 JTD POWER
2.8 JTD POWER
2.8 JTD POWER
2.8 JTD POWER
2.8 JTD POWER
2.8 JTD POWER
2.8 JTD POWER
2.8 JTD POWER
2.8 JTD POWER
2.8 JTD POWER
2.8 JTD POWER
2.8 JTD POWER
2.8 JTD POWER
2.8 JTD POWER
2.8 JTD POWER
2.8 JTD POWER
2.8 JTD POWER
2.8 JTD POWER
2.8 JTD POWER
2.8 JTD POWER
2.8 JTD POWER
2.8 JTD POWER Version 15
Chassis cowl long wheelbase low roof special Camping car automatic gearbox
Chassis cowl 4050 wheelbase special Camping car automatic gearbox
Van short wheelbase low roof without EGR
Van short wheelbase high roof without EGR
Van medium wheelbase low roof without EGR
Van medium wheelbase high sided without EGR
Van medium wheelbase extra high
Van long wheelbase high sided without EGR
Van long wheelbase extra high without EGR
Truck short wheelbase without EGR
Truck medium wheelbase without EGR
Truck long wheelbase without EGR
Truck 4050 wheelbase without EGR
Truck 4050 wheelbase crew cab without EGR
Truck medium wheelbase crew cab without EGR
Truck long wheelbase crew cab without EGR
Chassis cowl short wheelbase without EGR
Chassis cowl short wheelbase Camping Car without EGR
Chassis cowl medium wheelbase without EGR
Chassis cowl medium wheelbase Camping Car without EGR
Chassis cowl long wheelbase without EGR
Chassis cowl long wheelbase Camping Car without EGR
Chassis cowl 4050 wheelbase without EGR
Chassis cowl 4050 wheelbase Camping Car without EGR
Chassis cowl short wheelbase special Camping Car without EGR
Chassis cowl medium wheelbase special Camping Car without EGR
Chassis cowl long wheelbase special Camping Car without EGR

208TECHNICAL SPECIFICATIONS
Version MAXI
Chassis cab short wheelbase without EGR
Chassis cab short wheelbase Camping Car without EGR
Truck short wheelbase without EGR
Chassis cab medium wheelbase without EGR
Chassis cab medium wheelbase Camping Car without EGR
Truck medium wheelbase without EGR
Chassis cab with load bed short wheelbase automatic gearbox
Chassis cab with load bed short wheelbase
Camping Car automatic gearbox
Chassis cab with load bed short wheelbase
Chassis cab with load bed short wheelbase Camping Car
Chassis cab with load bed short wheelbase without EGR
Chassis cab with load bed short wheelbase Camping Car without EGR
Chassis cab with load bed medium wheelbase without EGR
Chassis cab with load bed medium wheelbase
Camping Car without EGR
Chassis cowl short wheelbase without EGR
Chassis cowl short wheelbase Camping Car without EGR
Chassis cowl medium wheelbase without EGR
Chassis cowl medium wheelbase Camping Car without EGR
Chassis cab long wheelbase without EGR
Chassis cab long wheelbase Camping Car without EGR
Truck long wheelbase without EGR
Chassis cab with load bed long wheelbase without EGR
Chassis cab with load bed long wheelbase Camping Car without EGR
Chassis cowl long wheelbase without EGR
Chassis cowl long wheelbase Camping Car without EGR
Chassis cab 4050 wheelbase without EGR
Chassis cab 4050 wheelbase Camping Car without EGR
Truck 4050 wheelbase without EGR
Chassis cowl 4050 wheelbase without EGR
Chassis cowl 4050 wheelbase Camping Car without EGREngine
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTDEngine
code
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43SBodywork
version
244CPMAA AY
244CPMAA AYC
244CPMDA AY
244CPMAB AY
244CPMAB AYC
244CPMDB AY
244CPACA AX
244CPACA AXC
244CPMCA AX
244CPMCA AXC
244CPMCA AY
244CPMCA AYC
244CPMCB AY
244CPMCB AYC
244CPMBA AY
244CPMBA AYC
244CPMBB AY
244CPMBB AYC
244CPMAC AY
244CPMAC AYC
244CPMDC AY
244CPMCC AY
244CPMCC AYC
244CPMBC AY
244CPMBC AYC
244CPMAG AY
244CPMAG AYC
244CPMDG AY
244CPMBG AY
244CPMDA AX

209TECHNICAL SPECIFICATIONS
Version MAXI
Chassis cab medium wheelbase crew cab without EGR
Chassis cab medium wheelbase crew cab Camping Car without EGR
Chassis cab 4050 wheelbase crew cab without EGR
Chassis cab 4050 wheelbase crew cab without EGR
Chassis cab 4050 wheelbase crew cab
Chassis cab 4050 wheelbase crew cab
Truck 4050 wheelbase automatic gearbox
Truck 4050 wheelbase
Truck 4050 wheelbase without EGR
Truck 4050 wheelbase crew cab
Truck 4050 wheelbase crew cab without EGR
Truck medium wheelbase crew cab without EGR
Chassis cab long wheelbase crew cab without EGR
Chassis cab long wheelbase crew cab Camping Car without EGR
Truck long wheelbase crew cab without EGR
Minibus long wheelbase without EGR
School bus (primary school) long wheelbase without EGR
School bus (secondary school) long wheelbase without EGR
Van short wheelbase
Van short wheelbase
Van medium wheelbase
Van high sided medium wheelbase
Van high sided medium wheelbase
Van high sided medium wheelbase automatic gearbox
Van high sided medium wheelbase automatic gearbox
Van high sided long wheelbase
Van high sided long wheelbase
Van high sided long wheelbase automatic gearbox
Van high sided long wheelbase automatic gearbox
Chassis cab short wheelbase
Chassis cab short wheelbase Camping Car Engine
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTDEngine
code
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43SBodywork
version
244CPMBG AYC
244CPMHB AY
244CPMHG AY
244CPMHG AYC
244CPMHG AX
244CPMHG AXC
244CPADG AX
244CPMDG AX
244CPMDG AY
244CPMGG AX
244CPMGG AY
244CPMHB AYC
244CPMGB AY
244CPMHC AY
244CPMHC AYC
244CPMGC AY
244CPMMC AY
244CPMEC AY
244CPMLC AY
244CPMFA AX
244CPMFA BX
244CPMFB AX
244CPMNB AX
244CPMNB BX
244CPANB AX
244CPANB BX
244CPMNC AX
244CPMNC BX
244CPANC AX
244CPANC BX
244CPMAA AX

210TECHNICAL SPECIFICATIONS
Version MAXI
Truck short wheelbase
Chassis cab short wheelbase automatic gearbox
Chassis cab short wheelbase Camping Car automatic gearbox
Truck short wheelbase automatic gearbox
Chassis cab medium wheelbase
Chassis cab medium wheelbase Camping Car
Truck medium wheelbase
Chassis cab with load bed medium wheelbase
Chassis cab with load bed medium wheelbase Camping Car
Chassis cab medium wheelbase automatic gearbox
Chassis cab medium wheelbase Camping Car automatic gearbox
Truck medium wheelbase automatic gearbox
Chassis cab with load bed medium wheelbase automatic gearbox
Chassis cab with load bed medium wheelbase
Camping Car automatic gearbox
Chassis cowl short wheelbase
Chassis cowl short wheelbase Camping Car
Chassis cowl short wheelbase automatic gearbox
Chassis cowl short wheelbase Camping Car automatic gearbox
Chassis cowl medium wheelbase
Chassis cowl medium wheelbase Camping Car
Chassis cowl medium wheelbase automatic gearbox
Chassis cowl medium wheelbase Camping Car automatic gearbox
Chassis cab long wheelbase
Chassis cab long wheelbase Camping Car
Truck long wheelbase
Chassis cab with load bed long wheelbase
Chassis cab with load bed long wheelbase Camping Car
Chassis cab long wheelbase automatic gearbox
Chassis cab long wheelbase Camping Car automatic gearbox
Truck long wheelbase automatic gearboxEngine
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTDEngine
code
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43SBodywork
version
244CPMAA AXC
244CPAAA AX
244CPAAA AXC
244CPADA AX
244CPMAB AX
244CPMAB AXC
244CPMDB AX
244CPMCB AX
244CPMCB AXC
244CPAAB AX
244CPAAB AXC
244CPADB AX
244CPACB AX
244CPACB AXC
244CPMBA AX
244CPMBA AXC
244CPABA AX
244CPABA AXC
244CPMBB AX
244CPMBB AXC
244CPABB AX
244CPABB AXC
244CPMAC AX
244CPMAC AXC
244CPMDC AX
244CPMCC AX
244CPMCC AXC
244CPAAC AX
244CPAAC AXC
244CPADC AX

211TECHNICAL SPECIFICATIONS
Version MAXI
Chassis cab with load bed long wheelbase automatic gearbox
Chassis cab with load bed long wheelbase
Camping Car automatic gearbox
Chassis cowl long wheelbase
Chassis cowl long wheelbase Camping Car
Chassis cowl long wheelbase automatic gearbox
Chassis cowl long wheelbase Camping Car automatic gearbox
Chassis cab 4050 wheelbase
Chassis cab 4050 wheelbase Camping Car
Truck 4050 wheelbase
Chassis cab 4050 wheelbase automatic gearbox
Chassis cab 4050 wheelbase Camping Car automatic gearbox
Truck 4050 wheelbase automatic gearbox
Chassis cowl 4050 wheelbase
Chassis cowl 4050 wheelbase Camping Car
Chassis cowl 4050 wheelbase automatic gearbox
Chassis cowl 4050 wheelbase Camping Car automatic gearbox
Chassis cab medium wheelbase crew cab
Chassis cab medium wheelbase crew cab Camping Car
Truck medium wheelbase crew cab
Chassis cab long wheelbase crew cab
Chassis cab long wheelbase crew cab Camping Car
Truck long wheelbase crew cab
Minibus long wheelbase Engine
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTD
2.8 JTDEngine
code
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43S
8140.43SBodywork
version
244CPACC AX
244CPACC AXC
244CPMBC AX
244CPMBC AXC
244CPABC AX
244CPABC AXC
244CPMAG AX
244CPMAG AXC
244CPMDG AX
244CPAAG AX
244CPAAG AXC
244CPADG AX
244CPMBG AX
244CPMBG AXC
244CPABG AX
244CPABG AXC
244CPMHB AX
244CPMHB AXC
244CPMGB AX
244CPMHC AX
244CPMHC AXC
244CPMGC AX
244CPMMC AX

216TECHNICAL SPECIFICATIONS
BRAKES
SERVICE AND EMERGENCY
BRAKES
Front: disc, floating caliper with two
operating cylinders for each wheel and
pad wear warning light.
Rear: self-centring shoes and micro-
metric mechanism for clearance take-
up.
Certain versions are fitted with rear
disc brakes with Drum in hat device
(i.e. drum on disc to block the vehicle
when parked with handbrake en-
gaged).
Cross-over hydraulic circuit control.
Four sensors ABS system with EBD.
Automatic recovery of the friction
gasket wear; versions with rear disc
brake excluded (Drum in hat ver-
sions).
Lacking ABS system brakeforce dis-
tributor acting on rear brake hydraulic
circuit according to rear axle load.HANDBRAKE
Controlled by a lever, it works me-
chanically on the rear brake shoes.
For versions with rear disc brakes,
the handbrake works on the Drum in
hat device shoes.
IMPORTANTPull the handbrake
lever only when the vehicle is at a
standstill, or when the vehicle is run-
ning, but however only in case of a
failure of the hydraulic system.
Should the handbrake be exception-
ally used when the vehicle is running,
it is suggested to keep a moderate
traction to avoid causing the rear axle
block, entailing vehicle side skidding.
TRANSMISSION
CLUTCH
Hydraulically controlled without
travel-free pedal.
MECHANICAL GEARBOX
AND DIFFERENTIAL
Five forward gears and reverse with
synchromesh for front gear engage-
ment.
Cyclical gear reduction and differen-
tial assembly incorporated in the gear-
box.
Drive transmission to the front
wheels by means of drive shafts con-
nected to the differential assembly and
the wheels with CV joints.
Water, ice or salt on road
surfaces can deposit on
brake discs, reducing braking effi-
ciency on the first braking.
WARNING

217TECHNICAL SPECIFICATIONS
ELECTRONIC AUTOMATIC
GEARBOX
(2.8 JTD versions only)
Automatic gearbox with four speeds
plus reverse with self-adapting control
(i.e. capable of adapting to the driver’s
driving style), which transmits power
continuously and with very fast elec-
tro-hydraulic gear engagement times.SUSPENSIONS
FRONT
Independent wheel, McPherson sus-
pension.
Telescopic dampers with flexible an-
chorage to the body and dust guards
on buffers.
Coil springs offset with shock ab-
sorbers and knock-guard buffers.
Lower wishbone with twin taper
rubber bushing on chassis and ball
head on wheel stud.REAR
Rigid tubular axle type.
Lengthways single blade (two-blades
as optional) leaf spring.
Vertical shock absorbers anchored
above on the body (on the inside of
the wheelhouse) and down on the
axle flange.
Knock-guard buffer fixed to the side
member.
Coupling for brake load proportion-
ing.

240TECHNICAL SPECIFICATIONS
Fuel tank:
including a reserve of:
Engine cooling
system:
Engine sump:
Engine sump and filter:
Transaxle:
Automatic gearbox
Hydraulic power steering:
Front and rear hydraulic
brake circuit:
11-15 versions
MAXI versions
Hydraulic brake circuit
with ABS:
11-15 versions
MAXI versions
Windscreen and rear window
liquid reservoir:2000 JTD 2300 JTD
Litres
80
8 ÷ 10
9
–
6.25
2.7
–
1.3
0.59
0.62
0.59
0.62
4.2Litres
80
8 ÷10
10
5.8
6.3
2.7
–
1.3
0.59
0.62
0.59
0.62
4.2 kg
–
–
–
5.6
2.43
–
–
–
–
–
–
–kg
–
–
5.2
5.7
2.43
–
–
–
–
–
–
–Litres
80
8 ÷10
10
5.0
5.7
2.7
8.2
1.3
0.59
0.62
0.59
0.62
4.2kg
–
–
4.5
5.1
2.43
–
–
–
–
–
–
–Prescribed fuel
Recommended products
Diesel fuel for motor vehicles
(EN590 specifications)
Mixture of distilled water and
PARAFLU 11(blue) at 50% or
PARAFLU UP(red) at 50%
SELENIA WR
TUTELA CAR MATRYX
TUTELA HP 20
TUTELA GI/A
TUTELA TOP 4
TUTELA TOP 4
Mixture of water and TUTELA
PROFESSIONAL SC 35 2800 JTD -
2800 JTD POWER

242TECHNICAL SPECIFICATIONS
Use
Lubricants and grease
for transmission
Products for brakes
Radiatorantifreeze
Diesel fuel
additive
Windscreen/
rear window/
headlight washer fluid
(*) IMPORTANTThese two fluids cannot be mixed with each other. Contact Fiat Dealership for topping up.
Recommended
fluids and lubricants
TUTELA CAR
MATRYX
TUTELA GI/A
TUTELA HP 20
TUTELA
W 90/M-DA
TUTELA TOP 4
PARAFLU 11 (*)
or
PARAFLU UP (*)
DIESEL MIX
TUTELA
PROFESSIONAL
SC 35 Fluid and lubricant specifications
for correct vehicle operation
Fully synthetic lubricant SAE 75W-85 meeting API GL-4,
FIAT 9.55550
Lubricant for transmissions with ATF DEXRON II D LEV
properties
ATF DEXRON III oil type
Lubricant, grade SAE 80W-90 that passes API GL5, MIL-L-
2105 D, IVECO 18-1804, FIAT 9.55550 and FIAT 9.55523
specifications
Synthetic fluid, FMVSS n° 116 DOT 4, ISO 4925,
SAE J-1704, CUNA NC 956 - 01
Protective with antifreeze action based on
inhibited monoethylen glycol, CUNA NC 956-16
Protective with antifreeze action (red colour) based on inhib-
ited monoethylen glycol, with O.A.T. formulation, that passes
CUNA NC 956-16, ASTM D 3306 specifications.
Diesel fuel additive providing diesel engine protection
Mixture of alcohol and surfactants CUNA NC 956 -IIApplications
Mechanical
transaxles developping
high temperatures
Power steering system
Automatic gearbox
EP oil for standard and
self-locking differentials
Hydraulic brake and
clutch controls
Cooling circuits.
Proportion: 50% down
to -35° C Not to be
mixed with products
having different
formulas.
To be mixed with
diesel fuel
(25 cc every 10 litres)
To be used pure
or diluted