transmission FIAT DUCATO 244 2005 3.G Owners Manual

10GETTING TO KNOW YOUR VEHICLE
IMPORTANTThe remote control
system frequency can be disturbed by
significant radio transmissions outside
the car (e.g: mobile phones, HAM ra-
dio systems, etc.) that could cause re-
mote control malfunctioning.
MINISTERIAL
HOMOLOGATION
In the respect of the legislation in
force in each country in the matter of
radio-frequency devices, please note
that:
– the market-specific homologation
numbers are listed in paragraph “Ra-
dio-frequency remote control” in sec-
tion “Technical Specifications”.
– the homologation number is print-
ed on the component for markets
where this is required.
fig. 6
F0D0130m
To insert the metal insert in the key
grip, keep the button Epressed and
turn the insert in the direction shown
by the arrow until hearing the click as
it locks into place. Then release the
button E.
For instructions on ordering addi-
tional remote controls or replacing
the batteries, refer to the relevant
paragraphs in the following pages. Re-
fer to “Radio-frequency remote con-
trol” in section “Technical Specifica-
tions” for the relevant ministerial ho-
mologation.
When pressing the button
E, take care to prevent the
metal insert from causing harm or
damage when it comes out. The
button E should only be pressed
when the key is away from the
body, in particular from the eyes,
and from objects that can be spoilt
(e.g.: clothes). Make sure the key
can never be touched by others, es-
pecially children, who may inad-
vertently press the button E.
WARNING

78GETTING TO KNOW YOUR VEHICLE
SUN VISORS fig. 119
These are positioned to the sides of
the rearview mirror. They can only
swing up or down.
The driver and passenger’s sun visors
are both equipped with a document
pocket on the back and also the in-
structions for demisting the front win-
dows.
fig. 119
F0D0056m
CENTRE SIDE REAR
WINDOWS
(Panorama and Combi versions)
The centre side windows can slide
horizontally.
To open the windows, operate the
tab as shown in figure fig. 120.
fig. 120
F0D0087m
MULTIMETER
See the booklet provided by the mul-
timeter Manufacturer for more de-
tailed information on operation and
use.
Multimeter is compulsory on vehicles
with weight exceeding 3.5 tons (with
or without trailer).
IMPORTANTChanges to the in-
strument or to the signal transmission
system which effects the instrument
recordings, especially for fraudulent
purposes, may be a criminal offence.
IMPORTANTFor all versions fit-
ted with tachograph (excluding the
Minibus version), it is suggested to re-
move the 10 A red fuse marked with
F34 (CFO control unit on dashboard
right side) in case of prolonged vehi-
cle stop (over 10 days).

101GETTING TO KNOW YOUR VEHICLE
RADIO
TRANSMITTERS AND
CELLULAR
TELEPHONES
Cellular telephones and other radio
transceiver equipment (e.g. HAM ra-
dio system) must not be used inside
the vehicle unless a separate aerial is
mounted on the outside of the vehicle.
IMPORTANTThe use of cellular
telephones, HAM transmitters or oth-
er similar devices inside the passenger
compartment (without external aeri-
al) produces RF electromagnetic fields
which, amplified by the resonance ef-
fects inside the passenger compart-
ment may cause vehicle electrical sys-
tem to malfunction.
Moreover, the transmission and re-
ceiving quality deteriorates due to the
screening effect of the vehicle body. Have the cellular phone and the con-
nections to the system installed by a
Fiat Dealership.
The hands-free tele-
phone you purchase will
need to be compatible
with your cellular telephone.
Have the cellular tele-
phone and the connec-
tions to the system in-
stalled by a Fiat Dealership only.
This will ensure the best results
and prevent problems which
could impair vehicle safety.
ROOF RACK/
SKI RACK
Use the special pins fitted to the edge
of the roof panel to attach the all-pur-
pose roof rack support bars fig. 150
Vehicles with long wheelbase have
eight pins and those with short or
medium wheelbase, six.
There are two different types of pins
for fastening the roof rack in place:
A- pins for vans with normal and
high roof
B- screw with housing for roof rack
closed with a threaded plug for vans
with extra high roof.
fig. 150
F0D0088m

117GETTING THE BEST OUT OF YOUR VEHICLE
CONSTRUCTION FEATURES
DUCATO automatic gearbox is con-
trolled electronically with four for-
ward gears and reverse.
It is controlled by an electronic con-
trol unit which handles:
– the torque distributor;
– gearshifting;
– specific programmes.
The gearbox is coupled with a flow
power torque distributor with piloted
antislip device which makes it possible
to obtain demultiplication ratios.
The characteristic of this gearbox
which works without idle gear enables:
– higher compactness and weight re-
duction;
– improved output due to less fric-
tion;
– lower stress of transmission com-
ponents.GENERAL FEATURES
Electronic gearbox control makes it
possible to obtain gearshifting suited
to momentary engine characteristics
with a certain elasticity.
The electronic control unit has the
following task:
– adapting the oil pressure for
gearshifting to the engine torque;
– activating safety functions;
– defining the manual gearshifting
programme;
– system diagnostics.
For controlling these operating log-
ics the control unit uses the follow-
ing signals:
– engine rpm;
– engine temperature;
– engine torque;
– vehicle speed;
– gearbox oil temperature;– gearshift lever position;
– accelerator pedal position;
– brake pedal position.
The control unit also communicates
with the injection system electronic
control unit.
Conditions of use analysed by
the control unit
The control unit analyses each single
condition of use of the vehicle, dis-
criminating it on the basis of the sig-
nals received from the various sensors.
Analysed conditions are the follow-
ing:
– starting (position/accelerator ped-
al changing speed);
– acceleration (accelerator pedal
completely pushing down speed);
– full load (number of engine full load
kickdown signals or position mainte-
nance time);

164VEHICLE MAINTENANCE
thousands of kilometres
Replace fuel filter cartridge (Diesel versions)
Replace air cleaner cartridge (Diesel versions)
Replace air cleaner cartridge (petrol versions)
Replace spark plugs (petrol versions)
Top up fluids (engine coolant, brakes, power steering,
battery, windscreen washer, etc.)
Check timing belt conditions (***)
Replace timing belt and various control belts
(or every 48 months) (*)
Check engine control systems via diagnostic socket
Change gearbox - transmission - rear axle oil (4WD version)
Check gearbox/differential oil level (automatic transmission)
Change engine oil (**)
Replace engine oil filter (**)
Change brake fluid (or every 24 months)
Replace pollen filter (or every 12 months)
(*) Replace every 240,000 km or every 60 months for 2.3 JTD versions.
(**) Change/replace engine oil filter and oil every 40,000 km for 2.3 JTD versions
(***) Every 120,000 km for 2.3 JTD versions
30 60 90 120 150 180
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165VEHICLE MAINTENANCE
ANNUAL
INSPECTION
SCHEDULE
The following annual inspection
schedule is required for vehicles trav-
elling 15,000 Kmapprox. a year. The
schedule includes the following oper-
ations:
– check tyre condition and wear and
adjust pressure, if required (including
spare wheel);
– check operation of lights (head-
lights, direction indicators, hazard
lights, boot light, passenger compart-
ment light, instrument panel lights,
etc.);
– check windscreen wiper/washer
and adjust nozzles;
– check position and wear of wind-
screen/rear window wiper blades;
– check front pad conditions and
wear;
– check for bonnet and boot lock
cleanness, lever cleanness and lubri-
cation;– inspect conditions of: engine, gear-
box, transmission, piping (exhaust, fu-
el feed, brakes), rubber parts (boots,
sleeves, bushings, etc.), brake and fu-
el line hoses;
– check battery charge status;
– check conditions of various control
belts;
– check and top up fluid levels (en-
gine coolant, brakes, windscreen
washer, battery, etc.);
– check and top up engine oil;
– replace pollen filter.
ADDITIONAL
CHECKS
Every 1,000 km or before long
trips, check and top up as necessary:
– engine coolant level
– brake fluid level
– power steering fluid level
– battery electrolyte level
– windscreen washer fluid
– tyre pressure and conditions.
Every 3,000 km or before long
trips, check and top up as necessary:
engine oil
Every 10,000 kmor at cwarning
light coming on (diesel engines only):
bleed water from fuel filter.
You are recommended to use FL
Seleniaproducts designed and pro-
duced for Fiat vehicles (see the “Ca-
pacities” table in the “Technical Spec-
ifications” section).

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

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

250INDEX
Rev counter ................................. 30
Reversing light replacement ..... 146
Rims
- understanding rim markings .. 219
Roof rack/ski rack (presetting) .. 101
Rubber tubing .............................. 179
Safe driving.................................. 119
Scheduled Service ....................... 162
Seat belts ....................................... 15
Seats ............................................... 42
Self-standing supplementary
heater .......................................... 59
Service indicator .......................... 33
Service Schedule .......................... 163
Side central windows (opening) 78
Side/taillights ................................. 65
- front bulb replacement ......... 146
Smart wash ................................... 67
Snow chains .......................... 133-218
Snow tyres ............................ 132-221Sound system ............................... 98
- aerial ......................................... 100
- heavy set-up ............................ 98
- light set-up ............................... 98
Spare wheel .................................. 218
Spark plugs .................................... 215
Speed limiter ................................ 177
Speedometer ................................ 30
Spray nozzles ............................... 181
Starting the engine ...................... 105
- bump starting .......................... 137
- Diesel engine procedure ...... 106
- emergency starting ......... 107-135
- ignition switch ......................... 28
- jump starting .................... 136-157
- petrol engine procedure ...... 105
- stopping the engine ................ 108
- warming up the engine after
it has just started ................... 107
Steering ......................................... 218
Steering column lock .................. 28Steering column stalks ............... 65
Steering wheel ............................. 51
Sun visors ...................................... 78
Suspensions .................................. 217
Symbols ......................................... 7
Tank cap ................................ 99-103
Technical specifications........ 185
Third brake light
replacement ................................. 146
Tools ................................................ 138
Top speeds ..................................... 226
Tow hitch
(fitting diagrams)................... 130-131
Tow hitch installation .................. 129
Towing a trailer ............................. 129
Towing the vehicle ....................... 159
Transmission .................................. 216
Transporting children in safety .. 22
Tyre pressure ................................. 220
Tyres ......................................... 178-220