2012 FIAT Ducato Clutch Woes
Pulled off the pitch and heading off to dump grey water at the MWP. Tried to stop and reverse our Autotrail Savannah onto the MWP, but the clutch pedal became limp and remained flat on the floor. Tried to stop but the brake pedal had very little response. With the vehicle heading off in first gear towards a wooden information hut, the only way to prevent a collision was to turn the engine off and come to a grinding halt using the handbrake.
The vehicle is a 2012 FIAT Ducato 150 multi-jet 21944 miles on the clock and is serviced every year. There were no warning lights or vehicle messages displayed until after the event when a message came up warning not to drive as the brake and clutch reservoir was empty. There was evidence of fluid pouring out of the gearbox housing on the passenger side of the vehicle.
Phoned for AA assistance as it comes with our van insurance and forty minutes later they arrived on site. As our vehicle is 4250 Kg we passed this and relevant dimensions to the AA at the first contact with them. The diagnosis was a failed clutch slave cylinder, which in models of our year and later, is housed inside the gearbox casing resulting in a gearbox removal to fix it. As this is a major job, the vehicle had to be recovered by the AA as it could not be rectified on site. It is worth noting that these vehicles have a shared brake and clutch hydraulic reservoir which is quite small and priority is given to the brakes. Fine if you have fluid in it!
An hour later, the AA sent their standard 12 tonne flatbed recovery lorry, but it could not take our motorhome as it was over 3500 Kg and it has a large rear end overhang which would ground if it went on the ramps. The AA then subcontracted out for a larger 14 tonne vehicle which can take 4250Kg weight but we were still doubtful about the rear overhang and getting it on the back of the truck!
Two hours later a rather small looking recovery vehicle arrived, which picks up the front wheels and then tows the motorhome. Still concerned about the overhang, the driver showed us photographs of all the motorhomes he had recovered included a 2018 Ducato similar to ours which had a seized engine with only 33 miles on the clock. Also the recovery vehicle, despite looking rather small, was capeable of towing up to 5000 Kg.
With the front wheels in the air and attached to the recovery vehicle, there was sufficient clearance at the rear end although some up and down adjustments were required to get over speed bumps. Our motorhome was recovered to a dealership near to our home, but as they are inundated with Ducato gearbox changes, we might have to wait a month before it can be repaired! The ride in the back of the recovery truck was a bit like being on a rocking horse but otherwise trouble free.
Reading various internet posts on this clutch problem, it would appear that this is a common occurrence with Ducato base vehicles, typically failing between 19 and 22 K miles!
Lessens learnt - check your reservoir levels and for leaks before setting off on a journey. Make sure that your recovery specialist sends the right vehicle! We were very lucky that this did not happen on the open road!
Comments
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Just enlarged your second piccy, John S. Reckon you could not use that system in South Cheshire -- not even on the good roads -- you would be in danger of grounding, and Heaven forfend you should meet up with one of our carriageway wide potholes
. Hope you're back on the road again ( shades of Willie Nelson 
) with a clean bill of health as soon as possible.0 -
Thanks ABM. The ground clearance in the piccy looks worse than it was, as the rear end was pointing up a slight hill.
We live in South Manchester and suffer all the sink holes in the local roads. In fact driving around the local area might have contributed to the failure!
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Hope you're up & running soon as. Toroidal slave cylinders inside the gear box seem quite common but as you say require the removal of the gearbox to replace them, at one time the cylinder was outside the gearbox & could be replaced in minutes ..... such is progress. I'm surprised that you lost your brakes too, even though clutch & brakes share the same reservoir, in my experience, there's a baffle/wall inside so that a leak on one doesn't drain the reservoir completely.
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We were surprised that we lost the brakes too and the reservoir quickly emptied. I could not see a baffle in the reservoir which is a clear plastic and small, size a bit like a shampoo bottle. There is not much distance between the max and min levels, so when we get the van eventually fixed I will be keeping a keen eye and carry a bottle of top 4 with me!
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