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Brambles

Hi,
Does anyone else with the newer Ducato have problems with the black plastic plug/bung about 3" dia falling out of the chassis leg behind the front wheels. I have replaced 3 times so far with mastic failing to hold it in when going through water puddles. This time I have tried silicon sealant/adhesive. They are not expensive (53p) but most annoying.
Jon.

Red0ne

hi jon

where exactly are these bungs positioned

i will have a look

Paul

Brambles

Hi Paul,

They are behind the back of the front wheels on the inner wings near the bottom. They cover the access holes to one of the lower suspension mounting bolts. I first lost one in a strong cross wind, and next two I lost going through water. With out them fitted water spray would enter into the chassis leg. I actually wonder how many people may have had then fall out and not noticed although I have not noticed any other ducatos or peugots with tehn missing but not something I go around peering behind peoples wheels for. It is easy to spot them - just crouch down at back of front wheel and look straight in perpecticular to side of 'van'.

Jon.

P.S. Paul - we went up to Fort William last weekend instead of the Trossachs and met a friend. Stayed at Killiecrankie on way up, then Glen Nevis and came back home through Glencoe with a beautiful sunset on Sunday evening.

camoyboy

I had one of these plugs fall out, but I put it down to thew fact I had not refitted it correctly after I waxoiled inside there. When I went to the Dealers for a new one he said he had sold a few before, so it must be an issue. I guess that the inside of the chassis leg must get air forced in through the open holes at the front when driving, and this would help them to pop out. I may stick a couple of self tappers in to stop it happening again.
Colin

cappuccino

Just checked my Nuevo ( six weeks old, chassis made 03/04) none fitted in mine, off to the Peugeot dealers tomorrow.

Brambles

Thanks for comments camoyboy and cappuccino,

I would be against using self tappers as its an untreated hole then that could (will) start a rust point. I used silicon and just checked and it seems to be holding it firm now. I put enough on that it would ooze behind the flange as well and will be easily removed if I have to.

Nice to know it is not just me that is losing them but not nice to know its a design flaw. Just worries me mud and silt could collect in the chassis leg if not fitted. I also waxoiled inside the leg after they came out.

Jon.

Red0ne

Hi jON AND OTHERS

just had a look to see if my black plugs were intact, YES is the answer.
Mine is a 2005 model fiat and the plug appears to be in 2 parts, one being an outer grommet to go arround the hole and the other is a plug that fits into the outer hole, and the inner is attached to the outer by a plastic strip
So if i remove the inner plug it stays attached to the outer grommet by this plastic strip
Is this the same as yours

Paul

camoyboy

Yes, that is the same, the problem is that the whole lot falls out, as the inner bit doesn't put enough pressure onto the outer to hold in place. I have just been out and stuck mine in with some silastik, as Brambles suggested. I hope I don't have to take them out again, that wil be for the next owner to worry about!!
Colin

Brambles

Yep, the outer part is not actually a grommet as such but a bung with a recess to give the shape to grip hole (not that it works very well), the second bit being a cap to fill the recess to give a smooth surface to wheel arch side. Actually sticking in with a silastic is no problem as if you need access to bolt behind you can remove the inner cap , cut through inner section to form a grommet to get access to bolt and the replace inner part afterwards ( I think). All the other holes (drain holes probably for when they dip the chassis in primer paint etc during manufacture have similar plugs (but oval) and they seem to grip the holes much better.

Red0ne

jon

thanx for info, have just spent the last 15 mins fixing the plugs in with silicon, will never fall out freely

Plus i feel i have given the hole a better seal than it had before

Paul

Brambles

Hi Paul,
Did you ever get your door sealing sorted in cross winds - I meant to get back to you and mention it probably is more likely to be the alignment of the door on the hinges - seems to be quite a few I have heard of where the door is too low. Mine had to be raised about 4mm. It is still not perfectly aligned but it's a heavy door to do fine adjustments and requires a bit of skill to get it right. Afterwards the striker lock plate may also have to be adjus