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Most vans I've driven have had gear boxes made of gravel.
Economy wise have found latest diesels (euro 5 and 6) are quote a lot worse than older version, figured you get more power and with diesel power = fuel, and emissions stuff sucks up the rest, use more fuel to burn hotter = more complete combustion so less nasty stuff.
Also no van ever has a long enough top gear, always very revvy.
Got any pics, sounds like a spacious beast
Boxer findings: