Technical FIAT Ducato 5th gear failure

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Technical FIAT Ducato 5th gear failure

Langman

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The 5th gear on my Fiat Ducato 2007 motorhome suddenly failed to engage without warning and has not engaged since. The AA mechanic looked at it and said that the gear linkage was engaging but the problem was inside the gearbox-requires new or recon gearbox. Have since received conflicting reports such as " cheaper to buy Peugeot parts (gave me part number) and DIY with basic tools" to "need to remove gearbox to clear out all teeth from damaged 5th gear and replace" and "I can repair that for £648 (inc VAT)" Any clues to best action to take?
 
Model
Fiat Ducato Bessacar E435
Year
2007
Mileage
45000
What model is the base vehicle? See first three nunbers of VIN. ZFA244xxxxxxxx, or ZFA250xxxxxxx? As it is a MH, it could be either a late registered 2006 x244, or a 2.2multijet x250, which I think used the same 5 speed box.
 
Thank you - nice to hear from someone so quickly! Just checked and it's the ZFA250. kind regards
 
Thank you - nice to hear from someone so quickly! Just checked and it's the ZFA250. kind regards
As I said the x250 2.2 multijet used as standard the same 5 speed box as the x244 model, but 6 speeds may have been an option.

If it is the 5 speed box then searching for 5th gear repair on forum or internet may reveal what is involved. With the six speed box, I do not know without checking, but think that all gears are in the same housing. In the five speed box the 5th gear is added on the end in an extra housing, and drip fed from the main box. Less chance for debris to get into the main box.

Peugeot parts will be cheaper for the same item. DIY if you are competant will obviously be cheaper, and if the five speed box it can be repaired insitu.

I could be wrong , but I doubt the £648 quote will include more than the DIY option, as new parts could cost hundreds of £s.

The advice that I usually repeat in conjunction with the five speed box, is not to use 5th gear for the first mile or so, if the vehicle has been standing for several days or more.

You could start by draining the oil, and seeing what comes out. Do at least refill with clean oil.

Perhaps @bugsymike may have something to add, or disagree with. His experience in such matters should be greater tham mine.
 
Kind of you to say, but no I definitely have less current knowledge than you guys on these models I freely admit.:)
The older Sofim engines were more my forte and mainly those used in Iveco Daily's.
The little I would add, is I understand the 2.2 HDi 2179cc is Peugeot based as in the PSA 4HY engine, so would assume related data gearbox and issues wise may be something Peugeot Forum may have experienced also.
Much like the 2010 Scudo 2.0litre 16 valve I have is the one Peugeot derived from their earlier 8 valve engine much used in taxis etc.
I see from 2007 the 2.2 was the Ford Puma engine 2198cc, so it may be worth checking actual cc and engine serial numbers etc.
To that extent I would be surprised if the gearbox was a straight swap between 2.2 Peugeot based 244/250 models etc. and the 2.3 Iveco Fiat design engines. I only had one 2.3 F1AE type engine and that was in a Iveco Daily RWD extended long wheel base van, all the rest were Sofim 2.5 or 2.8s mostly in Daily's and one a Ducato 2.8 that I fitted in a boat.
Apart from the current Scudo I have a Doblo 1.6 multijet and the 1.3 Multijet in a Vauxhall Combo, plus other non Fiat..
When I ran the Daily's I found Fiat parts for the same engine to be cheaper then genuine Iveco, you merely had to remove the 100 from the start of the part no. Sadly they have wised up to that nowadays, plus the same Company owns both franchises amongst several others.:)
Any other knowledge I have/had is from 55 years general motortrade on most makes.
 
I replaced a Fiat 5th gear but it was a long time ago, if I remember correctly it didn't take long (couple of hours) the biggest problem at the time was getting the new part.
 
I replaced a Fiat 5th gear but it was a long time ago, if I remember correctly it didn't take long (couple of hours) the biggest problem at the time was getting the new part.
It's not one I have done, I assume where 5th gear has been in effect an add on behind the tin cover through the wheel arch rather than a full gearbox strip down.
 
It's not one I have done, I assume where 5th gear has been in effect an add on behind the tin cover through the wheel arch rather than a full gearbox strip down.
Yes if it is the 5 speed box, but the OP has not confirmed this.
 
Yes if it is the 5 speed box, but the OP has not confirmed this.
Sorry for delay in responding but to confirm it is a 5-speed box and someone on the internet explained that the synchromesh could be removed and 'flipped over' as it is identical both sides. Watching a YouTube video ir was clear that this indeed looked like the case but I'm in my 78th year and not sure I would undertake such a DIY job!
 
Sorry for delay in responding but to confirm it is a 5-speed box and someone on the internet explained that the synchromesh could be removed and 'flipped over' as it is identical both sides. Watching a YouTube video ir was clear that this indeed looked like the case but I'm in my 78th year and not sure I would undertake such a DIY job!
Rather older here. In the last month I have changed the cambelt on my 2.8jtd, and I am contemplating a similar job on the gearbox.
 
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