Technical Gearbox Issue

[bri52]

Just suffered what I have since found out a very common fault on Ducato 1998 gearbox. 5th Gear fails to engage. According to internet this gear is a ''bolt on'' to a 4 speed box and can suffer from lack of lubrication over time. Well documented by Gary Box (Motorhome Vagabond) and although can be fixed 'in situ' if you can find a gearbox specialist, not a garage, to do the work. In any event a very expensive project. Anyone had this done?
I live in Shropshire and looking for hopefully a recommended repairer. Fiat Ducato 2.5tdi 1998 Motorhome.

 

[KSay]

I've just replaced the complete 5th gear plus syncro (1999 2.8 ducato 164, 000 kms)
£399.24 View attachment 420037
Done in situ in 2hrs including oil refill.
In my case the captivated nut had worked loose holding syncro (center of large cog).
2 x teeth broke and found in casing.

Method was Jack up nsf wheel to gain access then jack stands.
Drain g. Box completely.
Carefully remove 5th gear casing to expose gears.
Flatten out nut retaining ring and remove with flat nut.
Pay attention on how gear is situated and carefully remove off spline, being careful not to let any of the 3 ball bearings to drop from the inner face of the syncro hub.
Familiarise yourself with new parts and how they go back in.
Clean up, lubricate shaft splines and carefully reassemble.
When it came to tightening hub/gear nuts I searched high an low for torque settings without avail.
So tightened to first grunt and made sure locking tabs were good in place. Managed to get 3 to line up.
View attachment 420039

1500 kms later all good.
Refilled g.Box via reverse switch 2.7L .EP 75W-80. GL4

Hi, may I ask if you changed the smaller cog also?
Mine has two indentations in the nut which a lock washer is hammered into. I suppose these need to be hammered out using an old screwdriver or suchlike. Can they be re-used? I'd have thought they were difficult to find.

 

[Jr1944]

Hi, may I ask if you changed the smaller cog also?
Mine has two indentations in the nut which a lock washer is hammered into. I suppose these need to be hammered out using an old screwdriver or suchlike. Can they be re-used? I'd have thought they were difficult to find.

Yes they came as a kit and all replaced .
As you say ,has a locking(knocking tab)

Though inspection on mine showed no damage or signs of ware . But as it was exposed ......

 

[KSay]

Yes they came as a kit and all replaced .
As you say ,has a locking(knocking tab)

Though inspection on mine showed no damage or signs of ware . But as it was exposed ......

OK, thanks for quick reply

 

[KSay]

See my privious post the recited pic they advertise on the fleabay site but I rang them very helpful and very much cheaper.
They do the complete baring set but it's a box out job. View attachment 420040

Are you sorted yet? Maybe consider spending £30 to change the oil. I've heard of poor gearchanges being caused by contaminated gearbox oil. Fiat, in their infinite wisdom, decided to site the outlet for the scuttle drain pipe directly over the gearbox breather inlet. Result, watery emulsified oil. Not good for syncromesh which can need a bit of drag from the heavier oil. Worth a shot anyway. Fairly easy fix on the scuttle drain too.

 

[Jr1944]

Are you sorted yet? Maybe consider spending £30 to change the oil. I've heard of poor gearchanges being caused by contaminated gearbox oil. Fiat, in their infinite wisdom, decided to site the outlet for the scuttle drain pipe directly over the gearbox breather inlet. Result, watery emulsified oil. Not good for syncromesh which can need a bit of drag from the heavier oil. Worth a shot anyway. Fairly easy fix on the scuttle drain too.

Aye aye bud
Nothing nothing to do with skuttle drain on this occasion.
That fix had already been done.
Was last year almost at the end of a 3000ml tour of Galicia, Portugal, Spanish costas etc, during that very hot wx and coming up through France on final leg.
All gears there but, started getting clicky going through the gear to 5th.
The clutch had been changed prior to going and with oil change.
I decided to drain down and inestigate 5th gear, and found the flat locking nut loose and and teeth had escaped from syncro hub.
Chrome on the hub bush was pretty worn with age I suppose.I don't know, could of been the mountain roads lots of low gear, but no problems.
Replaced with all new parts
And 2.7L EP 80W-75 API GL4 through reverse switch apeture.