5th Gear Dropping out - Fiat Ducato 2.5 TD 1994 - 2001 - Motorhome Forums, Motorhome Discussion, Motorhome Chat

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post #1 of 10 (permalink) Old 21-05-2019, 22:37 Thread Starter
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5th Gear Dropping out - Fiat Ducato 2.5 TD 1994 - 2001

Just 500 miles and about 2 weeks after buying my 1998 Fiat Ducato 2.5 TDi, the 5th Gear started dropping out. It’s the gearbox where Fiat
changed a four gear box into a 5 gear box by attaching it to the outside. I’ve since discovered that this is quite a common problem.
During the research I found that it is more than likely because oil is not getting into the 5th gear chamber. Some suggested it’s just a 5th gear synchro change and a fairly simple 2-3 hour job.
Does anyone know about this issue and/or know a specialist who knows how to do it? Thanks in advance.
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post #2 of 10 (permalink) Old 22-05-2019, 07:50
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It is a very simple job for a good DIY mechanic, and a doable one for a less adept.
I have seen reports of parts now being difficult to find.

The problem is very well documented but unfortunately there is a lot of peoples beliefs and ideas spread around as well as good info.

If you do the job, when finished refill the box with good quality synthetic gear oil, not auto transmission fluid as many forums will suggest.

.

John
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post #3 of 10 (permalink) Old 23-05-2019, 14:05
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I had one go in a similar fashion in my 2.5TD Pilote Galaxy from 1999 (T reg?). I had a new gear put in by a local gearbox speciailst. I can't remember how much it was - probably 10 years ago? They said it was fairly common, and the parts were made of cheese!! If I could remember how to search the old site for the posts I put up at the time, I would be happy to help.....
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post #4 of 10 (permalink) Old 23-05-2019, 14:09
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here's a link to a thread from 2011

https://forums.motorhomefacts.com/18...r-failure.html

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post #5 of 10 (permalink) Old 23-05-2019, 18:03
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In addition to the comment above by Eurajohn, I would add that the recommendation made by Fiat on the slightly later box is to increase the oil qty by approx 700ml, Iíd consider doing that in your case too.
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post #6 of 10 (permalink) Old 27-06-2019, 16:41 Thread Starter
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Quote:
Originally Posted by bognormike View Post
here's a link to a thread from 2011

https://forums.motorhomefacts.com/18...r-failure.html
Brilliant! Thanks for the thread link.
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post #7 of 10 (permalink) Old 27-06-2019, 16:44 Thread Starter
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Quote:
Originally Posted by eurajohn View Post
It is a very simple job for a good DIY mechanic, and a doable one for a less adept.
I have seen reports of parts now being difficult to find.

The problem is very well documented but unfortunately there is a lot of peoples beliefs and ideas spread around as well as good info.

If you do the job, when finished refill the box with good quality synthetic gear oil, not auto transmission fluid as many forums will suggest.

.
Hi John,
Could you possibly tell me what is a GOOD synthetic oil to fill the gearbox with?

Also, further in the thread, Sprinta suggested: "I would add that the recommendation made by Fiat on the slightly later box is to increase the oil qty by approx 700ml." Do you know what the total oil to add is, with the extra 700ml?

Thanks in advance if you can let me know.
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post #8 of 10 (permalink) Old 27-06-2019, 16:45 Thread Starter
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Quote:
Originally Posted by Sprinta View Post
In addition to the comment above by Eurajohn, I would add that the recommendation made by Fiat on the slightly later box is to increase the oil qty by approx 700ml, Iíd consider doing that in your case too.
Hi, Sprinta. You suggested: "I would add that the recommendation made by Fiat on the slightly later box is to increase the oil qty by approx 700ml." Do you know what the total oil to add is, i.e. including the extra 700ml? Do you know of the best oil to add. Eurojohn suggested the fiat suggested oil is not the one to go for?

Thanks ever so.
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post #9 of 10 (permalink) Old 27-06-2019, 17:55
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Exactly which you choose is a matter for you to decide, with prices typically ranging from £10 to £20 per litre they are not exactly cheap but good never is.
Go for a 75W90 grade and you'll not go wrong, just about all of the "known" brands are OK.

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post #10 of 10 (permalink) Old 02-07-2019, 17:15
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The 2.8jtd 2003 I had used 2 litres 75/90 ( I think) semi synth.

The later suggestion was 2.7 litres, so the 5th gear got a better splash, and to go for Fully Synthetic too.

As John says, above, donít go cheap.

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