Ducato Gearbox

Discussion in 'Tech/Mech General' started by Big Lad, Mar 30, 2015.

  1. Big Lad

    Big Lad Funster

    Joined:
    Mar 9, 2015
    Messages:
    97
    Likes Received:
    66
    Location:
    Tamworth
    I've read through some of the posts on this forum regarding the 5th gear problem, and seem to be stuck finding the right person to do the job.

    The problem I've got, is the gear stick popping out of 5th while driving.

    The garage I've approached near to me seems to think the 5th gear is no longer available but they're supposed to be getting back to me with a solution at some point today.

    I did see on ebay a 5th gear kit that looks like it's for my ducato but again, someone who's done one would know. It's priced at £239 all in.

    If this garage let's me down, is there anyone on here that can point me to someone who knows how to sort this at a fair price?

    We're booked up for Wales May bank holiday and time is running out...

    By the way, it's a ducato 2.8 i.d.t.d on a 51 plate.
     
  2. Portland

    Portland Funster

    Joined:
    Oct 31, 2013
    Messages:
    347
    Likes Received:
    489
    Location:
    Cheshire
    I'm looking at gearbox problems and I have been recommended to Black Diamond Transmissions at Warrington. The T/no is 01925416619. They should be trying to find out if I can do anything to change the final drive ratio on our van.
     
  3. pappajohn

    pappajohn Funster Life Member

    Joined:
    Aug 26, 2007
    Messages:
    29,461
    Likes Received:
    16,889
    Location:
    YO11 2BD
    If you are handy with spanners and sockets it takes around an hour to change with no special tools.

    Your garage is wrong, the parts are available.
     
  4. Big Lad

    Big Lad Funster

    Joined:
    Mar 9, 2015
    Messages:
    97
    Likes Received:
    66
    Location:
    Tamworth
    Pappajoh, i believe you, I'm just suprised how many mechanics I know have never done one.
     
  5. Forestboy

    Forestboy Funster Life Member

    Joined:
    Jul 31, 2007
    Messages:
    4,934
    Likes Received:
    7,659
    Location:
    Forest of Dean
    Just find a local garage that deals with HGVs and or coaches they'll do it in no time and won't be fazed by the size of the vehicle. To most car type mechanics its too big and they're frightened of working on motorhomes.
     
    • Like Like x 1
  6. Big Lad

    Big Lad Funster

    Joined:
    Mar 9, 2015
    Messages:
    97
    Likes Received:
    66
    Location:
    Tamworth
    That's what I've done. I contacted a place Friday who are either trying to source a part before they get back to me.

    I don't think it takes this long to do that though
     
  7. Big Lad

    Big Lad Funster

    Joined:
    Mar 9, 2015
    Messages:
    97
    Likes Received:
    66
    Location:
    Tamworth
  8. pappajohn

    pappajohn Funster Life Member

    Joined:
    Aug 26, 2007
    Messages:
    29,461
    Likes Received:
    16,889
    Location:
    YO11 2BD
  9. Big Lad

    Big Lad Funster

    Joined:
    Mar 9, 2015
    Messages:
    97
    Likes Received:
    66
    Location:
    Tamworth
    i'm not at the stage where i'm cracking my tool set open yet pappajohn, I've been given a number of someone that may do it local to me, but that kit above is the only one i can see for mine at the moment.
     
  10. Big Lad

    Big Lad Funster

    Joined:
    Mar 9, 2015
    Messages:
    97
    Likes Received:
    66
    Location:
    Tamworth
    by the way, how many variations are there?
     
  11. pappajohn

    pappajohn Funster Life Member

    Joined:
    Aug 26, 2007
    Messages:
    29,461
    Likes Received:
    16,889
    Location:
    YO11 2BD
    I would think, at most, two.
    a cruising 5th gear (high ratio) and a town driving one (lower ratio).....which is why i suggested counting the teeth.

    Only an assumption as they quote how many teeth.
    i did notice in the compatibility list there is bus and chassis/cab versions but the same part which could blow my theory out the window.
     
  12. Big Lad

    Big Lad Funster

    Joined:
    Mar 9, 2015
    Messages:
    97
    Likes Received:
    66
    Location:
    Tamworth
    I'm certain mine is the higher ratio one as in the kit as its a noticeable jump from 4th to 5th (feels like a 6th) and will happily cruise up to 70 no problem if needed. I've emailed them the reg number and chassis number so they can double check before i go down the route of buying the kit and not wasting my money, fingers crossed, I've got someone local that may be able to help and keep the costs down.
     
  13. DP_JAY

    DP_JAY Funster Life Member

    Joined:
    Mar 17, 2010
    Messages:
    1,797
    Likes Received:
    1,022
    Location:
    Cark, Cumbria
  14. Big Lad

    Big Lad Funster

    Joined:
    Mar 9, 2015
    Messages:
    97
    Likes Received:
    66
    Location:
    Tamworth
    Pappajohn, are you saying if I pop the faceplate off myself I'm not going to loose all the gearbox oil, so I could count the teeth and order the kit, then pop the face plate back on?
     
  15. Jonkil

    Jonkil Funster

    Joined:
    Dec 27, 2014
    Messages:
    964
    Likes Received:
    3,174
    Location:
    Ireland / London
    No
    5th gear sits outside the box covered by a tin cover.
    There is residual oil in there and only some will be lost when you remove the cover.
    The job is very straightforward and takes about 1.5 hours.
    We have done those in the shop, usual charge is about €500 including gear oil change.
    We buy all gearbox parts from a specialist trade supplier.
     
    • Like Like x 1
  16. B-well

    B-well Funster

    Joined:
    Apr 19, 2008
    Messages:
    1,161
    Likes Received:
    901
    Location:
    Kent coast
    Okay done it myself, jacked n/s of van up, removed wheel for easy access but no need, and can be done on side of road.
    Drain oil 2.7 litres, remove 5th gear cover on end of g/box exposing x2 cogs, one nut C type can be undone with sharp blow from blunt chisel. replaced 5th gear, kit costing £274 as several teeth were missing, swarth attached to magnet which i placed outside of cover when gear went, selectors were okay however i turned selector gear around as no 6th gear ,so teeth not worn on other edge side.
    replaced oil £30.60 this has to done through reverse light switch found on top of G/box. Old Oil was clear and gold colour but did not want to chance returning to box. gear cover gasket is rubber and can be re used.

    Be careful when removing selector gear as x3 springs and ball bearings likely to pop out, do check mechanism is moving properly though slight resistance felt as bearings seat. the whole cluster 5th gear and selector mechanism can be slid of the shaft as one piece, remember to remove selector fork nut though..
    estimate that job could be undertaken in a couple of hours now i know what to do, awaited for Fiat parts 2 days
    looked on e-bay for comparison ,however teeth numbers are different so this would alter the gearing ratio, and i did not want to chance it.
    The citroen and peugeot gearbox do sometimes differ in gearing and locking nuts sizes used on gear shafts, If you replace the selector mechanism this is another £330 odd.
    But be careful if you have difficulty with engaging other gears as this may require G/box overhaul.
    to date only covered approx 50 miles but all working and no unusual noises. hope this is useful.(y)

    B-well, Aug 8, 2014
     
    • Like Like x 2
  17. B-well

    B-well Funster

    Joined:
    Apr 19, 2008
    Messages:
    1,161
    Likes Received:
    901
    Location:
    Kent coast
    Big lad On front motorhome fun page top right corner search for 5th gear .(y)
     
  18. jonandshell

    jonandshell Funster

    Joined:
    Dec 12, 2010
    Messages:
    5,258
    Likes Received:
    7,875
    Location:
    West Norfolk
    Ignore search results which mention Quentin Wilson though!
     
    • Like Like x 1
  19. Big Lad

    Big Lad Funster

    Joined:
    Mar 9, 2015
    Messages:
    97
    Likes Received:
    66
    Location:
    Tamworth
    B-well, was the nut that required the c spanner reverse thread?

    I'll show all this to the mechanic who's going to do it. Glad to see its doable.
     
  20. B-well

    B-well Funster

    Joined:
    Apr 19, 2008
    Messages:
    1,161
    Likes Received:
    901
    Location:
    Kent coast
    NO
     
Loading...

Share This Page