Ducato Gearbox (1 Viewer)

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Big Lad

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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.
 

Portland

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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.
 

pappajohn

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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.
 
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Big Lad

Big Lad

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Pappajoh, i believe you, I'm just suprised how many mechanics I know have never done one.
 

Forestboy

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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.

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Big Lad

Big Lad

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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
 
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Big Lad

Big Lad

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I think this might be the kit i may need?

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pappajohn

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I think this might be the kit i may need?

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You have to strip it anyway so if you are confident enough do it yourself, or at least remove the end cover yourself, then count the teeth.
nothing will come out if the cover is removed except some oil Which can easily be caught in a tub or bucket.
 
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Big Lad

Big Lad

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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.
 
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Big Lad

Big Lad

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by the way, how many variations are there?

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pappajohn

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by the way, how many variations are there?
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.
 
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Big Lad

Big Lad

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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.
 
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Big Lad

Big Lad

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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?
 
Dec 27, 2014
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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?
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.

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Apr 19, 2008
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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)

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Apr 19, 2008
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Big lad On front motorhome fun page top right corner search for 5th gear .(y)
 
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Big Lad

Big Lad

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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.
 
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Big Lad

Big Lad

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Just a quick update... I'm parked up on the road awaiting recovery... gearbox or something has gone... gear selector don't want to play, on the plus side, the sun's come out, I could of been on my way to Wales when it happened, plus the toilets working....
 
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Big Lad

Big Lad

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Managed to get the motorhome back to my works compound (ended up being towed by a fixed bar)
I had to keep the clutch dipped all the way as the gearbox had crunched 5th and seemed to be settling in reverse gear. with the clutch out, grinding could be heard, so i avoided doing that from that moment on.

I can only think its going to be a gearbox out job now, but the most annoying thing has been enduring this bank holiday watching everyone going off in their working campers, while i wait it out until the morning when i ring up the gearbox specialists.
 

DBK

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Sincere commiserations :(:( Sounds like a new 'box required but perhaps it can be saved. There will be swarf at least in the oil.
 
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Big Lad

Big Lad

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i know, i just want it sorted now as quick as poss. Probably worth changing the clutch out while its out.. we've got Wales booked in 3 weeks

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Big Lad

Big Lad

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I think the X230 models are pretty much all bolt on 5th gears - someone correct me here, mine is the 2.8 idTD model but I don't think it makes much difference.

I'm suprised there's never been an alternative gearbox that could of been used that has the 5th gear all enclosed like the rest of the box.

I think this is probably the biggest problem with the x230 Ducatos. .. definately an expensive one in my case
 
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Big Lad

Big Lad

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Just an update - the garage thats sorting it out initally said from what i'd told them that if the box had gone, i'd be looking at a bill of up to £1200 for a replacement. As it turns out, they rang today telling me that it was the 5th gear thats gone and that i should have the motorhome back monday. what a relief!
 

Tootles

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i'd be looking at a bill of up to £1200 for a replacement.
That dosent seem too bad, I expected much more.......Considering the 'full house' price of the 5th gear spares comes to over £500.
 
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Big Lad

Big Lad

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well, it was last done in 2005 according to a genuine Fiat receipt I found in the service history,
so it must of been due to go again now its on 74k... not bad i suppose for a gap of 10 years, but i suppose the regular use has probably helped.

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