Fiat Ducato gearbox problems

[keith c parker]

Hi, I have a Fiat Ducato 1.9 turbo diesel T reg, 1999. I have a problem with the gearbox going from first to second, it grinds but goes in. From third to fifth and reverse there is no problem. We have asked the fiat dealer and other gearbox repair companies. they all say the same. This year of motorhome they can not get the parts to repair the problem.

Does anyone have any idea where I could get this gearbox repaired or get a re conditioned one. I have been told it is an ML gearbox if that is any help.
Thank you very much.

 

[trekkin]

Welcome to the forum

Sorry cannot help but I'm sure there will be someone along soon with an answer, there is a wealth of knowledge on here and rarely does a question go unanswered.

 

[PeteH]

HI
Found this on Yahoo?

http://www.reconditionedgearboxes.com/Manufacturers/fiat/ducato/index.html

Pete

 

[Tootles]

Hi, I have a Fiat Ducato 1.9 turbo diesel T reg, 1999. I have a problem with the gearbox going from first to second, it grinds but goes in. From third to fifth and reverse there is no problem. We have asked the fiat dealer and other gearbox repair companies. they all say the same. This year of motorhome they can not get the parts to repair the problem.

Does anyone have any idea where I could get this gearbox repaired or get a re conditioned one. I have been told it is an ML gearbox if that is any help.
Thank you very much.

Try this. Type EPER into your Google Search. That will open Fiats full parts inventory. Choose your model, then you may be asked to enter your vin number. Go to gearbox. All your part numbers are there. As far as I'm aware at this time, Fiat still supply everything for your gearbox.

 

[RS_rob]

Hi & welcome

Is your problem heat related ? my 2.5 hates shifting when cold & prefers to be warmed up & if I do have to move it straight off from cold I find it ridiculously hard to change gear until its warm.
I also wondering if any previous owners have found this & forced gear changes on your box.

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[Tootles]

This company supply reconditioned gearboxes.

http://www.stockportgearboxcentre.com/ They have a good reputation, and will advise over the phone.

However, it could be that you have a worn linkage problem.

 

[mariner]

Had a 2004 Ducato 2.8JTDI with that problem.

2nd gear syncro was shot, but being an ex army driver trained with crash gearboxes, I just used the double de clutch method to change up and down using 2nd gear.

Much cheaper than a new box.

 

[davidbaldam]

Sorry can't help you with your problem but welcome to FUN.

 

[pops]

I agree with Mariner, If you know how to double declutch do that. I found with my 1999 autosleeper Ravenna if I changed up slower it would fall into gear ok.

 

[Barclaybasher]

With my 1991 Renault Trafic diesel I 'blip' the throttle between gears, it just makes changes easier.

My previous MH, a 2004 Ducato had a seized linkage - a common problem that makes you think that the gearbox is a problem - sorted by freeing off the linkage

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[GWAYGWAY]

M 6 speed transit was very difficult to get into 4 gear, But when i let the stick find it's middle sprung position it just drop in. I was catching the gate either side of the gear slot when i hold it loosely it slides right in.

 

[keith c parker]

Thanks very much for all your advice. I have tried doubling my clutch up and down the box and slowing down to see if it drops in. I've been told by a gearbox company that it's the baulk ring that is worn and stopping gear changes and
For my model they no longer make parts for the gearbox.
I would like to think someone could tell me different.
Thanks again for the help.

 

[pappajohn]

Seized linkage will not cause gear crunching...it will just make shifting harder.
Gears grind, linkages don't.
Sounds like second gear synchro is shot.

 

[pappajohn]

The baulk ring is part of the syncro hub and gets everything lined up and turning at the same speed before fully engaging the gear.
If the ring is worn the gears rotate at different speeds causing the grinding as the gear teeth jump over each other.

 

[keith c parker]

Thanks for that. It's always better when someone takes the time to explain.
Much appreciated.

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[Tootles]

For my model they no longer make parts for the gearbox.
I would like to think someone could tell me different.

Already did. Read post's #4 & #6.

 

[Fulltiming Felines]

I want to share my experience getting the gearbox reconditioned on my 1991 Hymer 534 Fiat Ducato 1.9 TD.

I bought this motorhome in Germany and was driving it back to the UK. At high speed it would sometimes shake, but sometimes it would go away. I called ADAC (German AA) and their mobile engineer thought it was a wheel problem. It was very difficult finding a local garage in Germany that could look at it right away. Most needed to be booked in at least a week in advance, and I wanted to get it back home since we were moving out of our house and into the motorhome full-time.

On the way back to London, I stopped in at All Tyres in Whitstable (good shop, recommended). They balanced all the wheels and put some weights on the wheels. They said the balance was quite bad. £60, worth doing but unfortunately didn't fix the shaking.

Dropped it off at @dave newell lvs where we had a prior booking. He identified that the gearbox was whining when in 4th gear and that the driveshaft needed replacement. He writes:

"There is no guarantee that anyone can rebuild this gearbox, if it has extensive internal damage (which is quite likely given the noise it makes) it will be scrap and a replacement will be needed and as I said before they are rarer than hens teeth, even if you can locate one it could easily be as bad as the one in your vehicle now...

The support bearing is completely missing, presumably it came out of the support bracket but nobody noticed. The shaft has been thrashing around in the support bracket and has worn half way through the shaft, the bracket must therefore be worn to a similar level."

Dave doesn't work on gearboxes so I called around to over a dozen gearbox specialists (notes below). I ended up sending it to Geartech in West Midlands.

They drew similar conclusions as Dave, that the bearing popped out, causing the driveshaft to thrash around and then drain out the gearbox oil, which then caused the 4th gear to burn.

I wonder if I had stopped at a garage as soon as the shaking started that they could have just fixed the bearing and saved a lot of money.

Ended up paying £1537+VAT fitted for everything. Took about a week. 6 month warranty on gearbox. Longer for the other parts.

They couldn't find a replacement for the 4th gear so they just cleaned up the burnt gear as best as they could. It still whines and I need to minimize my use of it. That's not too hard, just shift to 5th early—unless I succumb to the notorious Fiat 5th gear problem

Costs below without VAT:

Gearbox repair £790—this could be cheaper if the problem was less serious

Gearbox fitting £300—fitting into an A-class motorhome is difficult

Gearbox oil £26

New clutch £96—when fitting a gearbox, might as well have a look at the clutch and see if it needs replacement

Driveshaft £190

Bracket and fit £135

Gearbox specialists
My notes from when I called around.

Geartech in West Midlands, as mentioned above.

Gear Up in West Yorkshire. www.gearupwakefield.co.uk £420+VAT for gearbox, £500 fitted. Sounds much cheaper than everyone else. Too good to be true? 6 month warranty.

Maltings Transmissions. Spoke to John. Might be able to. Probably around £1000. Needs to see photos.

Gloucester Road Gearboxes in Bristol. Can do but costs £1275+VAT

Essex Automatic Transmissions aka Essex Gears in Harlow. £1000+VAT. Couple hundred to fit. £25-50 to ship on a pallet, each way. 1 year warranty. Couple days to rebuild.

Alpine Transmissions in Glasgow. Not sure, needs to see the box in person, open it up and see if they have the parts

No1 Gear. Can't do

Hardy Engineering in Leatherhead. Best case £500+VAT, but can't guarantee they'll have the parts. 2-3 hours stripping it ~£150, only then can they diagnose it.

The Transmission People aka reconditionedgearboxes.com. Only do 1998 onwards

Gearbox Specialists in Southampton. Can't do

Re-Engineered Transmissions in Essex. Can't get parts.

Planet Gears in Peterborough. Wait for callback

I found a lot of these by searching on eBay for "Fiat Ducato gearbox" and contacting the sellers, even if they didn't have the same model. Many of them are garages and can do a rebuild.

It wasn't easy. The parts are no longer in production so everyone has to scrounge for them. There are so many variations of the gearboxes and the VIN plate numbers and the part numbers aren't completely reliable.

 

[gus-lopez]

Thanks for that ,very informative & glad to hear that you have it back working.

 

[Duckett]

Hi, I have a Fiat Ducato 1.9 turbo diesel T reg, 1999. I have a problem with the gearbox going from first to second, it grinds but goes in. From third to fifth and reverse there is no problem. We have asked the fiat dealer and other gearbox repair companies. they all say the same. This year of motorhome they can not get the parts to repair the problem.

Does anyone have any idea where I could get this gearbox repaired or get a re conditioned one. I have been told it is an ML gearbox if that is any help.
Thank you very much.

I have come across the same problem NO SPARES are made anymore 1 possible cure is change the gearbox oil I have not tried this so maybe it works maybe not worth a try though

 

[Grummyb]

The new to me peugeot boxer (known affectionately by son who is a Peugeot trained tech as the bag of shit) had the gearbox repaired just before I bought and it was done by Tram Valley Transmissions in Washington and I think they replaced some if the synchro rings although I didnt they were still available but it might be worth having a chat with them especially as they are just up the road from you

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