Hi all.
First post so be gentle if I'm in the wrong corner of the forum.
I have a 2004 Doblo 1.9 JTD Family but I can't select 4th gear
The gear lever feels slack especially in 3rd but all the other gears work fine. My instinct tell me it's a problem with the linkage being worn but I'm looking for verification here. There may be something more insidious that is common / likely that I don't know about

Any help, advice or even rumours would be appreciated. Cheers

If it were me and whilst the cables are still connected, I'd be inclind to check the leverage on top of the gearbox, purely for elimination purposes. Get somebody to hold to clutch down and go through the gear change sequence in the cabin. At the same time, with your head under the bonnet, follow the gear changes and see if the cables are pulling the gear levers fully to engage the required gears. If it's leaving the gearbox levers short, push the lever by hand to confirm the gearbox is OK. Might be easier if you take the battery and battery tray out for easier access.
All that said, I have seen posts on here where are a bracket does gives way. Believe a chrome bracket position down from the dash gear changing lever.

Hopefully it is something outside the cogs. I need a service manual and then I can get stuck in over a weekend. I'll post some pictures and results here too when I do.
As for that common issue you mentioned... Being in the manufacturing business, I would probably just reverse engineer the offending piece and make a stronger one out of stainless rather than weld up the original.

Stupoticus said:

I would probably just reverse engineer the offending piece and make a stronger one out of stainless rather than weld up the original.

Click to expand...

If you do, knock out a few whilst your at it, might turn into a little earner for you

Well...
I had a look at the gear selector while I was messing with my clutch actuator (don't ask)
Although the selector mechanism is slack and has also had the "common" weld up repair, it is not the reason I cannot select 4th.
Having tried to select the gears at the gearbox too I can now verify 4th is a no go.

Now, does anybody have an engineering drawing of the gearbox so I can dissect it and bring the thing back to life... Maybe in the spring.

Bump!
I'm still on the lookout for a schematic of the gearbox for this Doblo.
Anyone?

Stupoticus said:

Bump!
I'm still on the lookout for a schematic of the gearbox for this Doblo.
Anyone?

Click to expand...

I rebuilt the c510 box in my doblo only thing i can think off is the safety device to stop you selecting reverse straight out of 5th gear,my local fiat dealer simonstone copied off all the internals for my box i will dig them out and try and figure out how to put them on here!

boney said:

I rebuilt the c510 box in my doblo only thing i can think off is the safety device to stop you selecting reverse straight out of 5th gear,my local fiat dealer simonstone copied off all the internals for my box i will dig them out and try and figure out how to put them on here!

Click to expand...

I have found pics of internals dont know how to put them on here will try one of my daughters if all else fails!

boney said:

I have found pics of internals dont know how to put them on here will try one of my daughters if all else fails!

Click to expand...

I can post pics on my laptop unfortunately its in work,i cant figure out how to do it on my galaxy s5 i'm on now,i will even try my wife once she is home!

boney said:

I have found pics of internals dont know how to put them on here will try one of my daughters if all else fails!

Click to expand...

Managed to put 4 out of 7 photos in gallery section i could always e-mail them all to you if that help

That would be top notch chap!
I will pm you my email address for minimum fuss.
Thank you ever so much

Did the pics come through if not will get my 14 year old to do it!

Having run the offending Doblo for 3 years without 4th gear, I can now confirm that the synchro was broken for 4th and it would, on rare occasions, actually go in to 4th. Probably a broken piece of something jamming it up the rest of the time.
So there you go. That Dob's dumped, just got another (With 4th!)

Had it on 2 of ours the syncro hub sheds a piece of the carried & blocks the gear verry light item for commercial van