Technical 5th Gear Problem

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Technical 5th Gear Problem

bhillhct

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Aug 1, 2010
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Malmesbury
Hi, I have a 1995 2.5TD Hymer Motorhome and despite doing all the careful warm-ups before using 5th gear it has suddenly started jumping out of gear everytime its used. I have nursed it back home and noticed the gearbox has an end plate to expose the gears. I have had and restored Scimitars as a hobby for years and wondered if anyone could advise me of how to replace the fifth gears which are presumably located behind the end plate, assuming I can source the correct gears. Any advice appreciated.
 
Hi
There is a thread I posted a while ago with a link to a step by step description on how to replace the 5th gear on a 98 Ducato, how close to your 95 model it is I can't help but will at least give you an idea what's involved -
https://www.fiatforum.com/ducato/357888-5th-gear-1998-fiat-ducato.html
which was put up on Google Docs by a very generous Garry. It was originally on a MotorHome forum but they make you join it after 5 posts so Garry now has it on Google Docs.

There were step by step pictures associated with this replacement procedure taken by Garry as he did his but that link unfortunately no longer exists. But they are in the attached zip so a big thank you to Garry for posting this originally.
There is also a link to "Essanjay" who sell the lower ratio gearsets whether they do the "normal" OEM higher ratio gearsets as well I don't know?
Cheers
 

Attachments

  • Ducato5thGear.zip
    1.9 MB · Views: 828
Thank you Freespirit the images along with the text explanation (elsewhere) are an enormous help. I,m led to believe that the number of teeth on the repective gears are stamped on them some where? Thanks again for you reply.
 
Thank you Free Sprit for your advice - job done and at a fraction of the quoted costs. It turned out that the 1996 gearbox also had the same gears as the 2.8 i.e.58x35 teeth which were stamped on the old gears. It may be worth adding here that when replacing the new gears, place it in fifth gear, lock on the synchro hub to the gear. The springs and ball bearings will jump out if the ball bearing holder is round the wrong way - the Eper diagram is misleading on this as I found out. With the synchro locked to the gear, the gear and selector fork is gently pushed into place and ensures proper gear selection. The cheapest quote from gearbox repair shops came in at around £900. The replacements parts cost me £215. Once again thanks for the help.
 
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