5th Gear Dropping out - Fiat Ducato 2.5 TD 1994 - 2001

Hi All.... please can you help?
Just 500 miles and about 2 weeks after buying my 1998 Fiat Ducato 2.5 TDi, the 5th Gear started dropping out when at about 50mph. It’s the gearbox where Fiat changed a four gear box into a 5 gear box by attaching it to the outside. I’ve since discovered that this is quite a common problem especially if using when revs are too low.

During the research I found that it is more than likely because oil is not getting into the 5th gear chamber and has now worn. Some suggested it’s just a 5th gear synchro change (I think synchro is the right part) and it is a fairly simple 2-3 hour job. Does anyone know about this issue and/or know a specialist who knows how to do it, OR a thorough procedure on how to do it - I am prepared to get stuck in if necessary? Thanks in advance for any advice.

Regular gearbox oil change helps.
Redirecting scuttle water away from gearbox housing also helps.
As for repair, gearbox specialist should tackle it easily as it is common.

hi max.. axel Augustine de have complete fifth gear kits for that model. hope that helps

Hi Check this previous post about the 5th gear -
https://www.fiatforum.com/ducato/420430-5th-gear-problem.html
This was posted on Google docs by "Garry" which I think has since been trashed but attached is a PDF of Garrys step by step instruction on changing the 5th gear from his original post
Also there is a zip file containing Garrys original pictures he put up on google docs which have since been deleted from the original post on Google docs but are available from the above link & from below
So again thanks to Garry for the guide.
Hope that helps
Cheers

Sorry for the late reply. I did not get an email to say I had responses.

THANK YOU SOOOO MUCH FreeSpirit, Jev88, and jontee61, you are all amazing to help like this. New to forums so this is a lovely experience.

OK, great advice... so, as a first stab at this, Jev88, you reckon that a "Regular gearbox oil change" may well do the trick and it might not be worn teeth on the gear?

On the oil front, I had heard that the box needs pretty much overfilling so that oil gets into that chamber. Definitely, worth trying that first on next service.

THANKS to ALL of YOU.

Hi Jev88 and everyone in the thread. I have heard it suggested to change the oil to a good quality synthetic oil (not the recommendation made by Fiat) AND to increase the oil qty by approx 700ml.

Do you know what the best synthetic oil to add is AND what the total oil amount to add is, with the extra 700ml?

Your help is hugely appreciated.

Milomax said:

Hi Jev88 and everyone in the thread. I have heard it suggested to change the oil to a good quality synthetic oil (not the recommendation made by Fiat) AND to increase the oil qty by approx 700ml.

Do you know what the best synthetic oil to add is AND what the total oil amount to add is, with the extra 700ml?

Your help is hugely appreciated.

Click to expand...

hi milomax. I would be dubious of using fully synthetic but if you do make sure its gl4 not gl5 as the latter can cause damage to the syncros by removing the protective bronze coating. if you use the search engine for recommended gearbox oil for 94 through to 98 2.5tdi some good advise to be got.

Thank you SOOOO Much for your advice. It is HUGELY appreciated. Would never have thought of the GL4/5 issue at all! I will indeed Google some more to be sure I get the right one.

THANK you and EVERYONE for such amazing help.

The 5-speed gearbox can have either column change or floor change depending on model and year. My 1994 Ducato 10TD has column change and the rod and cable both have adjustments to get it properly into gear. You could try to see if there is any slack when in 5th or more likely if the cable is still tight, holding it slightly out of full engagement. If so it will soon jump out on the road. The linkage over the gearbox must be totally free with no play in the ball joints and bushes and well lubricated with duck oil or similar, regularly.

Regarding gear oil I pump 2 litres of sae140EP into mine against all the pundits recommendations. But avoid running too fast in any gear especially in 5th, that end section is known for getting insufficient oil so keep the temperature down by going steady, and changing down early on hills.

Lastly this is a terrible gearbox, Fiat should be ashamed to have ever built it.