General Lost 5th gear !

[missionary]

1992 115 JTD, 98500 miles.

After 3 years trouble free use, yesterday the 5th gear kept popping out. I can get 5th OK but the lever now seems to need an extra push to engage firmly.

I can hold it in in 5th but it will pop out as soon as I lift the throttle. When it comes out there seems to be almost a ‘thunk’ at the same time.

Cables all seem connected OK, and I can’t hear any odd noises from the gearbox. I wondered about the engine/gearbox mounts too. The top engine mount appears OK, no rubber crumbs or dust, but the rubber has a slight surface crack in it, much as one would expect at this mileage. Anyone any ideas please before I go to the garage. I can tackle most jobs but not gearbox removal on my drive. TIA

A similar problem was described here

https://www.fiatforum.com/multipla/134838-multipla-2002-jtd-gearbox-jumps-out-5th.html


But I can't see anyone has given a resolution to it, so is there an update please?

Cheers

Mish

 

[missionary]

OF COURSE ITS A 2002 MODEL - SORRY


mish

 

[T14086]

I'd be searching ebay/scrapyard for cheap box & getting garage to change it over...might aswell do clutch at same time.

 

[matt8772]

I'd be searching ebay/scrapyard for cheap box & getting garage to change it over...might aswell do clutch at same time.

and a flywheel!

 

[Zundapp]

and a flywheel!

Not convinced.

My flywheel's still fine after changing the clutch 20K miles ago. Total mileage now over 110,000.

 

[missionary]

Thank you gentlemen.

So you think its an internal gearbox problem then, and not external/engine mounts etc?

Not sure about buying a scrap gearbox, as it could be building up to the same problem as mine.

Are there any reliable suppliers of recon boxes out there? TIA

mish

 

[LIFTEX]

Hi,maybe of help to you, had a similar problem on Doblo jtd,basically same box I believe, theres a large nut think it was on mainshaft that can work loose and give selection problems.Unfortunatley it was too late on my box and had trashed the internals as been like it a while. Unsure whether it can be accessed by removeing end plate on box,someone on here with more knowledge maybe able to advise or a local garage/gearbox shop. May save a full strip down.

 

[missionary]

Thanks Liftex, very informative. All sounds OK in box at present. I was going to drive down to my local independent Fiat garage (Leighton Buzzard) today and ask their opinion. Good background info for me.

Cheers

mish

 

[missionary]

I spoke to the garage who tell me there is no definitve diagnosis for losing any particular gear. But they surprised me when they said they pull boxes apart and repair them in their shop, and would do the same for mine at minimal cost, compared with a recon or even fitting a second-hand one.

So I will report after it has been done, but not till after next Monday regrettably.

I noticed today there there is a light intermittent rattle from the box when cold which disappears after a couple of miles running.

mish

 

[matt8772]

I spoke to the garage who tell me there is no definitve diagnosis for losing any particular gear. But they surprised me when they said they pull boxes apart and repair them in their shop, and would do the same for mine at minimal cost, compared with a recon or even fitting a second-hand one.

So I will report after it has been done, but not till after next Monday regrettably.

I noticed today there there is a light intermittent rattle from the box when cold which disappears after a couple of miles running.

mish

it may just need the end casing taking off and the two stake nuts at the end tightening. may not even need to take the box out.

as for a flywheel it depends what way you want to look at it. if youre properly into saving money then take the risk.

from the point of view of having worked in a main dealer, its kind of best practice to at least advise that it needs doing and give the customer the option of replacing it while the box is out. otherwise if the flywheel goes 10k later then its poop all round really.

 

[T14086]

Hi,maybe of help to you, had a similar problem on Doblo jtd,basically same box I believe, theres a large nut think it was on mainshaft that can work loose and give selection problems.Unfortunatley it was too late on my box and had trashed the internals as been like it a while. Unsure whether it can be accessed by removeing end plate on box,someone on here with more knowledge maybe able to advise or a local garage/gearbox shop. May save a full strip down.

excellent point! had this on a .....aghhh cant remember...stilo? however yes an easy check. (skodas suffer from this aswell)

 

[missionary]

Thanks for the additions chaps. I am all for saving money and the clutch and flywheel were changed 30k ago by previous owner who towed ! He sold it soon after the overhaul. So I think that will be OK. But I only do 5/6k a year and I think I might change it for a nosejob before long anyway.

mish

 

[flying clutchman]

5th gear sits on it's own just inside the end casing so it's quite easy to check what's wrong without removing the box. The rest of the box does'nt need to be interfered with.

 

[missionary]

Thanks FD. Its just a challenge persuading the garage that I do have some genuine information about the potential fix for the problem, and getting them to listen.

Anyway, its been parked all week waiting for the garage Monday morning.

Nice to have such great help, thanks all.

mish

 

[missionary]

REPORTING BACK

So, it was fixed in 2 hours and was as you kind experts predicted. Except that just one nut had been stripped of its threads. All done in-situ for a total of £142.97 plus VAT. (£120 labour).


Thanks all for your help.

mish

 

[T14086]

https://www.fiatforum.com/donations.php :worship: