We have just had the same thing happen on our Frankia 2002 Fiat Ducato 2.8 jtdi. motorhome with 60,000 km on the clock. We were driving along the motorway in Germany and suddenly fifth gear just disappeared the gear lever didn't jump out , no grinding sounds it was just gone, it was as if I was revving the engine in neutral. Gears 1-4 were still functioning. We took it to a Fiat/Iveco commercial vehicle workshop in Kalkar by the dutch border. They removed the 5th gear housing and saw that all the teeth had been broken off the gears, so they ordered a complete new 5th gear set including the large nut on the end, the changing fork, seals etc...the lot.. it came to 700 Euros including a 10% discount, on top of this was the labour, with Vat the whole lot came to 1026 Euros....Gasp. They let us stay outside on the forecourt whilst we waited for parts overnight. Next day everything was fitted and we took it for a test drive.... changed into 5th and out jumped the gear, tried again the same. Well to cut a long story short, the gears have been taken out and put in about 5 or six times now. The cables from the gear lever have also been checked and are ok. We were stuck at the garage for 5 days and the problem has still not been resolved, we thought it had been sorted out after another replacement set was used, but after driving another 150 km the gear lever is still jumping out occasionally..... Now my questions, has anyone else had this problem after changing the entire 5th gear?, could there something wrong inside the gearbox? maybe a problem on one of the shafts that come out to the 5th gear. Just to add...prior to the repair the 5th gear had never before jumped out.... I would be very grateful for any replies.
Clive W
June 2014
howtomendit.com for free repair help, information and advice.
Try fixfault.com to fix vans.