Hymer B544 Fiat Ducato 2.8JTD Year 2000 motorhome. Lost 5th Gear Part 2 of 2

Рет қаралды 5,235

Жыл бұрын

We lost 5th gear on our Hymer Fiat Ducato 2.8 JTD. We investigated and found 5th gear stripped of teeth. So we replaced it with a modified set with lower ratio for 5th gear to help alleviate it happening again. Part 1 is covering the gearbox disassembly, analysis, modification details. Part 2 is preparation, reassembly and test drive. I hope you find it both entertaining and a good go to reference if you should lose your 5th gear on a 2.8JTD based vehicle. #hymer #hymermobil #fiatducatocamper #fiatducato #renaulttrafic #citroenrelay #peugeotboxer #JTD #2.8JTD #hymerb544 #b544 #5thgear #fiatducatogearbox #ducato #campervan #lovinglife #motorhome

Пікірлер: 23

@AlainGuillaume-qt7lw Жыл бұрын

Hello, We also have a Hymer B544 from 2000 with the 2.8 idTD of 122 HP with a long 5th gear. It has 180.000 km and this 5th gear still works well. On the highway at 100/ 110 km/hour it's perfect! But I'm careful not to make this 5th gear suffer at low engine speeds and with too much load! For information, the filler cap is located at the front of the gearbox, halfway up. Thanks for your video! Alain, Brussels.

@christoffsgarage8873 Жыл бұрын

Thanks Alain for your messages. I have heard some managing good mileage on the 5th gear. They undoubtedly have had owners being aware and taking care of the 5th gear. 👍

@Lincslad 6 ай бұрын

Hi Christoff. Thanks for this excellent video. I don’t have a problem with my 5th (yet) but if and when I do I now have the confidence to tackle it. I have a 2001 Laika ecovip with the JTD box and I change the oil every year religeously, as you say, with minimum 2.7l. Thanks, Trevor

@hymerlifetravels Жыл бұрын

Excellent video vlog I've got the B754 tag axle 2001 Fiat Ducato 2.8JTD with 5th gear I normally drive and engage it over 50mph as my REV counter doesn't work. If you decide to do a vlog on repairing the electronics of the REV counter that would be great. Thank you for the excellent video on changing the 5th gear will keep that in mind.

@christoffsgarage8873 Жыл бұрын

@hymerlifetravels thanks for your feedback👍. Fingers crossed as my rev counter is behaving itself. However my temperature gauge has a mind of its own 🙄

@neilmccartney6573 9 ай бұрын

I did this exact job on my 2000 bessacarr ,, and yes that moment of the fifth gear going in for the first time is nervy but soooooo satisfying lol ,, Wonder if you know if the older 2.5 td 1994 type models have the same problem ? I have just bought a gem of a campervan in france , it’s done 18k miles from new , sat on blocks for twenty odd years ,, it’s as new ! 15k ! Love it .. thanks for the memories of that job ,, and yes it can be done by anyone really ,,

@christoffsgarage8873 9 ай бұрын

Thanks Neil for you comments. Yes makes all worthwhile and very satisfying when a job goes to plan. Ref your 2.5td. Is it Ducato based. If it is I would expect the 5th gear layout will be the same. However with 18k on the clock if you drive it mindful of 5th gear does not like labouring ie up hills it will last for sometime 👍

@chrissheppard6999 7 күн бұрын

Excellent, informative videos. I have a 1997 B544 (2.5tdi) with similar issues (5th now pops out) and am contemplating the DIY approach to replacement, guided by your great videos. Just wondered, given that it's now a while since you did this, are you still pleased you went for the lower ratio gearing? Just trying to decide whether to go 'like for like', or go for the lower ratio option like you did (if I can lay my hands on the parts). Thank you so much... 0:47 ... another Chris!

@worldvisionable 5 ай бұрын

Thank you Christoff for a superb video. I've got a 1989 Hymer but with a Peugeot J5 engine which has the same type of set up and the 'bolt on' 5th gear. I have an issue with getting stuck in reverse. I'm not sure if this is fixable without removing the box as I have seen mention that 5th and reverse are somehow related. I think you may also be in the Classic Hymer Technical FB group and I have asked the same question there. Much appreciation.

@christoffsgarage8873 4 ай бұрын

Thankyou for your compliment. I apologise as I just seen your comment here. I am unsure that reverse is in the 5th gear add on box. I guessing it will be in the main box and removal and strip would be needed of the main box. I don’t have practical knowledge for the reverse as not had to deal with that issue yet!

@swillis7011 2 ай бұрын

Hi, great video and has given me the confidence to have a go. Just wondering where you got the gearbox end case gasket from. Do you have a part number. Did you buy the gear kit from anywhere in particular?

@jeffshaw4553 10 ай бұрын

Well done saved yourself few quid there I dread if we ever have issues with our ducato Swift it’s got the auto box which is bit awkward to select auto as it’s semi auto not long had it but presume I will get used to where auto rather than semi auto there nothing wrong with auto box just getting used to where it needs to be 👍🏽👍🏽

@christoffsgarage8873 10 ай бұрын

Thanks Jeff for the kind comments. 👍👍

@jeffshaw4553 10 ай бұрын

@@christoffsgarage8873 your welcome where are you based please presume you got your own garage or mobile??? After some one decent like minded in motor home to do some work on mine 👍🏽👍🏽

@christoffsgarage8873 10 ай бұрын

We only work on either our own vehicles or preparation of vehicles to sell. 👍

@jeffshaw4553 10 ай бұрын

@@christoffsgarage8873 oh ok thanks any way 👍🏽👍🏽

@nicktew5617 12 күн бұрын

Hi. I have a 2003 Fiat Ducato 2.8 (Swift Kontiki 660) Motorhome. Lost 5th gear and looking for parts but I understand there are 2 options regarding number of teeth on the dogs. Either 33/45t or 53/31t…..do you know which will fit my van, please?

@pierbartolucci7518 Жыл бұрын

Hello Christopher. I have a ducato with the same mechanism of this. Just a great doubt. My 5 gear is an 56x33 teeth which is out of production. Do you think possible to replace it with th 58x35 teeth one?

@martino009 Жыл бұрын

yes you can no problem

@christoffsgarage8873 Жыл бұрын

Sorry Pier for the late reply (vacation). What engine and year is your Ducato and is it a motorhome?

@pierbartolucci7518 Жыл бұрын

@@christoffsgarage8873 hello Christoff I hope that you will be more relaxed now. I have a Ducato 2.8 year 2001 230 12 tons. The same gearbox is out of production and I've to adapt the 18 tons gearbox models

@christoffsgarage8873 Жыл бұрын

@@pierbartolucci7518 Hi Pier, you need to do further research as Fiat changed their gearbox design post 2001 and moved away from 58:35 teeth (ratio 0.601:1) probably owing to teeth stripping. If I am correct yours is a non turbo so ratios will be different to turbo engines. You mentioned 12 tons and 18 tons which confuses me as neither the weight of the van and payloads are such high numbers

@xdelfinox 24 күн бұрын

@@christoffsgarage8873 where are you based? I have the exact problem you described, but would rather have you fix it if you can, than me (a newbie). Would it be possible?