New Recon Gearbox but when driving 5th gear randomly slips out

J

jaffacat

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Jan 30, 2025
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Fiat Ducato Ensign
Hi
I have had the gearbox in my fiat ducato royale ensign reconditioned because 3rd/5th gear were playing up. When I am driving now the 5th gear when i am driving it so 60-70mph randomly slips out the gearbox company dont know why, we have changed the cables, syncro mesh aswell. There is no noise or anything it will just slip out of gear - anyone any ideas what could be causing this? She is 25 years old
 
hi there welcome,

Don’t know the answer but surely if you have a reconditioned box then it wasn’t done thoroughly. So who ever reconditioned the box should sort it without charges or inconvenience to you.

Did the reconditioned box come with a warranty?
 
Yeah it did come with a warrenty and I have spoken to them - they do not think it is the gearbox as they stripped it down and replaced everything. I was wondering if anyone mechanical had ideas, I have googled things and it could be mounts, transmission fluid etc the list goes on. The gear randomly slips out, it doesnt do it all the time / its easy to get into gear as well so indicates something else possibly
 
does it happen under load or when you take your foot off the accelerator (on overrun)?
Is the gearbox one that had the 5th gear 'added' to the side of the box?
 
My initial thought was adjustment, but you need to gather a bit more info , like is it coming out while power is on or after you’ve lifted off .

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When it comes out of gear is the gear lever also moving out of its normal ‘engaged’ position?
i.e. would holding the lever in position keep it in gear?
I’m not saying you should have to do that, just trying to gather info!
 
KNWH said:
When it comes out of gear is the gear lever also moving out of its normal ‘engaged’ position?
i.e. would holding the lever in position keep it in gear?
I’m not saying you should have to do that, just trying to gather info!
Click to expand...
Dont know havent tried that will try at the weekend

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Bill-H said:
does it happen under load or when you take your foot off the accelerator (on overrun)?
Is the gearbox one that had the 5th gear 'added' to the side of the box?
Click to expand...
No not under load or when foot off accelertor, was just driving along the dual carriageway circ 60-70 mph and it slipped out for no reason. Only when it was in 5th cause I kept driving after going through a town and again it happened about 30miles later same situation
 
jaffacat said:
Hi
I have had the gearbox in my fiat ducato royale ensign reconditioned because 3rd/5th gear were playing up. When I am driving now the 5th gear when i am driving it so 60-70mph randomly slips out the gearbox company dont know why, we have changed the cables, syncro mesh aswell. There is no noise or anything it will just slip out of gear - anyone any ideas what could be causing this? She is 25 years old
Click to expand...
It's a synchromesh problem, the gear is not fully engaging. It could be just a simple adjustment on the lever that moves the synchro in the box, or the linkage.
 
Don't know if all gearboxes are the same, but on a motorcycle gearbox that fault would be the dogs on the gear aren't holding in [ usually due to wear] and get pushed out normally under load. 🤷‍♂️ As others have said, " it ain't right" and needs to go back ASAP.
Mike.
 
I had similar years ago. Under load or on over-run it would be fine. It would sometimes pop out when neither accelerating or decelerating. A different box fixed it.
 
try to find clear stretch of road , and select 5th a try hard acceleration and then go to overrun rapidly watching or lightly holding gearshift lever repeat several times, to try and determine what is causing pressure to move lever could be several possibles , not engaging fully , due to cable adjustment , lever linkage adjustment , selector rod detent position , incorrect adjustment/ build on gear shafts weak synchro hub springs. Whatever it is its down to the replacer/overhaulers .
 
The other question is; did it do it before the recon?

If yes, then it was not properly reconditioned.

If no, then they have caused it in their process, reconditioning or refitting.
 
On a new VW T5, I had an issue where it grated going into gear, and got progressively worse at engaging gears .At a couple of years old it just wouldn't select any gears.Turns out from the factory the ball selector on the top of the gearbox had never been torqued down, and was floating around, they were somewhat amazed it had lasted like it had for so long. Once properly torqued down it was silky smooth.
Mike.

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Phill D said:
The other question is; did it do it before the recon?

If yes, then it was not properly reconditioned.

If no, then they have caused it in their process, reconditioning or refitting.
Click to expand...
Yep.I'd be tempted into a bit off gridding outside their gate ;).
Mike.
 
The "added on 5th gear" gets starved of oil and wears fastest. Some can be flipped 180⁰ without opening whole gearbox.
Then add 500ml more oil than usual to ensure 5th gear gets some and don't use 5th gear until engine warmed after 5 minutes.
 

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