Fiat Ducato 2.5 / 2.8 Diesel MG5T 5th Gear Kit 34 / 53 Teeth 1994 to 2002

This may be of interest to those with a Ducato based camper of 1994 t0 2002 vintage. These models tend to suffer from 5th gear failures due to the dodgy design of sticking an " Add on " 5th gear to the original 4 speed box. I recently had the 5th gear synchro fail on mine so decided to get the complete 5th gear assembly replaced. I've always felt the ratio going from 4th gear into 5th was way too tall and felt more like going from 4th into a 6th gear. I ordered a shorter 5th gear kit from ebay and a friends son who is a fiat mechanic done the job for me on his driveway in around 2hrs or so. The gearbox does not need to come out as the gears can be replaced in situ, you dont even need to take left front wheel off! Anyway, the van is so much more enjoyable to drive now, plenty of pulling power when going into 5th at lower road speeds, before you had to be doing around 90kph or so when changing up in 5th for to keep good momentum. Hills are also much better too, huge difference and all but the steepest would you have to drop to 4th. Anyway, really happy I went this route with the shorter gearset 34/53 teeth set ( 35/58 teeth was in it originally ). The kit cost me 360 EUR on ebay.



https://www.ebay.ie/itm/Fiat-D…057872.m27

We only went to Wexford since it was done Tommy so haven't noticed over such a shortish distance. I'm not a mpg watcher to be honest so I couldn't tell you what I was getting to compare. I';m sure there may be some difference but can only be very small. It makes a huge difference though in drivability so that's good enough for me.

Hi Doc,

We have had no issues at all with 5th gear since replacing to the lower ratio. We sold the van in January this year to my sis and brother in law and zero issues with them. It was worth it to go for the 34/53 gear set....The taller gear was a pain in the ass, you had to flog the van in 4th to get good momentum for changing up to 5th. I would recommend the shorter gearset kit as it was spot on for the van imv.

I see they have gone up in price since we purchased? Still worth it though....Best of luck!
!

Doc.... my van was only 5.9 metres and under 3500kg. I still found the shorter 5th gear set way ahead of the taller ratio. I changed the complete 5th gear assembly...synchro, hub ...2 gears etc.

My advice would be stick to what ratio you have as you seem to be leaning that direction anyway.

There is a lot of info on the web about the older ducato needed the gearbox filled 10 mm above the max to ensure oil gets to the 5th gear on the top of the box, these gearboxes have the same add on gear

Where are you