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Fiesta IV gearbox (ib5)

  • 10-09-2011 7:46pm
    #1
    dgt
    Closed Accounts Posts: 12,985 ✭✭✭✭


    Hi all, I would like to pick the brains of Ford and Rover people :)

    My little fez has a horrible rattle on reversing and on lifting off the throttle. After some research I've come to the conclusion that my output shaft is failing... :(

    Recently, I got another fez as a spares car for my one :) However, I never realised 2 5 door cars could be so different... Mines a 1997 and the spares one is 1999. The rear axle is different. The suspension is different. Bonnet. Doors. Speedo. I could go on and on...

    Anyways, my problem. I decided after driving both cars that the box on the newer car would be installed on my car as its much tighter (less slop in neutral) and most importantly, quiet. The boxes themselves are the same in terms of ratios and bell housings however theres a plug on the 1997 casing that isnt on the 1999 box. I don't have a picture handy but there are other little differences.... :mad:

    My question: Will the car work without this stupid plug? Theres a speedo cable, I have no idea what this plug even does! Or will I have to go down the route of swapping the casings and internals?

    Any advice is much appreciated :)


Comments

  • #2
    dgt
    Closed Accounts Posts: 12,985 ✭✭✭✭dgt


    I've been doing more research on the subject...

    I have this plug on my box, can anyone tell me its full functions? I know its for reverse...

    IMG_1870.jpg


  • #3
    dgt
    Closed Accounts Posts: 12,985 ✭✭✭✭dgt


    Right, I solved the mystery :)

    First, these gearboxes suffer from a badly made output shaft. The signs for me were a horrendous rattle in reverse and on lifting off the throttle (other symptoms are the speedo intermittently working)

    Heres the worn shaft in my box. Its ground down due to poor construction materials
    Image1393.jpg

    The problem I was faced with is the gearbox itself. So far Ive had 3 Fords with the ib5 box, each of them different. The Escort has this box but with a clutch cable, Fiestas are hydraulic. So I got another Fiesta with he same box. However it was different, reverse switch wit 2 pins near the bellhousing as opposed to the one in the pic which has 4 pins, called the "multi functional switch" :mad:

    So did it fit? Yes it did and works perfect. Just need to wire up reverse and it will be ready for the road again.

    What does the "multi functional switch" do? It controlls reverse light and sends a signal to the ecu to tell it when its in neutral. My car works fine without it mind you :)


    For anyone else with a mk4 Fiesta and a wonkey gearbox, I hope this was some help :D


  • #4
    David09
    Registered Users, Registered Users 2 Posts: 541 ✭✭✭David09


    I had thought that gearbox failures are extremely rare on fiestas... Unlike peugeots, vws and fiats. I've never seen a ford gearbox fail before.


  • #5
    Slidey
    Closed Accounts Posts: 12,811 ✭✭✭✭Slidey


    FWD Transits?


  • #6
    David09
    Registered Users, Registered Users 2 Posts: 541 ✭✭✭David09


    Slidey wrote: »
    FWD Transits?


    Proves there's an exception to every rule.

    Mainly I was referring to older stock fiestas, escorts, etc..


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  • #7
    Slidey
    Closed Accounts Posts: 12,811 ✭✭✭✭Slidey


    Ha ha


  • #8
    [Deleted User]
    Posts: 23,339 ✭✭✭✭ [Deleted User]


    David09 wrote: »
    Proves there's an exception to every rule.

    Mainly I was referring to older stock fiestas, escorts, etc..

    not enough bhp or torque to trouble a gearbox :pac:


  • #9
    dgt
    Closed Accounts Posts: 12,985 ✭✭✭✭dgt


    David09 wrote: »
    I had thought that gearbox failures are extremely rare on fiestas... Unlike peugeots, vws and fiats. I've never seen a ford gearbox fail before.

    Well I've researched lots on gearboxes, the mtx-75 seems to be a tougher unit. You can see in my pic where the shaft is wearing away. The box wasn't gone but in a couple of thousand miles it would have been useless. What doesn't help is the fact its a sealed unit and you cant change the oil. My old Escort had the same box with the same problem but I didn't give a rats ass about it or I would have been on here asking about it :pac: I'm sure if you ask around here I wont be the only one with a rattling box in reverse...

    As for Fiat gearboxes the gearbox itself a tough unit (both the 5 speed and 6 speed, apart from worn syncros in 2nd from very hard driving) but the diff in mk1, mk2 Puntos and 1.2 Bravos are crap. The shafts where the gears are held in are bonded not bolted and after years of driving will fail without much warning. The first signs are what seems like a clutch slipping in high gears at high speeds. This progresses through the lower gears and eventually fails. The later mk2b Puntos, Stilos etc have these shafts bolted in so that was problem solved.

    I should know, I've stripped a few of those boxes ;)


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