IB5 gearbox issues.
#1
IB5 gearbox issues.
Right, I've had no end of issues with my gearbox not wanting to go into gear, loud whining noises, 3rd gear sometimes grating.
So I've had the box out, replaced the entire gearset, every bearing, every seal and every gasket.
Still grating in 3rd gear, whining in 2nd gear, no synchro from 2nd to 1st and once you put it in reverse it wont come out again whilst the engine is running?!?
I'm at the end of my patience after having this gearbox out and in 3 times and spending an entire bank holiday trying to sort it only for it to turn out worse.
So the only thing I can think now, is the case nackered? or could the diff be causing these issues? because they are the only two parts that haven't been changed.
Failing that I'm seriously debating breaking the car as I'm losing interest because of this on going issue.
So I've had the box out, replaced the entire gearset, every bearing, every seal and every gasket.
Still grating in 3rd gear, whining in 2nd gear, no synchro from 2nd to 1st and once you put it in reverse it wont come out again whilst the engine is running?!?
I'm at the end of my patience after having this gearbox out and in 3 times and spending an entire bank holiday trying to sort it only for it to turn out worse.
So the only thing I can think now, is the case nackered? or could the diff be causing these issues? because they are the only two parts that haven't been changed.
Failing that I'm seriously debating breaking the car as I'm losing interest because of this on going issue.
Last edited by Chopshop85; 30-05-2016 at 03:48 PM.
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#8
Yeah, all the bearings where replaced with the correct size. Each bearing was checked, then replaced like for like during the rebuild.
So I've made a bit of progress, I made several adjustments to the gear linkage to try and sort out the sticky reverse which worked.
3rd gear noise is if you leave your hand on the gearstick or push it too far forward whilst changing so something is catching. Same with second.
So I shall pull the gearbox apart, again, and see whats catching where as I should have fresh marks where parts are catching.
So I've made a bit of progress, I made several adjustments to the gear linkage to try and sort out the sticky reverse which worked.
3rd gear noise is if you leave your hand on the gearstick or push it too far forward whilst changing so something is catching. Same with second.
So I shall pull the gearbox apart, again, and see whats catching where as I should have fresh marks where parts are catching.
#9
PassionFord Post Troll
You say like for like, but what I'm saying is the IB5 requires the diff to have different bearings bolted on.
LSD diff in BC casing - bearings are the same both sides
Same LSD in IB5 casing - 1 BC sized bearing, 1 larger
So if you just fitted new versions of what was already on the diff, then one will be undersized.
LSD diff in BC casing - bearings are the same both sides
Same LSD in IB5 casing - 1 BC sized bearing, 1 larger
So if you just fitted new versions of what was already on the diff, then one will be undersized.
#10
Advanced PassionFord User
iTrader: (1)
You say like for like, but what I'm saying is the IB5 requires the diff to have different bearings bolted on.
LSD diff in BC casing - bearings are the same both sides
Same LSD in IB5 casing - 1 BC sized bearing, 1 larger
So if you just fitted new versions of what was already on the diff, then one will be undersized.
LSD diff in BC casing - bearings are the same both sides
Same LSD in IB5 casing - 1 BC sized bearing, 1 larger
So if you just fitted new versions of what was already on the diff, then one will be undersized.
I found this out the hard way, I'm sure it's the flywheel side diff bearing in the IB5 that is bigger, mine caused the crown wheel to make contact with the box casing very close to the main shaft bearing and knackered the casing in the process. It's only 2 or 3 MM aparently, I've got my box apart as I'm going back to a BC as I've had problems in other cars and mine with the clutch pedal hight with the IB5.
I'll measure them later if you want as I removed the bear seats from my BC box last night.
Ginger
.
#11
You say like for like, but what I'm saying is the IB5 requires the diff to have different bearings bolted on.
LSD diff in BC casing - bearings are the same both sides
Same LSD in IB5 casing - 1 BC sized bearing, 1 larger
So if you just fitted new versions of what was already on the diff, then one will be undersized.
LSD diff in BC casing - bearings are the same both sides
Same LSD in IB5 casing - 1 BC sized bearing, 1 larger
So if you just fitted new versions of what was already on the diff, then one will be undersized.
Since then it just seems to get worse and worse which is why im scratching my head and wondering if the diff itself or case wear could be causing my problems.
Last edited by Chopshop85; 01-06-2016 at 02:53 PM.
#12
PassionFord Post Troll
Ah ok cool, least that idea can be written off!
Take it the selector shafts were all checked to be straight and true? And the selector gate isnt bent (the pin could also be bent/would probably bend first)
^^Realise the above could be stupid/obvious/annoying questions but I've been in a similar boat - box out 3 times to resolve a reverse gear issue
Take it the selector shafts were all checked to be straight and true? And the selector gate isnt bent (the pin could also be bent/would probably bend first)
^^Realise the above could be stupid/obvious/annoying questions but I've been in a similar boat - box out 3 times to resolve a reverse gear issue
#13
Ah ok cool, least that idea can be written off!
Take it the selector shafts were all checked to be straight and true? And the selector gate isnt bent (the pin could also be bent/would probably bend first)
^^Realise the above could be stupid/obvious/annoying questions but I've been in a similar boat - box out 3 times to resolve a reverse gear issue
Take it the selector shafts were all checked to be straight and true? And the selector gate isnt bent (the pin could also be bent/would probably bend first)
^^Realise the above could be stupid/obvious/annoying questions but I've been in a similar boat - box out 3 times to resolve a reverse gear issue
It turned out to we a warn alloy selector fork that had deposited swarf into places it shouldnt have. So various parts were replaced and further checked using bits out of 2 other gearboxes and finding the best bits.
I'm all for stupid annoying obvious questions incase its something I have overlooked. It's just driving me mad now.
#15
Ok got the bottom of the problem. For some bizarre reason, the 1.3 KA gearset that I used to replace the 1.3 KA gearset I had before were slightly different. This amounted to the whole shaft moving when trying to change gear!
Its all sorted now and working as it should
Its all sorted now and working as it should
#16
PassionFord Post Troll
Glad its sorted.
So was it a bearing size difference then? Cant see how the gearset being different can alter shaft play. Really this is only controlled by the input/output bearings
So was it a bearing size difference then? Cant see how the gearset being different can alter shaft play. Really this is only controlled by the input/output bearings
#17
No, first gear was a few mm thinner. So the intermediate shaft had slightly thicker gears to compensate. However, as we were using the best parts of each and didn't notice the size difference it meaning that there was movement in 1st gear once all back together.
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