IB5 Gearbox - Clutch Release Shaft/Fork - "Issues" ?!
18-08-2013, 03:00 PM
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IB5 Gearbox - Clutch Release Shaft/Fork - "Issues" ?!
Hi Guys,
I am new to this forum, have "used" it before as a guest reader, and there is a lot of good information always on here, but now I am stuck with the problem bellow and decided to register
The vehicle in question by the way, is a Ford Escort MK6 Ghia X 1.8 16v
Ok, now to the problem at hand, if someone would be kind enough to give me a little help and advice…
My problem is and has been for a while, my gearbox and related… clutch and so on…
This started nearly two years ago, when I made the mistake of having Ford (Dagenham Motors in Epsom/Surrey) replace my clutch with a stage two clutch kit from Black Diamond, soon after this was done, my problems started, I won’t go in details, but the clutch vibrated when revving at about 2000/3000rpm, I was in and out of Ford all the time trying to get this issue sorted, I think there maybe one or two posts on here about this issue too, anyhow Ford accused my clutch at first, obviously because obviously that was the only thing not under guarantee due to the fact that it was not theirs, so I had to pay more money to have a genuine Ford clutch kit put in, so that I could get the Black Diamond clutch sent/brought back to Black Diamond for inspection, as I paid over £300 for it, when they took it out at ford they managed to snap the thrust bearing, somehow, anyhow, after months of arguing with Black Diamond and Ford, I managed to get £750 back from ford, plus they paid Black Diamond directly for a new clutch kit, and had it ready for collection at Ford…
After few more months, my gearbox went, for some reason after Ford had been fiddling with the clutch and taking the gearbox in and out several times, maybe coincidence, maybe NOT, but my differential went and I had a bitch of a struggle to get the gears to go in, not wanting to go to Ford anymore, due to the way I was treated, I looked up an independent gearbox specialist, and ended up finding a place called Gravesend Transmissions in Kent…
Had to drive the car there as it was, which was “fun” on the M25 and so on… I asked those idiots to rebuild the gearbox with genuine Ford parts and to fit the NEW Black Diamond clutch Ford had ordered me, they quoted me just over £600, with a 12 month or 10000 miles guarantee on the work…
I collected the car a week later, and had nothing but problems since… as soon as I got back home I realised that they had re-sprayed the gearbox silver, but fitted it with old bolts which looked really stupid, I had problems with revers and so on, but they said to give it some time to wear in a little, never been 100% happy, especially since the clutch was heating and started to slip, even if I just balanced it at road junctions for a minute or less, however within 6 months one Sunday morning I was going out with the family, and 2 mile from home the gearbox packed up again, this time I could not select any gear at all, and had to leave the car where it was…
E-mailed Gravesend Transmissions, gave then some attitude, and managed to get the car collected under warrantee, they took the car back, and returned it within a few days, and apparently the differential had gone again…
All working again, but within a month I started to hear a noise when pressing on the clutch, like a hamming noise, many people advised me that was the thrust bearing, and all that, but I didn’t know where to bring the car or who to trust, as I had never taken a gearbox out, and it looked like a big job for me to, so I put up with the problem, until one morning I was driving a felt a “pop” under the clutch pedal, and the gears would not go in, when in the engine bay and could not see anything wrong, apart from the clutch cable being slightly loose, so I went under the pedal and adjusted it a little, all seemed ok, so I headed back home…
Then I went out again, with the family, as the good sh*t always happens when the family is in the car… as I got a few miles from home I started to hear crunching noises in the gearbox, and the clutch really smelled, but not the normal clutch smell, some sort of melted plastic smell…
Anyhow I could not drive the car anymore, so had to again leave it where it was, to be towed home…
Now the car is finally hope, I took the gearbox out myself, as I am fed up of all those idiots!
Got a new clutch kit from Ford and all… when I took the gearbox off, I found the thrust bearing destroyed, part melted, with all the bearings out, but the gearbox itself sounds fine when spun by hand…
Installed the new clutch, which is nicely lined up and ready for the gearbox to go back in, but when I went to place the new thrust bearing this morning I noticed that the little pins on top of the clutch release fork that holds the thrust bearing in place are actually snapped off…
NOW my questions are:
1) How do I remove the clutch release shaft from the gearbox?
I removed the bolt on the outer liver, removed the liver, pushed the shaft inwards after unhooking the bottom of the shaft inside the dear box, but there seems to be no enough clearance to fully remove the shaft
2) Where do I find a replacement part? Ford doesn’t even list the part in the eCat…?!?!
Thank you in advance
I am new to this forum, have "used" it before as a guest reader, and there is a lot of good information always on here, but now I am stuck with the problem bellow and decided to register
The vehicle in question by the way, is a Ford Escort MK6 Ghia X 1.8 16v
Ok, now to the problem at hand, if someone would be kind enough to give me a little help and advice…
My problem is and has been for a while, my gearbox and related… clutch and so on…
This started nearly two years ago, when I made the mistake of having Ford (Dagenham Motors in Epsom/Surrey) replace my clutch with a stage two clutch kit from Black Diamond, soon after this was done, my problems started, I won’t go in details, but the clutch vibrated when revving at about 2000/3000rpm, I was in and out of Ford all the time trying to get this issue sorted, I think there maybe one or two posts on here about this issue too, anyhow Ford accused my clutch at first, obviously because obviously that was the only thing not under guarantee due to the fact that it was not theirs, so I had to pay more money to have a genuine Ford clutch kit put in, so that I could get the Black Diamond clutch sent/brought back to Black Diamond for inspection, as I paid over £300 for it, when they took it out at ford they managed to snap the thrust bearing, somehow, anyhow, after months of arguing with Black Diamond and Ford, I managed to get £750 back from ford, plus they paid Black Diamond directly for a new clutch kit, and had it ready for collection at Ford…
After few more months, my gearbox went, for some reason after Ford had been fiddling with the clutch and taking the gearbox in and out several times, maybe coincidence, maybe NOT, but my differential went and I had a bitch of a struggle to get the gears to go in, not wanting to go to Ford anymore, due to the way I was treated, I looked up an independent gearbox specialist, and ended up finding a place called Gravesend Transmissions in Kent…
Had to drive the car there as it was, which was “fun” on the M25 and so on… I asked those idiots to rebuild the gearbox with genuine Ford parts and to fit the NEW Black Diamond clutch Ford had ordered me, they quoted me just over £600, with a 12 month or 10000 miles guarantee on the work…
I collected the car a week later, and had nothing but problems since… as soon as I got back home I realised that they had re-sprayed the gearbox silver, but fitted it with old bolts which looked really stupid, I had problems with revers and so on, but they said to give it some time to wear in a little, never been 100% happy, especially since the clutch was heating and started to slip, even if I just balanced it at road junctions for a minute or less, however within 6 months one Sunday morning I was going out with the family, and 2 mile from home the gearbox packed up again, this time I could not select any gear at all, and had to leave the car where it was…
E-mailed Gravesend Transmissions, gave then some attitude, and managed to get the car collected under warrantee, they took the car back, and returned it within a few days, and apparently the differential had gone again…
All working again, but within a month I started to hear a noise when pressing on the clutch, like a hamming noise, many people advised me that was the thrust bearing, and all that, but I didn’t know where to bring the car or who to trust, as I had never taken a gearbox out, and it looked like a big job for me to, so I put up with the problem, until one morning I was driving a felt a “pop” under the clutch pedal, and the gears would not go in, when in the engine bay and could not see anything wrong, apart from the clutch cable being slightly loose, so I went under the pedal and adjusted it a little, all seemed ok, so I headed back home…
Then I went out again, with the family, as the good sh*t always happens when the family is in the car… as I got a few miles from home I started to hear crunching noises in the gearbox, and the clutch really smelled, but not the normal clutch smell, some sort of melted plastic smell…
Anyhow I could not drive the car anymore, so had to again leave it where it was, to be towed home…
Now the car is finally hope, I took the gearbox out myself, as I am fed up of all those idiots!
Got a new clutch kit from Ford and all… when I took the gearbox off, I found the thrust bearing destroyed, part melted, with all the bearings out, but the gearbox itself sounds fine when spun by hand…
Installed the new clutch, which is nicely lined up and ready for the gearbox to go back in, but when I went to place the new thrust bearing this morning I noticed that the little pins on top of the clutch release fork that holds the thrust bearing in place are actually snapped off…
NOW my questions are:
1) How do I remove the clutch release shaft from the gearbox?
I removed the bolt on the outer liver, removed the liver, pushed the shaft inwards after unhooking the bottom of the shaft inside the dear box, but there seems to be no enough clearance to fully remove the shaft
2) Where do I find a replacement part? Ford doesn’t even list the part in the eCat…?!?!
Thank you in advance
18-08-2013, 04:18 PM
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Ok, I took it off... Eng. Part no: 91AB-7503-AG - Fin: 6928449
Ford wants over £80.00 for it, I am looking for it now, if anyone knows where to get it let me know, its meant to have 2 pins at the top by the way, not just one
Thanks again
Ford wants over £80.00 for it, I am looking for it now, if anyone knows where to get it let me know, its meant to have 2 pins at the top by the way, not just one
Thanks again
20-08-2013, 10:31 AM
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https://www.dropbox.com/s/hg1xzgbh8rmcfwd/IMAG4412.jpg
https://www.dropbox.com/s/0kxsqtkkmj7ruo2/IMAG4413.jpg
Hi Guys,
I though I would share this info as it may help someone else, along with some pix...
First of all in the photos you can see the old Fork - Release Shaft" and the new Genuine one from Ford, you can also see a "Spring Dowel Pin", which was given to me for FREE from a local "old style" independent car part shop, after having purchased the new shaft from ford for, as mentioned above, about £90.00, I happen to go to a local engineering place with a friend this morning, and brought the old and new part with me, so that I could ask for some advise, turns out the pin is not pressed or welded in, but simply slotted into place, and being a "Spring" Dowel Pin, it holds it self into place once tapped in, the pin can be cut to size, and you can therefore use 1 x pin to replace both of those on vehicles that have both like the MK6, but if I am not wrong, I have seen that the MK4/5 seems to have only 1 pin, but obviously the principle is the same.
In conclusion, I will install the new one in the car, as I have it now, and the forks on the old one seem to have a little bit of wear, although the engineering place said that the forks are still strong and the car would probably do another 60,000 mile if not more on the old one, once the pins are replaced, I will fix the old one and place it for sell, maybe someone else can make use of it, as apparently those parts are becoming rare.
As usual, any comments are welcome, and I hope this post can help other people
Attached Images
https://www.dropbox.com/s/0kxsqtkkmj7ruo2/IMAG4413.jpg
Hi Guys,
I though I would share this info as it may help someone else, along with some pix...
First of all in the photos you can see the old Fork - Release Shaft" and the new Genuine one from Ford, you can also see a "Spring Dowel Pin", which was given to me for FREE from a local "old style" independent car part shop, after having purchased the new shaft from ford for, as mentioned above, about £90.00, I happen to go to a local engineering place with a friend this morning, and brought the old and new part with me, so that I could ask for some advise, turns out the pin is not pressed or welded in, but simply slotted into place, and being a "Spring" Dowel Pin, it holds it self into place once tapped in, the pin can be cut to size, and you can therefore use 1 x pin to replace both of those on vehicles that have both like the MK6, but if I am not wrong, I have seen that the MK4/5 seems to have only 1 pin, but obviously the principle is the same.
In conclusion, I will install the new one in the car, as I have it now, and the forks on the old one seem to have a little bit of wear, although the engineering place said that the forks are still strong and the car would probably do another 60,000 mile if not more on the old one, once the pins are replaced, I will fix the old one and place it for sell, maybe someone else can make use of it, as apparently those parts are becoming rare.
As usual, any comments are welcome, and I hope this post can help other people
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