Hi All,

Started putting the stuff together for my ZT build and have hit my first hurdle, I cant get the gearbox to line up with any of the holes on the side of the sump. Was doing this so that I can line stuff up to see if any needed trimming back.

it was a long day so I might have just lost patience with it but I really couldnt get the bolt holes to line up, Anyone offer any help lol.

Its a Ka 1.3 Gearbox and Blacktop Sump

There is every chance that I have bought the wrong gearbox! here are the pics and part numbers:






And pictures of the sump

 

I don't use the bolt holes on the bottom section.

 

So is this the correct gearbox, Does it not flex if none of the bottom holes line up as that would mean there are like 3 bolts at the top holding it onto the engine? Surely that would just break no?

I am struggling to find info online on this and looking for some help as its a showstopper at the moment.

Thanks

 

Top 5 bolts should fit.

 

Ok, so been doing a bit more research on this and it appears that there are 1.3 gearboxes with a front starter and some with a rear starter, It would appear I have one with a rear starter. Does this matter? Is this maybe a sign I have the wrong box or are they both IB5?

 

It would appear that the front mount starter are off the duratec ones and the rear starter ones are from a 1.3 Endura version (The older Ka)

There is also talk of an electronic speedo as well? How is this so difficult lol

Any ideas? Mine appears to be a rear starter model

 

As suggested, it only need the top 5 holes to line up, which it does. Ignore the bottom section; they won't line up as a 2.0-litre Black Top never came fitted to an IB5 gearbox.

Think you might have to do some fiddling to get the rear starter set up to work on a Zetec but it's been done before.

As for electronic speedo; what car is it going into?

 

Hi mate it is for a mk4 Escort / Orion so would need to be a manual speedo as opposed to electronic ideally, from what I can see the Ka boxes are Front starter / electric speedo and rear starter cable speedo not found the best of both yet!

Thanks

 

Rear starter is what you want (1.8/2.0 Zetec's are rear starter! lol), as said the sump does not bolt to the box only the block, speedo just needs you to unscrew the speed sender from the box and screw your cable in just like normal (although looking at your picture does it not have a hole and thread on the top of that sender for a normal cable just like an RST that has a trip computer uses?), the speedo drive gear inside the IB5 box is the same as the RST BC box so works just fine

 

Thanks Karlos, that clears that up that I have infact bought the correct gearbox lol. Yeah there is a bit to plug the speedo cable in I think at the top of that sensor ( I will double check later), I have an EFI car already from factory so as my trip comp is also EFi I might just leave it in and hopefully it should work, failing that I will use one I took off when taking the engine out the Orion to see how much fuel my ZT uses

Do you happen to have a side on shot of the sump so I see how much meat i need to trim off the sump (same as pic above) as I couldnt make it out very clearly in the conversion thread, Only reason I ask is lining it up isnt easy as where the flywheel goes is where it is currently mounted on my engine stand

Also finally does the metal shim thing need to go back on as I broke mine taking it off

Many Thanks Everyone!

 

I have mine in bits if you need a sump picture I can take one for you, mine is modded for front starter too although this is not relevent.

 

Hi stu that would be ideal it's just so i can compare it to the pic I have above!

Cheers mate!

 

Just cut the 'wing' off so it's flush with the rest of the sump is the easiest way to describe it, I'm sure Stu will stick a pick up too.

 

If you convert to a silvertop sump it will bolt up to that. At least my 1800 escort rear start IB5 does, I have 7 bolts fitted.

 

Hi Mannion, Too late to swap over as I've had the breathers and oil return fitted to the blacktop sump already so don't want to do all that again

I assume the 5 bolts hold just fine Karlos? No Flex ? Does the metal guard / shim need reattached too? Only reason I asked is I broke the black plastic clips taking it off so need to know if I need to change it lol.

Cheers

 

2.0 Silver top sump is the wrong shape to use with an RST exhaust.
They do hold fine yes, I've no way to know if there is flex or not (would be hard to be in the bay looking whilst driving! lol), shim plate doesn't need to be refitted no.