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.

 

Send it into a gearbox specialist, or just buy a xr3i box throw that in till you get a ib5 sorted.

 

It was a gearbox specialist that has just rebuilt it this weekend.

I cant understand it. How a slightly iffy gearbox can have everything refurbed and then it be worse.

 

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Does it have an Escort LSD???


Ginger


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It does. Used the S2 LSD and a mk5 diesel final drive.

 

And you/the specialist swapped the diff bearings to match the LSD casing? (they're diff sizes compared to BC)

 

Just in case:
http://www.burtonpower.com/catalogse...ult/?q=GBIB606

 

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.

 

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.

 

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


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Yeah I meant like for like as in the correct bc and ib5 on the diff. Sorry I should have said that the gearbox worked perfectly for 3 years until the stiff selection issue cropped up.
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.

 

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

 

Yeah they both looked fine as well. Was the first place we looked when the selection issues cropped up the first time around.
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.

 

Is the clutch travel set properly? Too much travel can cause just as many problems as not enough if you're having selection issues.

 

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

 

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

 

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.