Austinman

I have an Escort RST with a BC box which im not too happy with. Can the internals of an IB5 be fitted into the bc box ? if not can the LSD from the BC box be fitted into the IB5 if so what mods are needed

studabear

The lsd will swap over, the ib5 should be a stronger box, with bigger bearings.

McCloud 85

As above the LSD will fit in either box, companies like Quaife make one diff for both boxes. The ib5 internals will not fit easily in the b5 casing, the shaft bearings are larger and I'm not sure if you can machine these into the B5 box. The IB5 box has a stronger casing so you're better of using this box and adapting the starter motor housing to suit the cvh.

GINGExR2 T

iTrader: (1)

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LSD will go in (S2 LSD is 8 bolts crown and S1 is 6 bolt crown) but you need to use the correct crown wheel for the main shaft, the IB5 internals will also fit a BC box but you have to use the BC bearings which is the weak point. The main shaft bearing (bell housing end) is bigger (also there is a sleeve pressed on the shaft if I remember correctly which need to be removed to fit in a BC casing) the bearing on the bell housing side of the diff is also bigger.
You can get a late BC casing that already has the IB5 size bearings but they only came in the late XR2i 16v 130bhp and the RS1800 (so I've read).

I have pics in my cabby thread but photo bucket direct links no longer work



Ginger


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Adam-M

The diff needs machined down to fit in the ib5 crown wheel

GINGExR2 T

iTrader: (1)

I read that before doing mine, but the two I've done went on fine, just cleaned the edges with thinners to get them clean and dropped on no issues with a good 1mm gap all the way around.
They're must be different crown wheels with a slightly smaller inner diameter


Ginger


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Rsmat

iTrader: (2)

I've got a IB5 front starter motor cable clutch box to fetch ..so basically all I have to do it Fit my LSD out of my turbo box and away I go ?

studabear

Ka gears Mat as I believe the ratios should be almost identical to a S2 Rs turbo then, the box I have here for you is from a 1.4 mk6 escort, I don't know what the ratio's will be.

Matt Lock might know.

Rsmat

iTrader: (2)

Got a KA box off Stuart collins so ill get the gear set put in as well mate ..im going to take to gearbox place and have it all built up properly .

Adam-M

I don't know if all ib5's are the same but when researching doing s2 rs turbo lsd into puma 1.7 box I found that one of the diff bearings was a different size and needed the puma one fitted, think it was the speedo drive side of the diff. I just replaced both anyway would be criminal not to. Also the speedo drive gear was different.

Think I had to take 1.5mm off my diff to fit the crown and even then it was still a tight fit.

Karlos G

iTrader: (4)

The IB5 box's have a little more webbing which prevents flex under torque too, the real weak point sadly is the shafts and teeth, these snap and strip at peak torque in 3rd or 4th usually.

Adam-M

I snapped 5th gear selector fork on mine, only made out of alloy which is far too soft for that purpose.

Karlos G

iTrader: (4)

What were you doing to snap the selector fork?! lol

GINGExR2 T

iTrader: (1)

Yer the drivers side diff bearing is about 2-3mm bigger



Ginger


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Austinman

So I have the IB5 from a Ford Ka 1.6 Duratec Sport with front mounted starter (sits slightly lower than the Rs so may be a little cooler. I am going to go fully hydraulic to get away with the clutch pawl problem. is there a specific release bearing that I will need for the application or should the standard 1.6 one be okay. When I am happy with the box I plan to get another and have it rebuild with the LSD in as I will have 2 surplus RST boxes.

It's Czech Mate

given that the mighty ford puma was torque limited in 1st and second gear to protect the gearbox why bother with an ib5 with a stock gearset?

MT conversion all the way

Karlos G

iTrader: (4)

The 1.6 Sport ratio's are terrible for forced induction, I really would not use them! Also that box specifically is rotated at the bell housing about 8 degree's or so and will tilt your engine back so requires fabrication to get ti to sit correctly.
Use a 1.3 Ka box from an early Ka with the Endura engine.
Cheap and ease of fitment is the only real reason.

Rsmat

iTrader: (2)

My friends daughter is scrapping her KA 1.2 he says ..will that be the right box mate ..?

studabear

1.2 is the newer shape fiat engined KA so won't be any good.

Austinman

What fabrication is required is it a matter of modifying the gearbox mounts ?

Austinman

is this the box I really need
http://www.ebay.co.uk/itm/FORD-KA-KA...wAAOSw2xRYlBZr

Austinman

The only 1.3 KA boxes I can find are rear mounted starter which wont fit the CVH I can only find the duratec box which I subsequently purchased dont suppose you can direct me to the box I need before I start hacking my engine mounts and crossmember

The box I have has part number xs6r-7f096-ab on the bell housing

Karlos G

iTrader: (4)

Ah shit sorry I totally didn't notice you were CVH, the box's I was referring to are for use with Zetec turbo's.... For CVH you only have the MK5 Escort and Escort Van IB5's to choose from IIRC.

Just seen your PM too so this answers that as well.

Austinman

Hi KArlos thanks for getting back to me the bellhousing boltholes are the same as the escort box so this should still bolt to the engine all I can foresee is that the CVH will have the same mounting problems as you have had. I plan to remove engine and box as 1 unit then lower into position and fabricat the crossmember I have the KA IB5 box with front mounted starter (similar to the CVH starter is lower than the CVH any thoughts

Karlos G

iTrader: (4)

I did make my Sport Ka box fit, I just cut a hole in the cross-member to allow the 'corner' of the box to poke through and re-drilled the front and rear mount brackets to correct the rotation... this worked just fine but the ratio's are terrible for FI applications, you will literally spin up in any gear if you have decent power! lol Plus at 70mph you're doing about 4000rpm!

Austinman

The Box I have was advertised as a 1,6 sport box howevere when I have looked on Ebay etc there are boxes with the same number stamped on them but also advertised as 1.3 boxes I have since noticed that there is no speedo drive in this box either it was just a blanking plug.

Karlos G

iTrader: (4)

Probably ebay sellers not knowing where they got the box's from! lol The 1.3 would not fit a Sport Ka because of the bell housing rotation.

jaiscossie

IB5 Is still dog shit, mine lasted no more than 50 miles on a 2.1 zvh, save your pennies

Austinman

I have seen a car running well over 200bhp with the KA box in it ime only running arouns 170 to 180 the original IB5 lasted 120K so even if I get 20 K it will be a bonus at least I will have the car on the road

Austinman

Well shes fitted not running yet got to put the bits back one driveshafts in etc . also need to locate the push in connector for the slave cylinder I have one from a fiesta but it appears to be too small

Rsmat

iTrader: (2)

No shit Sherlock with a 2.1ZVH

studabear

I think it's the luck of the draw at times. I got 3 years out of a bc s2 box that cost £75 yet my fully rebuilt box was ruined in 500 miles.

Austinman

well all in up and running the engine must be slightly rotates as the alternator managed to chew through the bottom hose (silicon so not the cheapest) managed to get a standard hose as an interim and moved the rad forward for clearance. she changes like a dream clutch is so light too and the self centering is out of this world due to the springs being in the box just have the speedo to sort she aint working for some reason. Thanks to Karlos for his input and advce helped me out no end