I've managed to remove 5th gear from my IB5 gearbox and now I want to put it back on but I'm really struggling.

I've put the gear inside the oven at Gas Mark 9 for 30mins then tried to put it on but I can't get it on enough to put the snap-ring back on. It's about 5mm from being fully on.

Anyone got any tips or do I simply need to get the gear even hotter?

Many Thanks
Ste

 

you are using the original shaft and gear arnt you because there are different depth of 5 th gears.

 

Yup, I took it off to replace the 5th gear housing gasket which was leaking.

Would taking the box completely off the car and using a press to put the gear on help?

Cheers
Stephen

 

if you moved the two c clips that hold the two top bearings on you might be fowling on the 5th gear plate so the gear wont go all the way down.

 

My iB5 5th gear gasket has a small leak and I was wondering how difficult it is to replace.
The dealership told me it requires gearbox removal and splitting and most of the Ł750 quote was labour.
Its an 03 fiesta and its looks fairly accessible in situ.
Not that I would attempt it myself but wondering if another garage would / could do it without removing the box.

I have to add its a very minor leak and doubt that there is much oil loss, I did wonder if it would be possible to just remove the end cover and re-torque the 5th gear housing.

Any suggestions greatly appreciated,

Regards,

D.

 

To replace the 5th gear housing gasket, the special tools you will need are:

• Collet style gear/bearing puller
• Snap ring pliers
• Circlip pliers

Jack up the front of the car and put on angle stands. Remove the gearbox side wheel (and brakes for better access).

Remove the lower gearbox mount, and then undo the nut on the upper gearbox mount. This will lower the engine/gearbox so that the 5th gear housing is accessible via the wheel well.

Remove the end plate and allow the gearbox oil to leak into a container.

Remove the circlips and snap rings. Then the selector mechanism. Then both 5th gears.

Remove the 5th gear housing. Replace gasket. Put back together.

 

Thanks, will see if I can find a local garage to do it (now I know its possible).
I had a sneaky feeling the dealership didn't want to do the work... They don't like the EST gearboxes even though its just a standard iB5 with a few motors for gear selection and clutch actuation.

 

did mine the other day just heated it up with a blow lamp and it prety much slid right on last bit put a socket on to it and gave it a few smacks with a hammer job done

 

hammer and socket after heating is the key.

 

yeah i have done many of these gearboxes and a bit of heat and a bit of a tickle with a hammer always works for me.

 

Not having much luck finding someone to do the job, as soon as they hear the words semi auto they say they don't touch them.

Will start again on Monday but feeling thoroughly disappointed that so called specialist will not take on what appears to be a simple job.