Im waiting for quite a few bits for my build, so thought id do my gearbox while waiting. Im using the IB5plus box from the Fiesta ST, and the speedo drive from and gear from a puma/fiesta box, and a 5th gear set from a 1.4 fiesta/puma gearbox, as its taller and better for cruising (cheers Tye) :thumbs: ! And a big thanks to Jacko, your guide was a big help mate.
Trying to get the speedo drive out of the puma box was impossible!!! Tried pulling the the drive holding pin out, and it snapped, so tried drilling it out with cobalt drill bit, but after 2 hours of drilling and head scratching, this was the result!!!
Here is the drive when i finally got it out!
The puma box with the 5th syncro taken out
The Fiesta ST box showing 5th gear
Slightly different to the puma box, and the 5th gear housing is different.
Tried to use a 3 leg gear puller to get 5TH gear off, and it just wouldnt budge, so managed to get hold of a proper ford IB5 fith gear puller, its so easy with the correct tool!! I brought the tool, so if anybody needs to borrow it, give me a shout.
Anybody attempting to take a fiesta ST box appart, the process is slightly different to the puma box. The gear selector is on the front, but the middle housing wont come off unless you take the end off the selector. Its a PIG to get off!! I had to heat it for about 15mins to get it to budge, and it was still a struggle!!
The selector is on the left of the pic here
And eventually off!!!
ST box inside is a little different to the puma again
ST box has a hole where the speedo drive goes, which makes it alot easier!!
ST box without Speedo drive.
And with drive fitted
I got a Tran-X LSD to fit to the box.
But its 5mm bigger then the standard diff, so im going to have to get it machined down, about 1mm off the diameter.
Here are 2 pics of the diameter of the 5th gear on both boxes. First the ST 5th gear (sorry about the blurred pic)
And the 1.4 5th gear.
Around a 4mm bigger gear in the fiesta, so revs should be considerably lower at motorway & cruising speed.