fiestaturbo.com

[MarkRS2K]

Help me, just spent 8 hours working on the frst.

got a stg 1 cts gearbox- when we were trying to take out the old one it was bloody difficult, just didnt wana come out.

Now the cts box wont mate with the clutch, weve tried everything, it just wont mate up, it sits about 1cm out from the flywheel- really confused.

Anyone got any ideas?

(big thanks has to go to Dannyboy for his 95% involment in the box change )

[Xr_Dub]

have u asked gav? mark.......

it [ERRR] be a straight fit

[dannyboy]

Just to clarify a few points for Mark, the old old box took ages to get out, it didnt want to budge, on closer inspection we found there is a slight bur on the input shaft, the splines are worn and it is slightly twisted.
We measured the diameter of the input shafts on both boxes with calipers thinking they may be different, we turned the crank over by hand while trying to mate up the new box thinking it may not be locating the splines properly. would the wear on the old box have affected the flywheel/clutch in any way preventing us fitting the new box. My friend suggested using a few g-clamps to pull the gearbox up to the block but dont want to do any damage.
Think ive slipped a disc from hauling the bloody things around under the car all day

Any suggestions?

[heeman10]

Will check my thread for pics of when I fitted mine. Also a Stage 1 CTS 'box and AP paddle clutch It got most of the way on but was stubborn for the last few millimetres, I took a pic of where it got to.

[dannyboy]

Thamks James that would be cool, I know they are usually a bugger to get in normally but no amount of brute force would get in on.

[heeman10]

Finally found it after some crafty searching! Hope it helps?

[MAD_Adamski]

shafts should all be the same but remember if the clutch isn't perfectly lined up it will not go on!!!!! i mean perfect!!! also remember if you get the box on the spline remember it has to go on the dowels it can be tricky on your own, me and jambo did it today it took us about 10 mins on a 2 post ramp if everything is lined up and you wriggle the box when it gest on the spline if your doing it right it will go on...... i know its easier said than done but sometimes getting it on the spline is not as easy as you think if the car is beaing a t.w.a.t....

i seriously doubt its the splines try again check everything lines up and do things slowly and careful, and give it a wriggle but not too much so you move the engine too much....

HTH

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[heeman10]

llama what a klutz! Spent 5 mins searching for it then forgot to post the link!

http://www.fiestaturbo.com/forums/viewt ... light=bell

I'm assuming you've aligned the clutch properly Dan, that's always going to be the first port of call, but it sounds like you've got the input shaft a long way in. I spent literally an hour or so on my own wiggling and pushing everything possible and it wouldn't go one millimetre further than you can see in the pics above. Read the short thread anyway, I hope it relates to your problem

[MarkRS2K]

so James you eased it on by doing up the top bolts a bit?

The clutch would have been aligned when it went in only around 2 months ago? could this become mis- aligned then?

[ianFRST]

as said by scort in the other post, yes the weight of the gearbox can move the clutch plate.

i know this from 1st hand experience, as when my engine ZT engine was in the garage, fully built up (CTS STAGE 2 box + alcon 6 paddle) i had to make the gearbox shim for it, and when i took it off, i couldnt get it back on, aligned the clutch again and it was ok

also a couple of times, the bearing slid off, make sure thats not effecting anything

[MarkRS2K]

so re-aligned the clutch and see if it mates then?

[ianFRST]

yeah, may aswell give it a go. only a few bolts and a clutch alignment tool

[MarkRS2K]

will try that tonight, hope it works as its the only thing anyone can think off

[MarkRS2K]

just spoken to a guy at cts- he reckons ive got a different size spigot bearing in my clutch? he said ford do two sizes and if the box doesnt mate up then i must have the wrong size bearing?

Anyone shed any light, probably next thing to do it take the clutch off and fit it to the box of the car and see if it mates maybe?

[ianFRST]

spigot bearing

the only bearing on the clutch is the release bearing surely? i dunno or are they called the same thing

but yes they do 2 size release bearings, but that goes on the gearbox, and you will know if its the worng size as it wont fit on to the shaft / release fork

[MarkRS2K]

well thats what i thought, buy the guy reckons there different things?

Im just gonna take the clutch off- offer it up the box- if it sits in- then ill put it down to the alignment issue.

If it still dont work....well im screwed basically!

[black2]

He dosnt mean the thurst bearing, does he? because i just replaced the clutch on my car the other day (1800 diesel, but same 5 speed box) and the main shaft that the thrust bearing sits on had a steel shim over it, which meant the thrust bearing supllied in the kit would not slide on to the shaft, so i had a look on one of my spare 5 speed boxes and they did'nt have a steel shim over them, so i removed the one on the diesel box, but im thinking that if you have the wrong thurst bearing then it wouldnt align properly??

Gareth.

[MarkRS2K]

im not sure, he just said spigot bearing thats right insude the clutch

[MAD_Adamski]

i think this is a case of stop talking and start fitting i can't see there being an issue the splines should be the same imo your worrying over nothing go line the clutch up and have another go

[MarkRS2K]

im stuck in the office at the moment! Will have to wait til 7.30ish to see what happens

[MarkRS2K]

Right update:

What a night, went round to the garage about 5.30ish with 'Carl s' he pulled the box up into place, gave it a wiggle and yep sure enough it popped in, in about 10 minutes Cheers for the help tho mate

Next thing- i go back round there about 7ish with Dannyboy to put everything back together- well as usual nothing went smoothing, pretty much every bolt or bracket we had to put back on was being a git!!

Anyway it come to about 11ish and we decide the next step is to attached the track rod ends- the nut just didnt want to mate with the screw, we tried everythin, in the end we sawed of about 2mm from the bottom (thought it nay have twisted on removal) then re-threaded the bolt then with so much effort it went on, not ideal i know- couldnt be bothered to do the other side as this was having the same problem- SO new track rod ends are needed then for safety mostly- anyone know the best palce to buy these from?

So what we have left to do now is- wire up starter motor, sort wiring the from the cps plug out as it keeps falling off to easily! sort the other track rod out, connect battery and hope to god everything works!

Didnt get intil gone 1 this morning, up at 6.30 for work. spent a total of 14 hours on the car so far- dont be surprised to see a for sale sign in the window at FF, im so fustrated with it all

[Dave_B]

i know how you feel being frustrated dude but dont give up with it, it will be worth it,

i got 2 new track rod ends yesterday from A R E about a fiver each, i take it the bolt was spinning when putting the nut on? needs downwards pressure on the bolt to hold it in the spline. i had the same problem

glad to see its going 'better' as the box is actually in!

dave

[MarkRS2K]

yep just spinning, clamped it down and tried turning the nut but it just wont happening.

Found a place near me that has some in stock, about £7 quid, so ill pick them up after work later, you fancy coming to fit them for me dude?

[Dave_B]

its one bolt you nutter tried to do mine earlier but failed wait for a second pair of hands!

fitted lower arms now, had wheels refurbed, but clutch is out of stock for a few days so its gonna be close

dave

[MarkRS2K]

well its one more nut i dont wana see, look at, touch, tighten or anything

Dannyboys coming around again so its cool

I had to wait a few days for my paddle to, they hadnt received their shipment from AP yet. Your be fine, altough everyone seems to be cutting it fine for FF this year.

Do you have ABS mate?

[black2]

Good to hear things are on the up, but dont sell her, a bit of persaverance and all will be fine.

Gareth.