fiestaturbo.com

[Ice 159]

Hi Guys,

I'm just wondering how you remove the remaining part of the drive shaft that someone has left on this gearbox or even if it can be removed?! The highlighted Red part of the photo.

Regards

Ice

[AW0L]

you'll need to give it some good wackin...

[Ice 159]

Yes that's what I thought, but even tugging at it with a crowbar it does not want to budge.... So the can be removed then and they are not a part of the gearbox itself?!

[AW0L]

yea its a pig job to get out, it will come out after a while, whin i did it to mine it took 2 hours to get it out, there is a wire c clip on the end of the spline shaft which makes it lock in, that, with the oil in the box makes for a good tight seal on the spline shaft. you may have/not tried or seen pulling a cylinder or rod that is oil. pulling on it creates a vaccumn and pulls against you. this is probably happening here. keep at it an eventually it will give.

there are others here who may know of a easier way to get it out, but this is what i had to do

[Ice 159]

Will I break anything if I tug it open with a crowbar?

[jayrs]

Shouldn't do.

I've found a old tyre lever works better for me, get it in as far as poss checking its on the cv joint fully, and located on a decent bit of the gearbox, then give the tyre lever a short sharp whack back to lever the cv out, the short shape bash does it every time to shock it out, as its only the clip holding it in.
Might need to do it a few times but it will come out.

If its a non LSD box, you could use a bar through the other side of the diff to beat it out.
Also, keep a note of this, if it is a non LSD box, once both cv joints are removed, there's nothing stopping the sun gears dropping out of place, and if they do, until you get them back in place the gearbox is useless! And although in most cases you can tease the gear back into place, there are times stripping the box is the only way if they slip too far

Once you remove the last cv joint, put a tube or bar, or bit of broom handle through the diff to keep the gears from dropping down, if they move a bit that's no buggy as you just put them back in place

[Ice 159]

Hi Jay
Thanks for the reply, so am I best not to bother messing around with regards to removing the cv. It is a non-LSD model of gearbox, so with regards to the driveshafts can I just remove the cv on the new ones and simply push them into the old cv that are on the gearbox? Then simply put new rubber boots on or is there more to it than that...

[jayrs]

Yeah you could do it that way, but fords used 2 types of cv joint, a 3 roller one and ball bearing ones, if you have a 3 toiler type in the gear box and ball type you wanna fit it won't happen unless the have the roller part to put on the drive shaft your gunna fit

Even if yours and the one in the box are roller ones its best not to the rollers from a different one.

If you change one cv joint at a time in the box your be fine though, provided one is in there no gears will move

[Ice 159]

Thanks for the help Jay it is appreciated.

So if I bolt the gearbox back onto the car and removed one cv at a time and then replace it with a full new drive shaft the 'sun' gears should all stay in place as appose to replacing both at the same time and them falling out

Sorry for all of the questions but my knowledge about gearboxes is a bit fat 0.

[russ-RST]

lever bar opposite sides of the cv joint and sharp tugs will pop it off normally fairly easy to get out, failin that a extension bare or something flat on the end through the other side of the diff and a couple of taps just to pop it out, can't say iv ever seen the sun gears drop in a box when the shafts have been removed tho :? iv had both my shafts out loads of times maybe I'm just lucky? alto in on my 3rd gearbox now ! haha not that lucky.. lol

russ

[jayrs]

Yeah basicallyate and as it will be bolted in the car it will be more stable

That said you might find it easier to pop them out with the box out the car if there giving you trouble

[Ice 159]

Russ,

Was yours a non-LSD Box or an LSD Box?

Thanks for all of the info guys. It's all a great help

[russ-RST]

I have worked on both mate both apply for both boxes just make sure you don't smack the diff trying to judge out the shaft

Russ

[Ice 159]

Spend a bit of time on it today.
I have a new xr2i gearbox to go in. Can I use my old fiesta rs turbo drive shafts in the new xr2i gearbox or wont they fit. Or any advice on the best approach to this please.

[rob pace]

Shouldn't do.

I've found a old tyre lever works better for me, get it in as far as poss checking its on the cv joint fully, and located on a decent bit of the gearbox, then give the tyre lever a short sharp whack back to lever the cv out, the short shape bash does it every time to shock it out, as its only the clip holding it in.
Might need to do it a few times but it will come out.

If its a non LSD box, you could use a bar through the other side of the diff to beat it out.
Also, keep a note of this, if it is a non LSD box, once both cv joints are removed, there's nothing stopping the sun gears dropping out of place, and if they do, until you get them back in place the gearbox is useless! And although in most cases you can tease the gear back into place, there are times stripping the box is the only way if they slip too far

Once you remove the last cv joint, put a tube or bar, or bit of broom handle through the diff to keep the gears from dropping down, if they move a bit that's no buggy as you just put them back in place

never knew this jay, bit random but i fitted a frst box to my old fiesta years back that had no cv joints on it when i bought it, didnt have any problems with a dropped gear?

[jayrs]

6 of one half Dixon of the other mate, it can happen, and does, but sometimes it font

Out if all the gear boxes I've messed with I only had it happen once, well twice in fact, but one time the gear slipped and I was able to hook it back up with a bit of stiff wire, the other I had to strip but I was putting the box back together at the time so wasn't that bigger deal

[Simon84uk]

I don't know if you've managed to get them out or not yet but when I was having a pain removing some I made some wooden wedges and sat them sideways either side of the cup and drove them in, needs to come out parallel might be worth a go if you're stuck.

Si