Ford Workshop Service and Repair Manuals

The iB5 manual transaxle in the Focus is a "2-shaft transmission" which has been revised to include a cable operating mechanism for the first time.

The aluminum transmission housing comprises two sections. Its rigidity has been improved thanks to the inclusion of reinforcement ribbing in the design. The transmission housing sections come in pairs and cannot be renewed one at a time. The clutch is hydraulically actuated.

On the 2 shaft transmission all the gears are in constant mesh (except reverse gear). In each gear, the required transmission ratio is achieved by means of a pair of gear wheels.

When reverse gear is selected, the direction of rotation of the output shaft is changed by an idler gear.

All gear wheels are helical toothed, synchronised (except reverse gear) and run in plain bearings.

First and second gears have dual synchronisers.

The iB5 manual transaxle is filled with 2.3 l liters of synthetic fluid, specification WSD-M2C200-C. The fill height is 10 to 15 mm below the lower edge of the check hole. Fluid changes are not necessary.

iB5 manual transaxle components

General view

In neutral, none of the gears is connected to the output shaft via the gear synchronisers. No input torque is transmitted to the differential.

Internal shift mechanism

Input shaft

Output shaft

Dual synchroniser

Dual synchroniser

First and second gear have dual synchronisers. By using a second synchroniser ring, the effective surface of the synchroniser is considerably increased compared with simple synchronisation. Dual synchronisation gives considerable improvement in gearshift quality.

The dual synchronisers comprise inner synchroniser ring, cone ring, outer synchroniser ring and synchroniser hub.

The conical surface on the gear wheel is discontinued. Synchronisation occurs via both synchroniser rings and the cone ring which is positively fitted to the gear wheel.

Differential

Major components of the differential include:

• Spur gear
• Differential housing with two taper roller bearings
• Differential pinions
• Input shaft pinions

The transmission and differential are housed in a two-section aluminum housing and flange-mounted to the engine.

The input shafts have splines.

The input torque is transmitted to the differential via a spur gear which is bolted to the differential cage.

The differential cage contains the differential pinions mounted on one pin as well as the front halfshaft pinions connected to the front drive shafts via the splines.

If the front wheels are travelling at different speeds (e.g. when cornering), the front halfshaft pinions can move on the differential pinions.

Power flow

Neutral

First gear

Second gear

Third gear

Fourth gear

Fifth gear

Reverse gear

The reverse idler gear is driven off the input shaft. Its purpose is to change the direction of rotation of the output shaft when reverse gear is selected.

The reverse idler gear runs in a needle bearing on the idler gear shaft and a bearing block.

The selector interlock mechanism and the selector finger are mounted on a sleeve in the selector mechanism housing. They hold the selected gear by means of a spring-loaded ball until a different gear is selected.

The selector interlock mechanism has three different positions.