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Focus 2004.75 (07.2004-)

Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer Case > 308-03B Manual Transmission-Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5) > Description and Operation > Manual Transaxle

Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5) - Manual Transaxle Focus 2004.75 (07/2004-)
Description and Operation

General

The iB5 manual transmission is a two shaft transmission.

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

1st and 2nd gears are double synchronised.

There is no need to change the oil.

Transmission construction

 
Item
Part Number
Description
1
-
5th gear housing
2
-
Transmission side housing halves
3
-
Breather
4
-
Hydraulic clutch connection
5
-
Clutch side housing halves
6
-
Slave cylinder with integral release bearing
7
-
Input shaft
8
-
Output shaft
9
-
Differential assembly

Input shaft

 
Item
Part Number
Description
1
-
Ball bearing
2
-
Input shaft
3
-
Reverse gear idler
4
-
1st gear wheel
5
-
Reverse gear wheel
6
-
2nd gear wheel
7
-
3rd gear wheel
8
-
4th gear wheel
9
-
Snap ring
10
-
5th gear wheel
11
-
Snap ring

Output shaft

 
Item
Part Number
Description
1
-
Open cylinder roller bearing
2
-
Output shaft with differential drive wheel
3
-
1st gear wheel
4
-
1st gear double synchronisation
5
-
Synchroniser - 1st/2nd gear with reverse gear wheel
6
-
2nd gear double synchronisation
7
-
2nd gear wheel
8
-
3rd gear wheel
9
-
3rd gear simple synchronisation
10
-
Synchroniser assembly - 3rd/4th gear
11
-
4th gear simple synchronisation
12
-
4th gear wheel
13
-
Ball bearing (closed both sides)
14
-
Snap ring
15
-
5th gear wheel
16
-
5th gear simple synchronisation
17
-
5th gear synchroniser assembly
18
-
Retaining plate
19
-
Snap ring

Double synchronisation

 
Item
Part Number
Description
1
-
Gearwheel
2
-
Inner synchroniser ring
3
-
Conical ring
4
-
Outer synchroniser ring
5
-
Synchroniser hub

1st and 2nd gears are double synchronised.

The effective synchronisation surface for double synchronisation is almost twice that of simple synchronisation. Because of this, the speeds of the gearwheels are equalised much faster, which considerably improves gearshifting comfort.

Differential assembly

 
Item
Part Number
Description
1
-
Bearing
2
-
Crown wheel
3
-
Differential assembly
4
-
Sender wheel - Vehicle Speed Sensor (VSS)
5
-
Crown wheel bolts

The differential assembly is built into the transmission housing.

The drive torque is transmitted to the differential by the crown wheel which is bolted to it.

The differential assembly contains differential pinion gears mounted on a spindle and the axle halfshaft pinion gears which connect to the front wheel axle halfshafts through helical gearing.

The axle halfshaft pinion gears can revolve around the differential pinion gears when the road wheel speeds are different (e.g when cornering).

On vehicles without Anti-lock Brake System (ABS) a VSS detects the speed of the differential assembly at the VSS sender wheel.

On vehicles with ABS the VSS sender wheel is also installed. The VSS is however not installed in this case. A plug with an O-ring closes the corresponding bore instead.

Internal shift mechanism

Layout

 
Item
Part Number
Description
1
-
Selector gate
2
-
Shift locking bush
3
-
Return spring from reverse gear position
4
-
Reverse gear selector shaft
5
-
Snap ring
6
-
Shift rod - 5th gear/reverse gear
7
-
Selector interlock
8
-
Selector shaft
9
-
Guide sleeve

The shift locking bush prevents two gears from being engaged at the same time.

The selector interlock maintains engagement of the selected gear.

Both the shift and the select process is performed through the selector shaft.

Select movement

 
Item
Part Number
Description
1
-
Shift locking bush
2
-
Selector shaft
3
-
Selector boss
4
-
Selector gate

The axial movement of the selector cable is transferred at the transmission to the selector shaft which can turn in its bearing.

If the gearshift lever is moved to the left or right, the selector shaft and the selector boss both turn together in the corresponding direction.

As this happens, the selector shaft is guided by a pin in the selector gate.

The selector boss selects the required selector fork.

At the same time the shift locking bush prevents access to other gear combinations.

Shift movement

 
Item
Part Number
Description
1
-
Shift locking bush
2
-
Selector shaft
3
-
Selector boss
4
-
Selector gate

After the gear pair to be shifted has been selected, the shift movement takes place.

Here the axial movement of the shift cable at the transmission produces an axial movement of the selector shaft.

If the gearshift lever is moved forwards or backwards, the selector shaft and the selector boss both move vertically together.

As this happens, the selector shaft is guided by a pin in the selector gate.

The selector boss shifts the required selector fork.

At the same time the shift locking bush prevents access to other gear combinations.

Engage reverse gear

 
Item
Part Number
Description
1
-
Shift locking bush
2
-
Reverse gear selector shaft
3
-
Shift rod - 5th gear/reverse gear
4
-
Selector shaft
5
-
Selector boss
6
-
Selector gate

In order to select reverse gear, the gearshift lever must be moved to the right over and past the reverse gear inhibit device. As this occurs the axial movement of the selector cable is transferred to the selector shaft which can turn in its bearing.

When shifting into reverse gear, the gearshift lever is moved backwards. The selector boss engages in the 5th gear/reverse gear shift rod, which in turn engages through a pin in the reverse gear selector shaft.

During the select and shift process the selector shaft is guided through the selector gate by a pin.

The reverse gear idler is slid by the reverse gear selector shaft and reverse gear is engaged.

At the same time the shift locking bush prevents access to other gear combinations.

Power transmission in the individual gears

Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer Case > 308-03B Manual Transmission-Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5) > Description and Operation > Manual Transaxle

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