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 Gearbox GuideLast  on September 01 2008Fiesta/Escort FWD Gear Linkage If you want information on how to modify a FWD linkage, to reduce play (especially if you have already fitted the B&M #45096 short shifter), check the guide at the foot of this page. Using the Zetec with front and rear wheel drive gearboxes One of the most common questions I'm asked is, "what gearbox can I fit to the Zetec engine?", and its a perfectly valid one, which I can hopefully answer below. If you're installing the Zetec in to a kitcar, or any other car, perhaps even a historic or classic car, then this guide should go some way to help you make your decision. Ford's silver top and black top Zetec engines have been fitted to Mk1 and Mk2 Fiesta's, Quantums, Mk1 and Mk2 Escorts, Anglia's, Orions, Cortina's, even Lotus Europa's, Westfields, and all manner of kit cars. Ford (being the sensible people that they are) decided to stick to the same bellhousing pattern that they have stuck to since the 1960s. So for a rear wheel drive (RWD) application, you can use the Type-9 five speed box from the Sierra, plus an RS2000 bellhousing. One simply bolts to the other. Note: The Type 9 has a 1" 23-spline input shaft and the 2000E four speed box has a 7/8" 20-spline input shaft. The MT-75 (Granada) or T5 (Sierra Cosworth) gearboxs also fit on the Zetec. Zetec crankshafts are already machined to accept a RWD spigot bearing, which again simplifies things somewhat. To fit the Zetec engine on the front wheel drive (FWD) Type BC gearbox, simply replace the Mondeo Zetec 2.0 flywheel with the one from the Silver Top Escort 1.8 Zetec, and use the clutch cover and friction plate also from an ST Escort 1.8 Zetec. And the clutch? The Silver Top flywheel should be used, as the later dual mass flywheel on the Black Top Zetec's isn't suitable due to their size and weight. The flywheel will need re-drilling to accept a Pinto clutch. Keep the Mondeo Zetec clutch cover. Use a sierra 1.8 CVH friction plate. Fit a ford spigot bearing, change the clutch release bearing to a capri part CT133 Quinton Hazel (available from most motor factors). A new spigot bearing costs approx £10 from Ford. For FWD applications, you should use an AP Racing 220mm clutch and clutch cover. You can get away with using a standard Zetec FWD clutch for RWD applications but, as the fulcrum point for the clutch release arm is in a different place on FWD cars, you'll find that in a RWD vehicle the clutch pedal will only have half its normal travel. Please note: This information has been taken (with very kind permission) from the TRANSMISSION page in the Burton Power catalogue. For more information, visit the Burton Power website. 2000E "Bullet" 
A medium duty 4 speed box with three selecor rails. Has been made with various gear selector positions; steering column change, two types of floor change and remote floor change.Fitted in:
Type 2, four speed single rail light duty gearbox as fitted to all Mk1/2 Escorts (Excluding RS/Mexio and Twin Cam). All type 2 gearboxes have integral bellhousings.
Type 3 
Type 3, four speed single rail version of the 2000E gearbox.Fitted in:
Type E 
4 speed single rail gearbox, used for more demanding applications than the Type 3 box. It is available with or without an integral bellhousing. Often referred to as the 'Rocket' box. (Rocket was the name of the original close-ratio competition gearbox that was based on the Type E).Fitted in:
Type 9 
The Type 9 was Fords first RWD five speed box, and based on the Type E. This gearbox is commonly used for 5 speed conversions on older vehicles. Some later versions were available with integral bellhousings, although they are more commonly found with removable bellhousings. A 4wd version of this box was also available for the early XR4x4 models. Power rating: Approx 200BHPFitted in:
Type F 4 speed box with unique side lever shift rods. Fitted in Capri 2.0 72-82 Type 5 4 speed, 3 rail heavy duty box, fitted to V6 models. Fitted in:
MT75 
The MT-75 5 speed gearbox, that relaced the Type 9. Available in 2wd and 4wd versions. Power rating: Approx 250 BHPFitted in:
Borg Warner T5 
5 speed HD Borg Warner box. One of the strongest boxes fitted to a production European Ford car - it should be since it originated from the American Mustang. Fitted in Sierra/Sapphire Cosworth 2wd
Front wheel drive Type B5 or BC 4 and 5 speed FWD transaxle. The original FWD box which superseded by the IB5 box around 1995. Fitted in:
Latest standard duty FWD transaxle which has been fitted since around 1995.Fitted in:
Type MTX75 
Newer HD version of the FWD transaxle. Originally fitted to the high powered Mk5 Escorts. Available in 2wd or 4wd versions.Fitted in:
Uprating the gearbox Zetecinside.com recommends the Quaife Straight Cut Gear Set and Automatic Torque Biasing differential for the front wheel drive Type B5/BC and IB5 gearboxes. 
How to reduce the play and friction in a front wheel drive gear linkage. Parts required: 25cm of 8mm diameter steel bar. Four M8 Nyloc nuts Supplier - rswww.com
If you wish to to fit the quick shifter (to reduce throw) you will need the following: Supplier - www.summitracing.com
I devised this solution in 2004. I'd fitted a B&M short shifter #45096 bought from summitracing.com, and was still concerned about 'play' in the mechanism. After closer examination, the two universal joint type connections in the linkage were identified as the source of the movement, and I set about re-working the joints. Read on... What you need to do is replace the pairs of plastic top hat bushes in the universal joints, with ball raced bearings bought from rswww.com. Using lengths of 8mm diameter steel bar, tapped with M8x1.25 threads on the ends to hold the bits together, the modification can be made in a couple of hours, and makes a world of difference to the gear change. The photo's below show what's involved.
 Finally to reduce the noise in the car, you should fit the B&M shifter using these rubber insulators (cylinder mounts). It makes a huge difference. The shifter assembly bolts directly to the floor, which means firstly when the engine and gearbox rock, the linkage is put under a lot of strain, and secondly all the vibration from the engine is transmitted along the linkage in to the floor of the car which makes the car extremely noisey and unpleasant to drive. These cylinder mounts definitely do the trick by isolating the noise created by the solid mounting of the gear linkage. |
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