Focus 6 sp into Fiesta Mk7.5 1.0

[Eatonm112]

I have just finished fitting a 6 speed gearbox from a 2013 Focus 1.0 125Bhp into my Fiesta as I feel this is the box that the car should have came with from the factory.

As mentioned on another thread I said that once it had been completed I would provide the information needed if anyone else should wish to go this way.

First I will go through the parts needed.

- Fiesta ST gearbox mount.

- 2 x P/S drive shafts (these are the shorter ones) I will cover why two are needed later.

- 1 x D/S drive shaft (the long one) NOTE - 5sp drive shafts will not fit into the 6sp box as the diameter is larger by 1mm on the 6sp.

- 6 speed gearbox from a 1.0 125Bhp Ecoboost focus built from 2012 to 2017 Mk3 Focus. The gearbox counter weight will need a good 10mm removing from it with a grinder its very easy to check the clearance by holding the ST Gbox mount upto its fitted location. 

https://photos.app.goo.gl/7erVBGfSwCW8S2ya6

https://photos.app.goo.gl/CQEeX9HhTS8Qqv7y6

- Dual mass flywheel, clutch and release bearing.Pics of parts - https://photos.app.goo.gl/th5JUdsaUoGdHYdn9 Focus clutch and fly fitted. https://photos.app.goo.gl/kf2nZDwK2Ttp3MFK7 Focus clutch on the left has a larger surface which means more capacity to take torque so is a good upgrade. The flywheel only bolts onto the crank one way due to bolt spacing.

- D/S drive shaft bearing holder. https://photos.app.goo.gl/67LW22GaGADyj8Gw7 Pic for part number.

- Gearbox shift cables and tower from a Fiesta ST + gear knob and material surround trim piece. https://photos.app.goo.gl/UQCp1bDtwxdu5HPz8

 

Rather than writing a very long piece about fitting it in stages I thought it would be better to just make some comments that would help someone with a good level of mechanical skills.

Removal and install of the gearbox is very straight forward I found it helpful to not have the gearbox mount fitted when getting the 6 sp into place. The standard torque mount will work with the 6 sp.

https://photos.app.goo.gl/q4MPuxGz2e5qxGyp9

https://photos.app.goo.gl/DCZ2a58wNS3PPxSi8

https://photos.app.goo.gl/ouB7V4kVR87SdCg59

There are two electrical connections that need to be taken care of. (Rev switch 2 wire and neutral magnetic sensor 4 wire)  But, it is a very easy plug in job that will require the excess cables to be secured with some cable ties or if you want cut and shorten the cables.

The hardest part of the job was to run the old selecta cables out and get the new ones back in along with the tower. To do this you will need to remove the front part of the exhaust and take off the heat shielding to get to the point where the cables come though the exhaust tunnel. WD40 or Dry PTFE spray is so helpfull when running the new cables in.

https://photos.app.goo.gl/oECAYc1QrqQK6MwC6

https://photos.app.goo.gl/NrR3oLvVxhCZT9kKA

The P/S drive shaft from a ST is a direct fit but the D/S one has to be altered as the outer tripod joint hangs out too far and will catch on the subframe.

P/S shaft fitted. https://photos.app.goo.gl/JgRzbHcj9A4mYFaH8

D/S shaft before cutting down. https://photos.app.goo.gl/8HHEsrjZyDFCFhEn6 The picture shows the bearing is too far out and thus cant be bolted to the back of the engine.

https://photos.app.goo.gl/UojykndRnckPQi5o7 Pic of the ST shaft fitted before I cut it down to move the shaft with the bearing on inwards to work with the bearing clamp.

Choppy choppy - https://photos.app.goo.gl/9H6w9naCzoxxVwS69 https://photos.app.goo.gl/bRMVTFjZZ9txz5q47 https://photos.app.goo.gl/mo4bmWRZQUXitZTu9

D/S inner shaft bearing holder. https://photos.app.goo.gl/eWufBNF8MJCjcHC36 The one on the right is what the 5 sp Fiesta uses but it mounts too low for use with the 6sp so the left side one is used.

D/S inner shaft pics after welding ( sorry no pics of the welding as it was a busy day) https://photos.app.goo.gl/nH7dK8wMm2pSbxXu7 https://photos.app.goo.gl/E7CjXu9TVBAELmgb9

More to be added -  in regards to the DS shaft.

 

 

 

 

Gear Ratios

5 speed box from Fiesta 2015 125Bhp ecoboost IB5

1. 3.58 overall ratio 12.91:1

2. 1.92 overall ratio 6.93:1

3. 1.20 overall ratio 4.33:1

4. 0.87 overall ratio 3.14:1

5. 0.68 overall ratio 2.45:1

FD = 3.61

6 speed box from Focus 2012 on 125 ecoboost IB6

1. 3.73 overall ratio 15.16:1

2. 2.05 overall ratio 8.33:1

3. 1.36 overall ratio 5.53:1

4. 1.03 overall ratio 4.18:1 * edit / thanks Splatman

5. 0.82 overall ratio 3.33:1

6. 0.69 overall ratio 2.80:1

FD = 4.067 other FD ratios are available for this box ST180 = 3.82 and ST200 = 4.3 As far as I am aware both have the same gear sets ie gears 1 to 6.

Its also worth noting that reverse gear is a syncromesh which means engaging reverse is super smooth and easy. 

 

Extras 

If you are considering going through with this I recommend adding the following two parts 

- Motorsport Billet Quick Shift Ford Fiesta ST180  as shown in this picture https://photos.app.goo.gl/xwgsm93Zxy5gL34LA

- Ford Fiesta ST180 IB6 M Factory Helical LSD https://photos.app.goo.gl/ZQAA8KAjzhWTpsBU7 https://photos.app.goo.gl/KqShkL6AFzARzv9u5

Having road tested my car a few days ago I can say it was well worth the effort the car drives so much better and puts the power down with ease thanks to the LSD. I had a issue with traction when coming off round about's  which has now gone the car just keeps grip and pulls its a really great mod. I am currently running a 200 Hp map in my car and intend to go further now I have addressed the drive train weakness. Next items for my car will be larger injectors, cams ( in the works ) and a bigger turbo.

 

 

UPDATE 26th July 2019

I have put about 5,000 miles on this conversion now and all is well the car drives really nice. There is a clutch slipping issue when I floor it in 5th and 6th from low RPM ie when on the motorway it judders a tiny bit SIGH that's why you do not use secondhand parts lol.

I am looking into an uprated clutch from a Focus 1.5 diesel not sure if it will fit. But, I will order a used one and try it. Another thing I would like to do is get the 5th and 6th gears from a Focus 1.5 diesel 6 speed to lower the RPM a tad when on the motorway I do long motorway trips every now and again and it would help the MPG.

I'll do some math on this and update with rpm / gear and so on.

 

 

UPDATE 18th Dec 2020

I think I have covered over 14,000 miles now and have not had any issues from this conversion I did have to replace the secondhand clutch as it was slipping a bit usally in 5 th or 6th when acelerating from 1600 rpm I decided to change the clutch spring plate with one from a Focus 1.5TDCI as they should have more clamping pressure. Another change was with the final drive ratio which is the 3.8 one used in the Fiesta ST 6 speed this has helped a lot with fuel economy around town and motorway as it lower the rpm in each gear a small amount. Also worth noting that I dont get the hunting issue in first gear when in traffic anymore.  I am now looking to loose the dual mass flywheel and go back to the 5 speed solid one and re drill is to accept the Fiesta ST clutch spring plate just need to figure out how to get my CNC mill to do that.

To anyone considering this swap I would recomend changing the final drive that the Focus box comes with from 4.05 to 3.8 as it give a much better spread although that would mean you would end up buying two gearboxes from a breakers. Its worth looking on eBay as 6 speed boxes come up with broken housings every now and again. I recently bought a 6 speed from a Focus 1.5TDCI with a cracked case for 150 delivered and one day I will get the 6th gear out of it for my fiesta as it will then make it as close to the 5 speeds 5th as youll get.

 

 

 

 

 

 

 

 

[Eatonm112]

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[Tounsi0008]

Nice ! Good job bro, how much torque you have now ? 

I have a ib5 and have 253Nm, I hope I do not have any problems ^^

[Eric Bloodaxe]

Great job! Look forward to further instalments!

[Eatonm112]

2 hours ago, Tounsi0008 said:

Nice ! Good job bro, how much torque you have now ? 

I have a ib5 and have 253Nm, I hope I do not have any problems ^^

Hi 

I am currently on a Pumaspeed 205 map which makes 258Nm.

 

I intend to switch the ECU to a aftermarket one later this year so I can have more control over the mapping. Along with this I will be changing the fuel injectors, turbo and camshafts at some point as I want to aim for 240 250Hp along with 275 to 300Nm this will be after the pistons and conrods have been upgraded as they will not withstand such cylinder pressures.

[Jakeashbyy]

Thanks for this. Please can you give an idea as to roughly how much you spent on parts?

Also how many hours did this take you? I’m looking to take this to a specialist to do the work for me as it is way outside my skill set 😂

 

thanks in advance

[Eric Bloodaxe]

3 hours ago, Jakeashbyy said:

 it is way outside my skill set 😂

Mine too! Had a few 'boxes on and off Cortinas and Escorts back in the day but things seem a lot more complicated now - but a fascinating project to follow. As a reference, I think Pumaspeed offer this conversion at something like £1600 parts/£2050 fully fitted.

On 4/14/2019 at 2:25 PM, Eatonm112 said:

I want to aim for 240 250Hp along with 275 to 300Nm

Wow!

[Eatonm112]

On 4/15/2019 at 11:45 AM, Jakeashbyy said:

Thanks for this. Please can you give an idea as to roughly how much you spent on parts?

Also how many hours did this take you? I’m looking to take this to a specialist to do the work for me as it is way outside my skill set 😂

 

thanks in advance

Sorry, I never answered your question. I missed it.

The whole job took about 3 - 4 days that included cutting and working out how long to make the DS half shaft as you have to rebuild the suspension to check there is sufficient length and it doesn't bind etc when steering etc. If I had been told beforehand what I needed to do it would have saved me a day.

As for cost 

ST driveshafts 2x PS and 1 x DS £570 

Focus 1.0 125bhp gearbox £265

Focus driveshaft mount £25

Focus 1.0 Clutch dual mass flywheel plate and release bearing £80 used/ I would try and buy a new clutch as mines slipping. Looking into an upgrade with OE Ford parts.

Gearbox cables and tower /gear knob £100

ST ps gearbox mount £35

Total around £1075 Plus any upgrades like quick shift gear linkage and torque bias diff.

 

[TDR|XTC]

Great post!

And regarding the bellhousing match and ECU tweaks, do you have any info?

Thank you

 

[Eatonm112]

The bellhousing was a direct match to the IB5. I have not done any ECU tweeks although I would love to adjust the throttle whilst at low rpm in 1st gear as it can be a bit jerky when you are on and off it at 1500rpm ish. I have an aftermarket ECU going on very soon once I finish making the adaptor loom out of a old ECU.

 

https://photos.app.goo.gl/hWEnZato1DE3akgb9

https://photos.app.goo.gl/hnMGHjPSV6eoHUb46

 

[Fezdup]

Hi there Eamonn I've got all the bits to do the job I just need a little bit of advice. Is there any chance I could e mail you?

 

[1bat]

Hi any more info on the driveshafts only thing putting me off this conversion ? Seen a kit for sale but has 2 d/s shafts and 1 p/s shaft is that right or do I need 2 p/s 

[Mavroz]

Why not just get a Mk8 Fiesta, they come with 6 forward gears ?? ....

[Eric Bloodaxe]

4 minutes ago, Mavroz said:

Why not just get a Mk8 Fiesta, they come with 6 forward gears ?? ....

I think these guys relish the challenge!😃 And the Focus box will still be stronger than the Mk 8 box if you're doing some serious tuning.

[Mavroz]

I know what I would prefer but as always, each to their own..

[Choco107]

Great stuff I'll be starting mine shortly. What was the engine reving at , say at about 60 ,70 mph in 6th with the focus FD ?? 

[Alex16s]

On 7/26/2019 at 4:02 PM, Eatonm112 said:

Focus 1.0 Clutch dual mass flywheel plate and release bearing

I did this conversion to but have a strange problem......

clutch got more have than original and after doing 50k miles my gearbox has a really strange issue when motor/gearbox is cold shifting to gear 1 and 2 is ''fine'' shifting in to 3/4/5/6 is hard and getting it out of gear to. but when motor/gearbox is warm all is oke and working perfectly...... I really have no clue what this could be

also do you have part nummers for clutch and pressure plate replacement

 

[axesuso]

Hi! 

i need help regarding this topic. My gearbox is screwed as the ib5 is a ***** gearbox and im considering converting to ib6 bcoz it doesnt make sense repairing a gearbox that can simply break again. Its all very confusing to me, whats the parts i need and obviously my local garage will have to do the job as im a noob! I dont even know where will i find the parts needed and if it will be more cheap than instead getting the kit from pumaspeed ?

thanks!!

[Chaz84]

pull it off get a replacement one from the scrappy yard fit a qualsd3 diff and a new clutch be the quick way what a would do lol 😂

[axesuso]

11 hours ago, Chaz84 said:

pull it off get a replacement one from the scrappy yard fit a qualsd3 diff and a new clutch be the quick way what a would do lol 😂

Hi! 
just fitted a new clutch, thinking the problem was the clutch... now i need a gearbox. There is one in my local scrappy yard. Whats the qualsd3 diff? Will that prevent from ***** the gearbox again?

thanks !

[Chaz84]

A have the same box on my st150 track car a has a similar problem so a upgrade the diff to the qualld3 diff £400 dropped a stage 2 clutch in and upgrade the master slave it’s better transfer for power to the road more robust and a haven’t had a problem since selection of gears is so much better and the car feels more responsive to gear changes mite be in my head but a do feel the difference

[Chaz84]

The id5 box dose suck tho still have to put it in first before selection of reverse but can’t have it all being a Ford lol 😂

[axesuso]

29 minutes ago, Chaz84 said:

A have the same box on my st150 track car a has a similar problem so a upgrade the diff to the qualld3 diff £400 dropped a stage 2 clutch in and upgrade the master slave it’s better transfer for power to the road more robust and a haven’t had a problem since selection of gears is so much better and the car feels more responsive to gear changes mite be in my head but a do feel the difference

I just replaced the clutch for Sachs performance one. So you suggest me to get a second hand gearbox, replace it and fit the qualsd3 diff? my car is currently remapped and im pretty sure the extra torque has helped to kill the gearbox so... im looking for something that prevents this?

Thanks!

[Chaz84]

Yeah you defo need a qual diff if you been running extra power that probably why it gave up am running 200hp defo a stage 2 min clutch and a better diff is need the ib5 box really only designed to run 150 bp any thing extra it’s just time before it go’s always remember more power = upgrade all your running gear brakes , diffs , clutch, just as important than cams and bigger turbos

[Chaz84]

A have upgrade springs , shockers , brake disc , brake clippers , gear box diff , clutch ,strut braces ,stripped it out before a even put a power mod on it no point in power mods if you can’t put it to the road lol 😂