eddie99
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| posted on 19/6/10 at 12:23 PM |
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Type 9 zetec clutch problem
Hi Guys,
Finally managed to get my engine out this morning and pull all the clutch bits to pieces.
We thought that the symptoms meant that the clutch plate was around the wrong way. Unfortunately it was round the correct way, so an easy fix is not
happening.
Here are some pictures, can anyone see whats wrong, following on from this post:
http://www.locostbuilders.co.uk/forum/9/viewthread.php?tid=137788
 
Gearbox1
 
Clutch Flywheel
 
Clutch plate
 
Clutch cover1
 
Clutch cover 2
Really struggling now, think i might end up going to Newark after all if i don't know how to fix this 
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big-vee-twin
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| posted on 19/6/10 at 12:30 PM |
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There's some dims here of a CT133 bearing worth checking yours
http://www.locostbuilders.co.uk/viewthread.php?action=attachment&tid=107081&pid=893307
All well image didn't quite attach but follow the address and the pic is there
[Edited on 19/6/10 by big-vee-twin]
Duratec Engine is fitted, MS2 Extra V3 is assembled and tested, engine running, car now built. IVA passed 26/02/2016
http://www.triangleltd.com
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eddie99
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| posted on 19/6/10 at 12:31 PM |
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quote:
Originally posted by big-vee-twin
There's some dims here of a CT133 bearing worth checking yours
[img]http://www.locostbuilders.co.uk/viewthread.php?action=attachment&tid=107081&pid=893307[/img]
[Edited on 19/6/10 by big-vee-twin]
Pic is not quite working buddy!
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big-vee-twin
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| posted on 19/6/10 at 12:33 PM |
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There's a pic on here some where with the standard and CT133 side by side so you can see the difference - still looking
Kev
Duratec Engine is fitted, MS2 Extra V3 is assembled and tested, engine running, car now built. IVA passed 26/02/2016
http://www.triangleltd.com
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eddie99
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| posted on 19/6/10 at 12:37 PM |
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Yup just measured against that and it matches up. Mine is the ct133!
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big-vee-twin
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| posted on 19/6/10 at 12:44 PM |
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is the arm stopping the bearing travelling far enough down the input shaft??
Duratec Engine is fitted, MS2 Extra V3 is assembled and tested, engine running, car now built. IVA passed 26/02/2016
http://www.triangleltd.com
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eddie99
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| posted on 19/6/10 at 12:46 PM |
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quote:
Originally posted by big-vee-twin
is the arm stopping the bearing travelling far enough down the input shaft??
It is a possibility i guess, used the arm from the sierra so guess its what everyone else with a zetec has used.
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big-vee-twin
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| posted on 19/6/10 at 12:49 PM |
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I've just lifted this off of www.zetecinside.com
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.
Could be worth a read through
Duratec Engine is fitted, MS2 Extra V3 is assembled and tested, engine running, car now built. IVA passed 26/02/2016
http://www.triangleltd.com
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eddie99
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| posted on 19/6/10 at 12:53 PM |
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Done everything there...
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IanBrace
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| posted on 19/6/10 at 12:54 PM |
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Whats happening at the pivot end of the arm? Not clear on the pic, has it been altered /welded?
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eddie99
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| posted on 19/6/10 at 12:54 PM |
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quote:
Originally posted by IanBrace
Whats happening at the pivot end of the arm? Not clear on the pic, has it been altered /welded?
Will go and get another pic but nope, not been altered or welded. Its how it came out of the sierra with a new release bearing
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eddie99
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| posted on 19/6/10 at 01:02 PM |
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Ok just got some more pics, When the pedal is up, This is how it sits:
 
Release Arm Open
When the pedal is fully down, the arm is bottoming out on the bellhousing at this point. Is this enough? Maybe i need more travel?
 
Release Arm Closed
Therefore maybe the arm is too bent. Some people have said, there are different arms, but this is the sierra one. And also if it had more travel, my
clutch slave cylinder might not have enough travel
[Edited on 19/6/10 by eddie99]
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MikeR
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| posted on 19/6/10 at 01:05 PM |
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check ur flywheel. I'm sure the 2.0 litre flywheel needs a diff release bearing due to it being thicker than the 1.8. (read it on here and some
where else. On phone so can't search myself. What bell housing hard u got. Rs 2000 ally bell housings have diff pivot point so u need diff
clutch arm.
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eddie99
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| posted on 19/6/10 at 01:08 PM |
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Normal steel/iron bellhousing from the sierra, so no adaptions should be needed for that.
[Edited on 19/6/10 by eddie99]
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eddie99
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| posted on 19/6/10 at 01:14 PM |
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Just reading Big_Vee_Twin's post. I think i've got the 1.8 blacktop flywheel, which came with the engine. Maybe i need the silvertop
flywheel. Are the thicknesses different?
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big-vee-twin
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| posted on 19/6/10 at 01:15 PM |
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Edd just had a good look over my box and it looks identical to your in terms of arm bearing shaft etc, On the assumption that they are all this
configuration its pointing towards your cover plate.
What is that taken from can you dim front to back and I'll check against mine off the rs turbo.
On the basis the 2.0 Zetec boys fit the Zetec 1.8 fly cos its lighter wouldn't think that is a problem
[Edited on 19/6/10 by big-vee-twin]
Duratec Engine is fitted, MS2 Extra V3 is assembled and tested, engine running, car now built. IVA passed 26/02/2016
http://www.triangleltd.com
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eddie99
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| posted on 19/6/10 at 01:17 PM |
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The clutch cover i got a part number of big_Wasa and went and bought the mondeo 220mm clutch cover or something along those lines!! Thats what we
thought it was before
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big-vee-twin
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| posted on 19/6/10 at 01:18 PM |
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Any early Zetec cover I understand is ok but you may be better with a RWD cover like mine off an RS Turbo get the dims and we can compare.
Kev
Duratec Engine is fitted, MS2 Extra V3 is assembled and tested, engine running, car now built. IVA passed 26/02/2016
http://www.triangleltd.com
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bob
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| posted on 19/6/10 at 01:22 PM |
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Arm
The pivot end of the release arm does look as if its been attacked at some time,does it look like this when its out.
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big-vee-twin
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| posted on 19/6/10 at 01:28 PM |
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My clutch plate is 40mm deep and the fingers are indented from the front face 9mm.
But I notice you have curved fingers not flat.
Aren't they designed to accept a round face bearing as the hydraulic one.
My fingers are flat to accept a flat bearing face like the ct133 -dunno if that' makes any difference.
Duratec Engine is fitted, MS2 Extra V3 is assembled and tested, engine running, car now built. IVA passed 26/02/2016
http://www.triangleltd.com
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bob
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| posted on 19/6/10 at 01:33 PM |
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I keep looking at the picture of the pivot end, it just doesnt look right to me.
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eddie99
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| posted on 19/6/10 at 02:03 PM |
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Bob - its just that there is lots of grease around it.
Kev - Im stuck, want me to measure my cover plate?
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les g
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| posted on 19/6/10 at 02:27 PM |
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please read u have u2u
les g
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RichardK
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| posted on 19/6/10 at 02:46 PM |
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Was this the picture you were looking for?
Cheers
Rich
Gallery updated 11/01/2011
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big-vee-twin
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| posted on 19/6/10 at 02:50 PM |
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Hi Edd I've done some measuring don't know if it will help but here goes.
Distance from face of fingers to bottom of Spiggot bearing 75mm.
Depth behind fingers to clutch plate 20mm
Pushing bearing forward down input shaft until it is leaving 75mm (ie contact point) aligns face of the bearing bearing with end of sleeve which input
shaft passes through and leaves a further 15-16mm of travel to push the bearing into the clutch cover plate.
At the contact point the Sierra lever is about half way through its travel.
Duratec Engine is fitted, MS2 Extra V3 is assembled and tested, engine running, car now built. IVA passed 26/02/2016
http://www.triangleltd.com
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