Tuesday, 31 December 2013

Upgrade Progress - final post of 2013

So the upgrades are taking their time but the weather hasn't been too good so no significant loss of drive time.

First of all the clutch - fundamentally 2 primary options for most Ford engine/gearbox combinations 220mm and 240m both with a 23 spline.  The original blacktop had a 240mm and the TTV light weight flywheel needs a 220mm, I could have returned the flywheel as there is a 2.0L blacktop version which would allow retention of the 240mm clutch but it's heavier than the 1.8L one I've got so I decided to keep it.  £80 bought a 220mm clutch but I could only get one for a MT75 gearbox which meant that I needed to get a new Release Bearing.  Basically needed a CCT132 rather than the CCT133 that was originally fitted to give an extra ~10mm of clearance unfortunately modern auto factors struggle with part numbers so it took a couple of goes (and ~£20) to get the right one - so now have the original CCT133,  a CCT134 as fitted to an Escort Mk1 (right offset but too small inner diameter), an MT75 one and the CCT132 (RS2000) that is now fitted to the car.  Still on the positive side I now know a lot more about clutches and how to measure offsets and have a clutch capable of supporting 220+ bhp so more than I reasonably expect to get out of the engine.

Christmas turned out too busy to allow any progress on returning the engine to the car but the Dorset WSCC Christmas Dinner was a real success with all who attended seeming to enjoy themselves - many thanks to Malcolm for all his efforts.

Myles and I fitted the flywheel (using ARP bolts) and clutch to the engine the release bearing to the gearbox just before Christmas but the garage was too cold and we had too much to do to make any really progress with the engine refit.

Weighed new flywheel at 3.7kgs versus 9.7kgs of the original Ford item.
With Christmas over and constant rain keeping temperatures in double figures James and I ventured into the garage.  First task was to replace the sump gasket, fairly straight forward and we did an oil change while we were at it.  Next we removed the engine mounts and made the finally preparation for reinstalling the engine. The actual installation was straight forward but we needed to jack up the gearbox bell housing as the gearbox mount is well forward and the only thing that holds up the bell housing is the engine.  Once the engine and gearbox were mated and bolted together and the engine mounts refitted the rest of the installation was a repeat of the original built with the only minor difference was significantly less access as the bodywork was now fitted especially for reconnecting the throttle cable - luckily Myles has long skinny fingers.

Fitting the new radiator presented a small problem with the temperature switch being in a slightly different place. James marked and cut out the fan mount to provide the clearance and we fitted the radiator.

Finally we fitted the new carbon fibre exhaust but will need to manufacture a rear bracket for it as the one from the original exhaust isn't suitable and I need to keep it for MOTs.

Once we'd checked everything was connected we started the engine and bled the cooling system - no leaks so far!

Just need to refit the front ARB, do the final torque checks and then wait for some decent weather in 2014.

Saturday, 7 December 2013

Upgraditis Strikes Again

Thursday night was Dorset WSCC night with only Colin braving the winter night in his Westfield. Chris' car is half way through an engine transplant replacing the silver top zetec with a blacktop and transferring over all the Raceline/TTV goodies.  Not many have SORN'd and we discussed a blat call up list if there's good weather over the coming weekends.

The WSCC night spurred me into action so when I got home from work on Friday I prep'd the car for engine removal with only the Alternator and fuel connects left to removed before the lift.  The plan is to:

  • Replace the sump gasket to stop the slight oil weep post ARP con rod bolt installation.
  • Fit the TTV light weight fly wheel inc ARP bolts
  • Fit the Radtec Alloy Radiator
  • Fit the Carbon Fibre Exhaust
  • Adjust the ARB to it's softest setting and investigate/replace the bent drop link rose joints
  • Refit front Mintex M1144 disc pads with ceratec grease in an attempt to cut down squeal.

Plus carry out an oils change and full service

I've decided not to fit the LSD yet as if I'm removing all the rear body work I also want to fit a rear ARB and nylon bushes that I've just ordered from Westfield.  Overall I want to drive the car next year, with plenty of track days to really get to know it before spending anymore money on it (possibly wishful thinking!)

James and I went out to the garage and he disconnected the alternator and fuel lines, removed the radiator and checked to make sure everything was ready to remove the engine.  We discussed the clearance from the ARB at the front of the engine and agreed that there was enough (wrong!).  After a quick clean up we setup the engine hoist and connected the leveller.  The lift initially went well with the engine and gearbox separating but then the flywheel and clutch were bigger than the gap between the front of the engine and ARB so the ARB had to be removed with the engine suspended on the hoist.  Once the ARB was out the engine lift was completed and the engine set down on a work table.

With the engine out we decided to replace the flywheel first.  James removed the 6 bolts holding on the clutch and after a slight tussle with a sticking dowel the flywheel was exposed.  The first attempt to remove the flywheel bolts failed as we could get enough leverage between the front main crankshaft and the flywheel bolt.  After a quick rethink James placed an allen key through one of the gearbox mounting bolt holes and braced a large flat bladed screwdriver in the starter motor drive ring and it worked very well.

Disaster - original clutch was too big for the new flywheel.  After an exchange of texts with Malcolm I had two options - 1) swap the flywheel 2) buy a pinto 220mm clutch.  unfortunately ECP didn't have a pinto clutch in stock but will have one on Monday so a tidy up of the garage and the end of work for the weekend.