Build Diary - 21st July 2005
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The type 9 gearbox is designed for use with the pinto engine which is quite a lot fatter than the Zetec engine. I decided that rather than have large gaps around the bellhousing I would make up an adaptor plate from 0.6mm galvanised steel. |
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The gearbox was placed on the sheet and I drew around it, then I placed the Zetec plate and drew around the inside of that. This is what I ended up with. |
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The lightened flywheel from Tiger comes bare. The ring gear needs to be fitted (place in oven for 30 mins on full whack, then gently tap home with a club hammer), and 3 dowels need to be purchased from Fords to locate the clutch. |
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Clutch cover dowels. |
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The dowels fitted!. |
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The flywheel was fitted with new bolts (from Ford) and torqued to 110Nm. The clutch was fitted using new bolts from Ford (mondeo) however they were too long and needed 3mm cutting off them. |
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Once I had bolted the gearbox to the engine I realised I couldn't get the car back in the garage (Doh!). I decided to see if it was possible to fit the engine and gearbox by myself without a hoist! It is, but I wouldn't recommend it... I placed the engine & box on a trolley jack, removed the front wheels and lifted the chassis over the engine and down on to axle stands. |
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Using a block of wood to simulate the engine mounts before drilling the holes. The engine bay is really designed for a pinto and there is very little clearance for the zetec. I had to fit the rear carb and make sure it cleared the brake master cylinder, then fit the exhaust headers and make sure they cleared the chassis rails. There was only a few mm either side |
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Lining up the gearbox would have been easier with a helper! |
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O/s engine mount bracket. |
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There we go - on all four wheels with the engine and gearbox in, all in under a month.... I'm gonna have some time off now! |
