I find it easier to see what you're doing.

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No pictures today as my phone would have been drier dunking it in the toilet.

But, first step in the hydraulic clutch done. One MK1 Mondeo clutch pedal and master cylinder unit obtained. The pedal shaft is exactly the same as the fiesta unit from what I can tell so it fits on. Just need to investigate pedal length and making the clutch cable hole into the correct shape. It looks like I just have to extend the hole upwards in a large gear small gear belt style.

Also should find out what gearbox is on the 1.8 MK1 Mondeos as afaik it looks like this will fit the 1.6 zetec and have the hydraulic clutch built in already. Stupid question about that really, but does the clutch/flywheel bellhousing actually come off the gearbox? Or would I have to swap the whole box? I know a Ford box out there should fit and have the hydraulic clutch, along with possibly better final drive ratios off the Mondeo.

When I was looking round in the scrapyard I think I have found the mecca for rear electric windows...

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Bell housing doesn't detatch. Would need to swap the gearbox over.

Rear window mechanism sounds interesting. There was a discussion about that on FT a while ago.

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is that not a popular thing to do with the rear windows on 5 doors?

nice ideas on the clutch dan.

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fifi

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whats the difference with a hydraulic clutch though? more reliability? lasts longer?

thats wierd that nobody has done it, looks like you and the si will be the genuie pig lol

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fifi

It should be easier to maintain a good bite, not snap cables every two months and be easier on the leg. Seriously I can't walk in a straight line any more.

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The gearbox will swap over no problem, it just uses different mounts.

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haha fair play. so it hasnt been done on an si has it danny? HAS IT!?

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fifi

Which shaft are you talking about? The one that goes into the servo?

It probably has in all fairness Ben, but not on this forum (that I can think of at the moment anyway) Reason I say that is because people who do zetec turbo conversions ect and use MTX boxes and stuff would probably use a zetec Si as a base to start with - not always, but sometimes.

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Over the last two days I got onto reconditioning the front calipers. Didn't take any photos as I put up the gazebo and still got soaked. There was a lot of grime in those piston bores and even though it doesn't seem to have affected it in any way good or bad it's still nice to know they're done.

I also noticed I had a horrifically warped drivers side front disc. So these went on:



Both sides done of course:



Brake pedal is nice and firm from the top again. I had a horrid noise at speed most noticeable at between 50 and 60 but also at other speeds above 40 when not on power. I think I may have an underlying issue in the form of a CV joint or bent driveshaft as if I listen very very carefully the noise is still there but barely. Only that would explain one badly warped disc!

Because of the discs I now have to hope that cable holds as I can't afford to source a hydraulic gearbox setup at this time. But next month I could look at doing the gearbox, clutch and driveshafts all in one go. Anyone wanna help me do a one day swap?

Edit: And I just noticed I'm getting some nasty sagging on the drivers seat back

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Haven't touched my thread in a while, but I do have a good amount of pictures coming up because some things have tried to explode.

So new CV Joints, new clutch kit and possibly a hydraulic gearbox. Going to get more pics today (and that's probably all I can do today with the weather).

Update coming soon.

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Well, here we go. Two different days worth of pics and each day I'm getting more knackered as I'm having to walk 5 miles to work with 10 or 11 hour shifts.

First day:



Best position I could get him for safe use with the stands etc.



Up and dismantled the offside knuckle and driveshaft.

Got the driveshaft off in preparation for the clutch change and found something wrong with the inner CV.



Looks ok doesn't it?

Well this doesn't!



I actually put that roller back on as it was rattling around in the CV joint completely loose! Think I've found the noise issue I was having!

Mark up two outer CV joints and one inner CV joint.

Then got on today with removing things ready for the gearbox coming off and looking at any other potential issues:

Other driveshaft popped out:



Bloody mucky:



Then took the thermostat housing off as oil is coming from somewhere:





Couldn't do much else as it looked like it started raining, cleared up, came inside. Sun came out. Grrr.

Got a clutch here and getting the CV joints tomorrow. Need some bricks for supporting the engine on the partial drop down then I can get this gearbox off and clean stuff up to find where this oil is coming from. I suspect the rocker cover gasket though.

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another jack dan! i used two jacks to support the engine at one point when i was removing it. then you have a spare for the future your driveshafts pop out ok?

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fifi

I'll be using my current jack to lower the engine onto bricks, then the jack can be used for lowering the gearbox off. Bricks are a lot cheaper than another jack!

Driveshafts popped out fine, fairly easy but the expected stubbornness in whacking them out.

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true that. i was short on a brick or two so another jack came in handy!

yeah one of mine came out with no bother, other took a fair few good whacks like! looking foward to progress. whats plans after this?

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fifi

Well, one has flat out refused to budge. I have even written off the hub and just went mental just to see if it would budge. Extreme heat, extreme force, both, other stuff. It's like it was bloody welded in.

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Well, todays update of yesterdays work.

New bits:



Big enough blocks?



Drive shafts dismantled:



The damage done getting one outer CV joint out:



As I said, the other one does not shift at all so I need to get a new hub carrier

This took around 3 hours as those CV joints were terrible! I like the shiny new ones though but I'll only be building the drive shafts up when the clutch/gearbox is done.



3 days of 10 hour shifts will prevent any work for a few days. Next day off is to get the gearbox down.

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