New guy. Here is my Cat

[yellowss7]

http://californiacaterhamclub.com/chat/attachment.php?attachmentid=1748&d=1565020583

[Vovchandr]

I'll try again. I just copied them and pasted them. They do show up on my computer.

 

They show up because you were given access to view attachments on the site. Which is exactly why I need help.

 

Even though I've been a member on their site for longer than a year and actually bought my car by messaging a member on there my account has never been activated. I can't post or view attachments. I've tried to contact admins but from what I gathered they are all inactive.

 

This is precisely why I need a previously activated member to save those pictures and re-host them here.

 

Much appreciated.

 

http://www.usa7s.net/vb/attachment.php?attachmentid=15828&stc=1

[JohnCh]

Here you go:

http://www.usa7s.net/vb/attachment.php?attachmentid=15829&stc=1

 

http://www.usa7s.net/vb/attachment.php?attachmentid=15830&stc=1

 

-John

[Vovchandr]

Alright new discoveries and questions as this rebuild continues.

 

Did Caterham USA source the Zetec engines locally (in US?) from some supplier or did Caterham UK ship them to be installed into US cars? Lots of part numbers coming off the motor only cross reference to obscure over seas websites and even dealer fails to match some.

 

Along the same note I've discovered that the Centerforce Ford Focus clutch for 2000 doesn't fit onto my Zetec. Too big for the fly wheel and bigger than my OE clutch (came with the car). 9in vs 9 7/16 as I discovered are the differences on Zetecs in different models.

 

Since I have VCT, I'm more than likely sourced from a ~2000 Contour.

 

However part number from Autozone for Ford Focus shows a 9in clutch that I matched in the store. No idea why Centerforce was bigger. Contour replacement shows to be 9 7/16. Escort ZX2 clutch looks similar but splines are different so that won't fit. Cougar 4 cyl also shows as a bigger unit.

[Kitcat]

Hey Vlad: I went thru this when I recently rebuilt my '03 Zetec SVT engine and clutch. No idea where Cat USA got their engines in '03 but doubt it was the UK.

 

As to the clutch, Raceline in the UK has everything you need. Call them, don't email. They tend to be slow, but thorough and very knowledgeable. I didn't hear from them for 3 weeks after I told them what I needed so we ordered a custom clutch from Clutch Masters. Then Raceline called and said they had everything. They also have the oil pan gasket and pick up oil rings which are very hard to find (buy several).

 

I can get the clutch specs from my mechanic and details of the order if you want. They come in all stages of durability and mine was designed for heavy track use. We had the flywheel resurfaced, we were not able to find a replacement, tho Raceline said had them, when they finally called me back.

[Vovchandr]

Hey Vlad: I went thru this when I recently rebuilt my '03 Zetec SVT engine and clutch. No idea where Cat USA got their engines in '03 but doubt it was the UK.

 

As to the clutch, Raceline in the UK has everything you need. Call them, don't email. They tend to be slow, but thorough and very knowledgeable. I didn't hear from them for 3 weeks after I told them what I needed so we ordered a custom clutch from Clutch Masters. Then Raceline called and said they had everything. They also have the oil pan gasket and pick up oil rings which are very hard to find (buy several).

 

I can get the clutch specs from my mechanic and details of the order if you want. They come in all stages of durability and mine was designed for heavy track use. We had the flywheel resurfaced, we were not able to find a replacement, tho Raceline said had them, when they finally called me back.

 

I came across many old threads where people had similar issues to mine such as

 

Determine if you have a Mystique/Contour flywheel or a Focus flywheel before purchasing replacement parts. The size of the friction surface and distance inside the towers is different. Bolt pattern of the pressure plates is the same, but again the friction surfaces are a little different. If the car came with a VCT engine, It's probably (although not certainly) the Mystique/Contour variant.

 

At this point I'm split two ways, find a new clutch to work with my flywheel (OEM or go overseas or source soemthing else) or option two, just get a new fly wheel that matches the performance clutch I already have (a 9 7/16 one) it seems to be more common as a size for zetecs and is likely going to be easier to source. This is likely the avenue I will pursue over the next couple of days trying to source parts.

 

Why did you say you were unable to find a replacement? It's an OEM flywheel isn't it? SVT might be a little harder to source if it's different?

 

 

In the mean time while taking everything apart I discovered that my gear selection output unit that sits on top of the transmission has started to fall apart over time and use. Plastic housing is split and mounting tabs are falling off. It still works but its in rough shape. Replacement again is hard to source and is about $200. I'll try to fix this one for now.

 

 

I'm learning that there is no quick turn around with fixing these cars even with US motors as a donor.

[kayentaskier]

Vlad,

i can't say for sure what the practice was in 2003, but in 1999/2000 Jon Nelson sourced my Zetec locally in CO.

[Lucky-7]

I would like to point out that I recently realized that my tail lights are "backwards". I don't believe they've ever been replaced or taken apart (messing with a lost power for one now)

 

Surprised nobody has ever pointed that out yet.

 

Actually, I believe your lights are correct for a USA spec car. Being that there are no rear red side marker lights that indicate the rear of the car from a side view at night, (Those were required by Fed. Law since 1968) I'm thinking it's best to leave them as is. When I put mine together just recently, I almost mounted them with the yellow turn signal on the outside, then realized there was no red quarter lights on the cars' sides. So I put the yellow inboard.

I'm sure it would never be a real issue but what the heck.

Kenny

[Vovchandr]

Current update: Car runs!

 

Who knew one little spring would be such a PITA?

 

After lots of troubleshooting, finding new problems, fixing old problems and mix and matching parts from different Zetecs car is together and I'm going through the period of breaking in the clutch.

 

Not sure yet if the clutch is slipping but it certainly feels "off"/weak on engage. I'm giving it benefit of the doubt through the break in process but not optimistic yet that everything is kosher and it will hold full power. Staying off getting too on the throttle for a few hundred miles.

[Vovchandr]

So far summary:

 

 

 

• Problem discovered - clutch spring retainer failure due to metal fatigue/defect. OEM Ford clutch
  
• T9 transmission leaks fixed in the front and top of casing and shifter housing (time will tell but old gaskets/seals were bad)
  
• Sequential shifter potentiometer housing was pretty destroyed and damaged. No direct replacement available so seals up as best as possible and put back in place. Works so far (fingers crossed)
  
• Rear main seal replaced as it appeared there was a leak there too
  
• TWM throttle bodies had 3 out of 4 runners fail by the gasket due to metal fatigue after being bored out by original builder/contractor. Manifold welded and machined back down to a flat surface. New single gasket made to replace individual runner o-rings
  
• Existing throttle body velocity stacks were a disaster. None sat flat and one of the runners was hammered down to fit under the hood and wasn't round at all. All replaced with shorter but uniform stacks
  
• Existing AIT sensor moved out of the velocity stack where it impeded air flow and new mount made on the new velocity stack housing
  
• Existing Zetec Centerforce clutch (came with the car) was confirmed to fit a Zetec before install, was actually for a different configuration Zetec than I had It was for a bigger flywheel configuration. New flywheel matched
  
• Existing starter did not work with new flywheel, a new one had to be matched (didn't quite reach for engagement)
  
• Existing slave cylinder bleeder configuration was poor, so remote bleeder hose was bought and adapted to fit. Now it will no longer bleed directly back into the bellhousing.
  
• While the console and passenger seat were out I rotated the passenger seat mounts to move the seat more forward out of the turbulent air flow when the windshield is on
  
• A brief test of MPG yesterday while breaking in the clutch, shattered the optimistic hopes that the ITB issues/air leaks caused the poor MPG. Went about 13 miles on one gallon all highway. Weak test, but also very bleak results.
  

 

 

Sourcing parts and figuring out the different configuration Zetecs was not fun, but I'm glad I did it as now I know a bit more about the car for future reference.

[Vovchandr]

Cold temp "conversion" complete just in time.

 

http://www.usa7s.net/vb/attachment.php?attachmentid=16020&stc=1

 

http://www.usa7s.net/vb/attachment.php?attachmentid=16021&stc=1

 

Not pictured but had my first outing with the half hood too

[Vovchandr]

A shot from a recent cars and coffee

 

http://www.usa7s.net/vb/attachment.php?attachmentid=16064&stc=1

Edited October 14, 2019 by Vovchandr

[Kitcat]

Vlad: It looks...perfect!

[Vovchandr]

Cold weather conversion done. It's toasty now!

 

http://www.usa7s.net/vb/attachment.php?attachmentid=16077&stc=1

 

http://www.usa7s.net/vb/attachment.php?attachmentid=16078&stc=1

 

Swapped badge over

 

Edited October 21, 2019 by Vovchandr

[Vovchandr]

End of season

 

 

 

Edit: not sure why the pictures are coming through as tiny attachments until you click

 

 

Edited November 10, 2019 by Vovchandr

[Croc]

I am actually seeing two small pics then below your edit, two large pics. Is that what everyone else has?

 

 

Really nice photos. Fall is a wonderful time for photography. I like the color matched half hood. I also see you have fixed the ride height/rake issue - it no longer looks like a dog with worms dragging its bum along the ground.

[Vovchandr]

I am actually seeing two small pics then below your edit, two large pics. Is that what everyone else has?

 

 

Really nice photos. Fall is a wonderful time for photography. I like the color matched half hood. I also see you have fixed the ride height/rake issue - it no longer looks like a dog with worms dragging its bum along the ground.

 

I added the large pictures again after the edit as a test to see if they are dynamic and get resized to screen. They do so I left them. I struggled with the upload/attachment limit for a while as the photos are ~14mb in jpeg and I got them down to about 1.5 in the end.

 

Also amusing you say that as I haven't touched the suspension/height settings. :leaving:

[xcarguy]

Great shots!

[Kitcat]

The fall foliage shots are great! And I think a Caterham looks better with its top up. That raked/sloping forward roof line looks a bit menacing to me and compliments the "hot rod" lines of the car. When I bought my first Cat, 12 years ago, I became fixated on the pics with the top up and had to buy it (resistance is futile...). And I discovered it did a good job of keeping the rain out, tho not so good and keeping the warmth in. Hey you cant have everything!

[Vovchandr]

I'm excited. My "impossible to source" center caps SLR wheel replacements are on the way