EburgE Posted August 15, 2007 Share Posted August 15, 2007 I'm just getting started and I'm already over my head. I have very little mechanic experience, and I decided to assemble a Seven because I could follow the manual and ask for advice along the way. Unfortunately I have all the parts for the drivetrain and no manual. :ack: So my question is: In what sequence do I put these together? Engine Flywheel Clutch Pressure Plate & Disk Bellhousing Gearbox (It's the 2.0 LTR Zetec and 5-speed Sierra transmission.) I would guess that the flywheel bolts to the crankshaft, but then what? :crazy: Maybe I should be looking for a book? Would I be able to Google and find enough information on this? I tried BlatChat but didn't find it right away. Link to comment Share on other sites More sharing options...
scannon Posted August 15, 2007 Share Posted August 15, 2007 You have them listed in sequence. You definately need a manual for the torque values if nothing else. You will also need a clutch alignment tool when you bolt the pressure plate and disk to the flywheel. Can you download the assembly manual on line? For the Zetec and Sierra trans, I'm not sure whether the bell housing bolts to the trans first and both to the engine together of if the bellhousing gets bolted to the engine and the trans added later. On my car, I found it much easier to install the transmission/bellhousing (trans and bellhousing are one unit on mine) into the car and then bolt the engine to it in the car. Link to comment Share on other sites More sharing options...
EburgE Posted August 15, 2007 Author Share Posted August 15, 2007 Thanks. Someone on BlatChat quoted "the book" as saying "Flywheel/drive plate bolts" 110-112nm or 81-83lbf ft I don't know what book it is. I have never seen or heard of a manual for this. Link to comment Share on other sites More sharing options...
slngsht Posted August 15, 2007 Share Posted August 15, 2007 Another thing to *possibly* look out for... Some engines are internally balanced - others are externally balanced. I don't know which is the case with the Zetec. If it is externally balanced, just bolting the flywheel any old way may result in vibrations down the road. There are enough Zetec gurus here to point you in the right direction. Link to comment Share on other sites More sharing options...
scannon Posted August 15, 2007 Share Posted August 15, 2007 Thanks. Someone on BlatChat quoted "the book" as saying "Flywheel/drive plate bolts" 110-112nm or 81-83lbf ft I don't know what book it is. I have never seen or heard of a manual for this. You should hold off any assembly work until you have the assembly manual. It will tell you not only the torque values, but the sequence to torque them. It will have a wealth of other information. If you can't get your hands on an assembly manual, a repair manual for a car that uses the Zetec engine will help some but the assembly manual for the car will be much better. Link to comment Share on other sites More sharing options...
Cherik Posted August 16, 2007 Share Posted August 16, 2007 Some items: in addition what was already mentioned.. after mounting the flywheel (use ARP bolts and blue locktite, no washers!) put on the disc, then the pressure plate and bolt it on, but make sure to very evenly crank the bolts to avoid cocking the plate. It is under full tension. The bellhousing goes onto the tranny with the four large bolts. Clean them up and use locktite and proper spring washers! If not, things will come loose... Also, there is a gasket between the bellhousing and gearbox. The shiftfork shaft does extend out of the gearbox and moves when shifting (for-aft), this allows for some slight oil seapage, thus requiring the gasket. If the engine came from an Automatic, make sure to switch the crank sensor for a manual type and also clean out the crankshaft pilot bearing entry and insert the pilot bearing for the gearbox primary shaft. The bearing is $10..15 from the local Ford dealer. Mount the clutch release before bolting the tranny/bellhousing to the engine. For bolting the engine and bellhousing together, use grade 8 plated bolts with spring washers. Mount the starter and verify that it fits properly - there are several versions of this - (starter / flywheel combinations). When lifting the engine, I suggest to tilt the whole assembly (use a cranked leveler for your hoist, so you can adjust the angle) about 45dg and stepwise go forward and lower, carefully clearing the top enginebay rail (watch the wiring...) and next watch the top of the transmission tunnel - on some cars there is a brake line running there and wiring... Be careful not to knock off the pins of the reverse switch on the gearbox (on the right, just below the shifter). They tend to get snagged once the box is in the tunnel. Easier is to temporarily remove the switch and put it back in later. There is a 1.5" rubber cover on the right side of the tunnel for that. Put a jack under the transmission when you get close, as next the propshaft must be guided. Careful with the seal, it's easily damaged by the edge of the propshaft. The jack will allow the transmission mount to clear the chassis plate. Go half inch steps at a time when you get close and wiggle the engine a bit. Good luck Cherik Link to comment Share on other sites More sharing options...
drew... Posted August 16, 2007 Share Posted August 16, 2007 In support of Cherik's advice, here is a photo of the engine going into my se7en. One additional tip cover the body panels and frame rails with cardboard and definently use cranked leveler. http://www.usa7s.com/aspnetforum/upload/1682719776_P3240008.JPG Link to comment Share on other sites More sharing options...
stevet Posted August 16, 2007 Share Posted August 16, 2007 This site might be useful - the guy logs and photographs the whole build process - the engine is Zetec SVT and I think the box is T9, but with long first gear. http://www.thecaterhamproject.com/index.html Can't remember who's site this is (on here?), but I enjoyed it very much :thumbs: Link to comment Share on other sites More sharing options...
slngsht Posted August 16, 2007 Share Posted August 16, 2007 In support of Cherik's advice, here is a photo of the engine going into my se7en. One additional tip cover the body panels and frame rails with cardboard and definently use cranked leveler. http://www.usa7s.com/aspnetforum/upload/1682719776_P3240008.JPG If you need it, I have an engine hoist you can use (with the leveler) when the time comes. Link to comment Share on other sites More sharing options...
EburgE Posted August 16, 2007 Author Share Posted August 16, 2007 You should hold off any assembly work until you have the assembly manual. It will tell you not only the torque values, but the sequence to torque them. It will have a wealth of other information. Thanks. Does anyone know of a manual that would apply? Link to comment Share on other sites More sharing options...
EburgE Posted August 16, 2007 Author Share Posted August 16, 2007 Cherik's reply is almost like a manual. :cheers: I've seen the www.thecaterhamproject.com but did not see details on the engine piece. Will look again. Thanks, Mazda for the engine lift offer. Will take you up on it, probably over the winter. I really appreciate every response. I have decided to hold still until I accumulate the information. I guess the manual I want to find is the the UK Ford Sierra, right? The Ford Contour/Mystique looks like a FWD horizontal mounting. So it would not be as helpful, right? Link to comment Share on other sites More sharing options...
Boxologist Posted August 16, 2007 Share Posted August 16, 2007 get in touch w/ caterham USA and see if the manual has been updated for the zetec. the one i have for mine has vauxhaul Fuel injected, but Rover and ford carb'd. no zetec info, but the teh sierra box is in there. hopefully the US program has all the updated info. Link to comment Share on other sites More sharing options...
EburgE Posted August 16, 2007 Author Share Posted August 16, 2007 According to Caterham USA there is no manual. :cuss: (I haven't given up, but I will have to look elsewhere.) Link to comment Share on other sites More sharing options...
BirkinBernie Posted August 16, 2007 Share Posted August 16, 2007 One thing to watch out for if you are using the stock crank position sensor, it's bracket must go on before the flywheel. I know a couple of folks who have had to remove the newly installed flywheel when they discovered this. Also, I didn't see anyone mention that flywheel bolts are a one use item. Once they have been torqued in place, do not re-use them. New ones from the Ford dealer are cheap.... Good luck! Bernie Long Keller, Tx Link to comment Share on other sites More sharing options...
Alaskossie Posted September 26, 2007 Share Posted September 26, 2007 EburgE, Send me your e-mail address and I will reply with a .pdf of the 134-page Caterham manual as an attachment. I downloaded it from the California Caterham Club website, but I can't seem to pull up that site tonight. I received a printed assembly manual with my kit in May 2007 (a slightly newer version than my .pdf copy), but I understand that Caterham is now accommodating frequent updates and changes by only doing a .pdf version now. My e-mail is tmeacham@gci.net Tom Alaskossie Link to comment Share on other sites More sharing options...
bsimon Posted September 26, 2007 Share Posted September 26, 2007 Some items: in addition what was already mentioned.. after mounting the flywheel (use ARP bolts and blue locktite, no washers!) put on the disc, then the pressure plate and bolt it on, but make sure to very evenly crank the bolts to avoid cocking the plate. It is under full tension. Make sure you align the disk with a pilot tool or an old input shaft before bolting up the pressure plate. If you don't, the clutch plate will be off center just enough to keep you from getting the transmission to slide home into the bell housing. Link to comment Share on other sites More sharing options...
Alaskossie Posted September 27, 2007 Share Posted September 27, 2007 Harold, The Caterham assembly manual is too large for me to send to you as an attachment (my five attempts have bounced), and I can't even send you a 2-line e-mail message minus the attachment (your server keeps rejecting my attempts). So please e-mail me your mail address, and I will send you a copy of the Caterham manual on a CD. Thanks. Tom Meacham Link to comment Share on other sites More sharing options...
bsimon Posted September 27, 2007 Share Posted September 27, 2007 Here's the build manual Link to comment Share on other sites More sharing options...
EburgE Posted November 10, 2007 Author Share Posted November 10, 2007 First bolts of the project, got the bell housing attached to the gearbox! :hurray: http://www.usa7s.com/aspnetforum/upload/32693320_2007-10-21-GearboxBellHousingD.JPG Link to comment Share on other sites More sharing options...
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