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I have a 1999 Zetec S-3 and broke the clutch at VIR. I contacted the clutch pressure plate manufacturer (LUK) and they told me the part number from the numbers on the pressure plate. When I got the new clutch it was 9 1/2 inches and the old one was 9 inches. LUK said it was superseded and it did bolt on. When I got it all together it was slipping badly. It appears the throw out bearing isn't letting the clutch engage completely. I am desperate to make it to NJMP!! Any help or good people to speak to would be greatly appreciated. 

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Sorry to hear of the misfortune Carl.  Given my Caterham is engine out as of today, I know the feeling.    I am on the wrong side of the Atlantic for 2 weeks to get near my T-9 documentation but...

 

@S1Steve had a write up on zetec/T9 clutches that I have in my files but never digitized.  I recall it having parts numbers and suppliers.  Calling Steve to this thread.

 

Hail Mary option - I have not bought a zetec T9 clutch in the last 12 years but I think TJ at TK Autosports did.  Give him a call at (609) 744-8232 and explain I referred you.  You may get Ian instead of TJ but thats ok - Ian can also potentially answer this question.  Apologize profusely for knowing me.   Say you are coming to the sevens event in 2 weeks time and that you trying to track down a clutch replacement for a T9 box and do they please have the part number and clutch supplier for Jeff's blue Caterham when they replaced it.  I think it was replaced when it had its engine rebuild 2 years back.  I think it is an identical set up to your car.  

 

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Carl and Mike, I’m not sure what I exchanged with Mike, but this is what I thought may help. My S1 has the standard Zetec flywheel,( wish I installed a lightweight one), a Ford Motorsports clutch and disc. At the time I thought that would work fine with it’s almighty 139.3rear wheel HP and curb weight of little over #1400. I’ll attach information another S1 owner decided to use…. Hope to see you at NJMP.

 

698180165_s1clutch.thumb.jpeg.c778cdcbb5f80ad080932238b6745c3f.jpeg

 

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Thank you all for replying. I hope I have a solution on the way. I think I have  a fix if it doesn't, I will make it work. Bruce Beachman is going through the same thing with a customer car. I am reasonably confident the slave cylinder (throw out bearing) was depressing the clutch in the static position. Kit Cat had a old post about getting a clutch from Clutch Masters and they were very helpful. Zetec cars came with a clutch used in the Focus ZX3. This is a 9 inch clutch and the finger height is different than what the stock replacement clutch people are selling now. The current replacement is a 9 1/2 inch clutch. Clutch Masters seemed to know the difference and were easy to work with. I should have the clutch Monday. I now know how much the clutch should push the clutch in and will make the measurements so I am confident the clutch is fully released before I put the car back together. If there is a issue, I learned a long time ago you can't work on a car without a lathe, a mill, a mig welder, and a tig welder.  That aluminum plate the slave cylinder mounts to will get changed so the slave cylinder works. I want to thank Kit Cat and  Vovchandr for there help. I have spoken to a number of people about this and will post a lot of information about this once I am confident of the solution. Bruce Beachman is a really good resource. He is trying to come up with the elegant solution. I want to get to NJMP. He is trying to find the parts used in the original design, so there isn't any need to make custom parts. 

My car is a very early if not the first Zetec car built. The car Bruce is working on is one that came with the SVT engine. The car Bruce is working on is original and it has the same Fidanza flywheel my car has. The SVT cars did not use the larger clutches the SVT Focus used.   

1870172355_Throwoutbearinginbellhousing.thumb.jpg.bb52f9fdf9ccc1ddb9605a4dd07c714b.jpg

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Good luck to you Carl.   Jay I’m sorry to hear of your misfortune. And Vlad. I don’t even know what say about your travails.   
 

But you guys are all scaring the crap out of me since I signed up for a track day this Friday.   I’m going to be babying the car and going even  slower than I usually go, hoping to keep the car together.   :classic_ohmy:

 

Hope to see you on track soon.  Fingers crossed.   Tom. 

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22 hours ago, yellowss7 said:

Jay I’m sorry to hear of your misfortune.

Thanks. I have not given up yet. But my time is limited and I need to make the engine run and more importantly make sure the throttle does not stick!

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