Caterham clutch replacement

[Richard]

I have a 2004 Caterham 7 with Zetec SVT, Fidanza flywheel and Ford T-9, 5 speed transmission. I've been told it has some sort of internal adapter between the T-9 and bellhousing - if matters. It needs a new clutch so TRYING to sort out (if not buy ahead) all the parts I will likely need, so the mechanic does not have the car sitting all winter in the shop while we try to figure out the origin of everything. 

The Cat dealer/importer has been trying to help but they are not the same operators and are less familiar with Zetec assemblies. The zone between the Zetec and the T-9 is where Frankenstein works with various bits. Any suggestions for better assembly would also be appreciated as seems 23,000 miles of street driving is a bit light for replacement.

 

Those familiar with SVT's / T-9's please advise on: Clutch assembly origin? ZX3?, Slave cylinder / T.O. bearing recommendations? etc, etc. Not sure if Fidanze replacement friction kit will work given my unit is 20+ years old. If I must replace the flywheel I don't even know which of theirs to use. (They have not yet responded). 

Products – tagged "2003-ford-focus-zx3-esi5577659" – Fidanza Performance

Products – tagged "2003-ford-focus-svt-esi5025756" – Fidanza Performance

Any thoughts/directions appreciated. 

[IamScotticus]

external or internal slave?

 

the spacer doesn't effect the clutch. it was used because the V6 T9s had longer input shafts and the back space extended the shifter some.

for a car this age, add T9 seals replacement and rear main engine seal and pilot/spigot bearing replacement to the order.

it may be better to get everything pulled apart and inspected to identify what you need.  it's been a long time.

Edited Thursday at 07:34 PM by IamScotticus

[CarlB]

I have a similar car. The cars sold here with a Zetec engine came with a bellhousing with the starter motor mounted under the intake manifold. There were cars that people put Zetec engines in that mounted the starter motor down low and could be on either side of the engine. My car has the type of bellhousing with the started mounted under the intake manifold. I do not know what clutch fits the aftermarket bellhousing. Fidanze can sell you a new friction surface for your flywheel. You will need to know the correct bolts that hold the friction surface. If I remember correctly the difference is the nuts. My flywheel uses jet nuts (small diameter flanged lock nuts used in the aerospace industry). The instruction sheet I got on the last one I purchased had the wrong torque setting. I torqued mine to 25-inch pounds. here is the clutch information. The clutch fits a 1995 to 2004 Ford or Mercury with a 2L engine. The hydraulic throw out bearing is from a 1995 to 2004 Ford/ Mercury with the 2.5L engine. The Luk part numbers are:

Pressure plate - LC5142

Disk      -             LD5142

Kit         -             07164 - The throw out bearing is not correct

 

Throw out Bearing - SLC273

 

Clutch Master is an aftermarket company, and I have one of their clutches. The part number is FX250:07168-HDOF. They are familiar with the car and know what to give you.  

 

[IamScotticus]

3 minutes ago, CarlB said:

25-inch pounds

???

[CarlB]

I believe that is the correct Torque setting. The bolt and nuts I used were 125,000 PSI. and the flywheel uses 10-32 bolts 

 

[Richard]

Thanks for fast replies. Appreciated.

The slave cylinder is inside the bellhousing. I see many variations/ "possibles" available when searching '04 2.0L Zetec SVT slave cylinder. However, given the location of the hydraulic lines, it seems there must be a fairly specific unit to work with the bellhousing opening for connections and bleeding. As suggested may just require head scratching / searching when torn apart. Understandably the mechanic would not prefer that. It also assumes parts can be identified in some way - and still available. I do kick myself (and dealer) for not getting more info when purchased. 

I have asked Fidanza whether the bolt patterns (for friction kit) have changed given the amount of time and no answer from them as yet.

Any other thoughts on what clutch plate / assembly it is? I have been advised it may be from Mystique or ZX3, but have also been told possibly Pinto....

Frustrating. 

[IamScotticus]

1 hour ago, CarlB said:

I believe that is the correct Torque setting. The bolt and nuts I used were 125,000 PSI. and the flywheel uses 10-32 bolts 

 

for the clutch cover, I can see that. they aren't usually very tight.  it's critical these are tightened gradually and evenly. 

[CarlB]

The torque setting I was talking about was for the number 10-32 screws that hold the friction surface to the Fidanza flywheel. The pressure plate / clutch cover uses M 8 bolts. 

 

The   '04 2.0L Zetec SVT slave cylinder will not work. the hydraulic connection will not fit in the bellhousing. This is based on using the bellhousing that mounts the starter under the intake manifold. You need the throw out bearing from the cars that used the 2.5L engine. The production car used a tube screwed into the throw out bearing. On our cars the tube isn't used. a flexible hydraulic line is connected. The throw out bearing housing on the 2.0L engine cars does not have screw in tube for the hydraulic connection. The housing sticks up. The protrusion from the bearing will not let it fit in the bell housing.  

"I have been advised it may be from Mystique or ZX3 but have also been told possibly Pinto....Frustrating." I believe the Mystique is one of the cars within the date range mentioned above. The bellhousings with the starter motor located low on either side of the engine, I believe, it is used on the Pinto and some English cars like the Escort. I haven't had those parts in my hand, but I looked into it because I was looking for a bellhousing. Be careful about speaking to anyone in the UK. Caterham never sold cars with Zetec engines in the UK, and most people are not familiar with the bellhousing with the starter under the intake manifold.     

 

[CarlB]

Here are some pictures of the throw out bearing.

 

 

This is the 2.5l engine one.

this is a picture of the box for the 2.0L throw out bearing. At the top of the picture is the hydraulic connection. The black part is made of rubber and the connection sticks out of the bellhousing. 

 This is the inside of the bellhousing showing how the throw out bearing mounts. the hydraulic line from the master cylinder is connected on the left. On the right is the bleed screw.. Yours will not look exactly like mine. where you see the brass color just before it sticks out of the bellhousing, I modified the stock piece. The stock bleed screw does not stick out of the bellhousing, and I did not like getting brake fluid in the bell housing.