illinipo's MTX swap w/ Torsen thread (Zetec) (pics... 56kthxbye) - Ford Focus Forum, Ford Focus ST Forum, Ford Focus RS Forum
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Old 05-06-2008, 06:39 PM   #1
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illinipo's MTX swap w/ Torsen thread (Zetec) (pics... 56kthxbye)

!! I AM NOT RESPONSIBLE IF YOU MESS UP YOUR CAR, THIS IS ONLY A GUIDE !!

Well it has finally come time for some more power to the wheels and a whole lot more fun driving. I have decided to take the mtx swap plunge. At first I wasnt gonna do a thread... but there are still so many questions out there and not very many pics at all. So since I have not that much to do this summer besides this swap, I figured I'd throw the Focus community a bone

By no means am I trying to step on anybody's toes who has done this before, this is just MY build thread In fact, I will probably reference others who have helped out.

I guess I will start off with sending you to boosted2nr's thread with a pretty thorough parts list and install procedure...

ATX to MTX Swap Guide

and then I can show you the parts list I put together with prices

http://spreadsheets.google.com/pub?k...ugDN-CQ3BofoCA

Your prices may vary. For instance, I chose to go with an OEM replacement clutch and a new stock flywheel in that spreadsheet. Not included on that spreadsheet but included in my build is the Torsen and its related parts. It should be noted that you would get a much better deal by buying from a partout thread or buying a parts car to part out yourself.

Why have I chosen the clutch I chose? Well, the simple fact is (and it has been hard to swallow this) I will not be able to afford a turbo for another 2 years or so. So a slightly stronger OEM-style clutch will do the job for now until I can afford better.

So then, why the Torsen? Well, the simple fact is, I am making enough power to do one-wheel peel whenever I want to... I expect to hit at least 155whp/150wtq with the mtx. Autocross is much more fun when youre not burning up your diff struggling to get traction

so, on with the pics.... feel free to ask questions, and to answer my questions as I go along. My first question is pretty simple, its about installing the clutch... you'll see it later on. EDIT, I answered this question myself, there are 3 locating dowels and 6 threaded holes on the flywheel, with holes to match on the pressure plate.




COMPLETE PARTS LIST
(see next post for pics)

Transmission
transmission, including:
-vehicle speed sensor and pigtail
-reverse sensor and pigtail
-shifter cable bracket
-rear mount bracket
-tripod of the upper mount
-gear selector

Clutch/Flywheel
flywheel
clutch pressure plate and disc
slave cylinder and throwout bearing (comes as one piece)
flywheel bolts (get new ones)
pressure plate bolts
clutch alignment tool

Shifter, etc
shifter and base and bracket from same era as trans i.e. 2000-2002.5
shift cables from same era as trans i.e. 2000-2002.5
shifter boot
shift knob
applicable nuts and bolts

Fluid and Pedals
brake/clutch fluid reservoir from a manual transmission car
the fluid lines coming off the reservoir
clutch master cylinder
the fluid line that goes from the clutch master cylinder to the slave cylinder
clips that hold the lines into the master and slave cylinders
brake and clutch pedal box and pedal covers
clutch position sensor (there is a way to wire it without this thing)
brake fluid (it would be good to have 2 liters ready) I prefer ATE Super Blue or Typ200, or if you are cheap Valvoline SynPower
3 quarts of Motorcraft XT-M5-QS fluid

Underhood
starter from a manual transmission car
crank position sensor mount from a manual transmission car
intermediate shaft bearing mount (bolted to the back of the engine)

Torsen LSD
M-4204-F20 -- Torsen
F7RZ-4221-AC -- 2 differential bearings
F5RZ-1S177-AA -- or, BRS46 -- 2 axle seals
YS4Z-17285-AA -- 1 vehicle speed sensor gear
possibly 1 differential shim (I got lucky and didnt need one)



TOOLS

Torsen
flathead screwdriver
T30 torx bit
3/8" drive torque wrench
3/8" drive ratchet
3/8" drive 3" extension
3/8" drive 6-point 10mm shallow socket
3/8" drive 6-point 13mm shallow socket
10mm combination wrench
13mm combination wrench
15mm combination wrench
17mm combination wrench
10mm ratchet wrench
hammer
plastic-tipped hammer
6lb pellet-filled mallet with plastic head
many, many, many large surgical towels (or lint-free equivalent)
flashlight
5 and 10 lb compact iron hand weights
handheld propane torch
something to light the torch
Permatex 51813 anaerobic gasket maker (you can get it on amazon for 10 bucks)
red threadlocker (Loctite 271 permanent threadlocker or equivalent)
a pretty big bench vice to hold the torsen at various times
piece of aluminum I tell you how to machine in post 32
another piece of aluminum about 2.7" in diameter not much bigger not much smaller, and yes 2.75" is too big.
set of angled feeler gauges (may also be called valve feeler gauge)
A good set of calipers accurate to 0.001"
patience. No, seriously you need it.

Swap
(work in progress)
DIY engine brace, see my how-to thread: http://www.focusfanatics.com/forum/s...57#post2202257 (thanks to cosworth from FJ for the inspiration)

Torsen install / how to info post #'s, YMMV on the times to do stuff im pretty slow:
day 1 - post 17 (pulling the trans apart, taking the open diff out) ~2 hours
day 2 - post 19 (removing the ring gear) ~1 hour
day 3 - post 32 (removing the old bearing races and oil seals, and installing the new bearings on the torsen) ~4 hours
day 4 - post 34 (installing new races in the case sans shim, installing the ring gear on the Torsen, playing with the gear selector, closing up the case, checking the preload, measuring the shim) ~4 hours
day 5 - post 36 (buttoning up) ~2 hours

parts that I still need as of 7/9 (feel free to donate / ask me to buy yours):
NONE IM READY TO GO!!!!


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Originally Posted by Dennis_Grant
Remember this list: Bilstein; Penske; Koni; Ohlins; Sachs; Dynamic Suspension.

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SUV this!

Last edited by illinipo; 08-05-2008 at 02:55 PM.
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Old 05-06-2008, 08:12 PM   #2
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so here goes, I have pics of all the parts I currently have. Turns out this part-out car had a LuK clutch on it thats supposedly only 5k miles old, so im gonna go with it and the throw-out bearing thats on there until the wifey learns how to drive stick better Plus this way I dont have to worry about the 500 mile break-in period while she's learning on it!! I will probably get a Spec stg 2 in the long run... but that's another conversation.

Trans and wiring harness, will need to splice in the reverse sensor and the vehicle speed sensor according to the diagram in boosted2nr's thread



shifter cable bracket



vehicle speed sensor on top the diff opening, rear mount bracket



throw-out bearing / slave cylinder



ouside of the slave cylinder, with the bleeder screw and pressure line input



tripod upper mount in the bottom of the pic, selector mechanism taking up the right half of it, and the reverse sensor smack in the middle



shifter



bracket that shifter sits on



shift cables



brake/clutch reservoir with lines... auto trans on the right, manual trans on the left. note the nipple on the lower, right corner of the manual trans version that has the line coming off it...



other end of the clutch pressure line - I need a new one this one was cut



these clips are VERY important, they hold the lines into the clutch master cylinder



clutch master cylinder



I believe deez nutz hold the pedal box to the firewall



pedal box



clutch position sensor



starter



crank position sensor



half of the carrier bearing mount... will update pic when I get the other half



edit, here is the other half



i believe these are bellhousing bolts



I have no idea what these bolts are,someone please enlighten me



clip for the clutch master cylinder



I have no idea what these nuts are for, someone please enlighten me... the washer part spins on the nut part...



overview of all that stuff



and the next post will have clutch/flywheel pics and questions


edit, 6/30/08... got my Torsen!!

axle seal



new, complete clutch pressure line



Ford "honey"



shift boot



diff bearing



VSS gear



overview, you can see the torsen in the blue bag. more pics later i know im a tease lol

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Quote:
Originally Posted by Dennis_Grant
Remember this list: Bilstein; Penske; Koni; Ohlins; Sachs; Dynamic Suspension.

Not on this list? Almost certainly crap.
SUV this!

Last edited by illinipo; 07-16-2008 at 10:23 PM.
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Old 05-06-2008, 08:22 PM   #3
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so here is the combo



the clutch fits nicely inside the flywheel



**I need someone's opinion of how worn this thing is!!



here is the flywheel side



**pressure plate... opinions on wear???



**aaaand the flywheel... how does it look??



I should note that there are 3 locating dowels and 6 threaded holes on the flywheel. these 6 bolts go in those holes



and these 6 bolts hold the flywheel to the crank



but you should replace those^ the ARP's are only 30 bucks.
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Originally Posted by Dennis_Grant
Remember this list: Bilstein; Penske; Koni; Ohlins; Sachs; Dynamic Suspension.

Not on this list? Almost certainly crap.
SUV this!
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Old 05-06-2008, 08:57 PM   #4
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Looks like a fun job Pete, but it will be well worth it in the wagon.
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Old 05-06-2008, 11:43 PM   #5
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oh lookin good!
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Old 05-07-2008, 07:57 AM   #6
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Where are you doing this? Not in your driveway I hope?
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Old 05-07-2008, 08:37 AM   #7
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haha no i was hoping we could do it on your lift sometime in July
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Originally Posted by Dennis_Grant
Remember this list: Bilstein; Penske; Koni; Ohlins; Sachs; Dynamic Suspension.

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SUV this!
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Old 05-07-2008, 09:30 AM   #8
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well let me know how the torsen install goes. i will be needing one for winters,lol.
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Old 05-07-2008, 09:53 AM   #9
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I will be posting LOTS of pics, part #'s, and how-to info on the Torsen
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Old 05-07-2008, 11:49 PM   #10
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if ur going to change the tranny, u might as well get new clutch/flywheel, that way u know for sure u dont have to change it out for awhile.
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