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Old 01-11-2017, 10:38 AM   #1
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'04 Screaming Yellow SVT Restoration - Code Name Rocket

Starting another build / restoration thread

I picked up a new to me 5 door '04 SVT in December of 2016. Has 106k Miles at the time of picking it up from Ohio. This car has spent its whole life in Michigan and Ohio.

The plan for this car is to be a daily driver kept to "stock" conditions.

To aid in some drive-ability that I have become accustomed to in the ZX3. I am planning on adding a short throw shifter, a tune, and possibly a larger TB. The car feels boggy off the line and the tune and TB are a hopes that it can help with some of this.

My SVT Focus is # 5 of 1079. With it being a 5 door in Screaming Yellow Euro Appearance Package it is one of 66 built.

The body and interior is kept in very clean condition. However, some of the suspension components (and by some I mean all) are fairly rusty. The body is clean and straight.

Pictures as I picked it up:













Before driving the 1500 miles out to Utah I did have a shop do a full inspection of the car and identified a few things:
- Shocks & Struts are leaking and/or shot
- The Fuel filter appears to be stock
- The Front control arms need to be replaced to address ball joints and bushings
- Tie Rod ends need to be replaced
- Exhaust heat shield is loose on all points (and was held in by wedging a hunk of aluminum between the header and the shield)



Work was performed regularly. Oil changes were done at a shop where a synthetic blend was used. This will change and will use Mobil-1 for all future oil changes.

Tires are a bit oversized as well but good tires of RE97's AS 205/50R17 with 10/32nd's of tread on all 4 tires.

Timing belt had not been changed on the vehicle yet. At 106k miles it was well over due. Replaced with Motorcraft Tensioner pulley. Which for an FYI the regular Zetec tensioner is a 1lb pulley when correctly set. The SVT one is a 2 lb pulley. I was impressed with the belt construction on the Gates Blue Racing belt so used that belt again. So far about 300 miles since the belt change and no engine codes. It took about 3-4 settings to align up perfectly. After rotating the engine about 10-15 times after each setting if the timing belt bar did not slide easily into the slots I adjusted again.



In the above picture I show the GoldCoastAutomotive Aluminum guide idler pulley. I would not recommend this part any more. I have tried to install it on two vehicle and every time it binds on the middle valve cover. This is now just a paper weight. They need to reduce the size of the lip. It has been replaced with a OEM plastic pulley just like was done on my ZX3 Zetec.

Replaced the spark plugs also at the same time with Motorcraft coppers AZFS22C (465's). Also added new water pump, Accessory belt, accessory belt tensioner and idler pulley.

Replaced with a motorcraft fuel filter.

Inspection of the engine bay showed that the top of the airbox had cracked and was being only held by one screw. A few trips to the junk yard later and clean up I was able to get the air box back to normal. The Fram airfilter had to go, so got a ITG foam drop in filter.





Had Recaro's for the kid seats since we needed them and now with the EAP having Recaro's also for driver and passenger. a family that rides in Recaros stays in Recaros.



The lower radiator support was the first item that needed to be addressed. I went to the junk yard to piece together the air dam. In securing it with zip ties to the lower support the zip crushed the metal and made the hole larger.



Got a new radiator support from RockAuto. During removal a bolt was seized. Bolt extractor did not work. drilled it out and tried to extract it that way. That broke off in the bolt. So ground out the bolt and had to figure out how to secure the lower support to the body.



Found that a Dual welded tab in the 3/8" size from Fasenel:
https://www.fastenal.com/products/details/0124624?r=~|categoryl1:"600000 Fasteners"|~ ~|categoryl2:"600072 Nuts"|~ ~|categoryl3:"600123 Weld Nuts"|~ ~|sattr02:^"Spot Weld Nut"$|~ ~|sattr06:^"Dual Tapped"$|~

These are a perfect fit. The center to center hole opening is exactly the hole spacing on the support. The bar is able to be fed up through a hole already in the body where the front crash bar is pinch welded to the side box frame/body.





After installing the lower radiator support I noticed that the radiator was moving around a bit to much and had about 1/2" to 3/4" inch of vertical movement. I went to the junk yard and picked up some extra isolators. I cut off the top of the junk yard ones and gorilla glued them and added the extra lift to support the radiator.

Also front lights were a bit foggy so got a Mothers Light restoration kit and got them cleaned up.



Also have changed the back up lights and license plate lights as LED's. I will be replacing them all over some time.
Before and after from regular incandescent lights vs LED lights.




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Old 01-11-2017, 10:40 AM   #2
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Old 01-11-2017, 11:38 AM   #3
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Old 01-11-2017, 12:17 PM   #4
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Nice start! I only have one complaint though. You did mention in the other thread that it's only this specific Gold Coast pulley you had figment issues with. It could very well just be a one off that slipped through QC. Just saying.. I don't think it's grounds for advising people to stay away from em.
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Old 01-11-2017, 12:23 PM   #5
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Congrats on the new daily, they never stay "stock" haha.
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Old 01-11-2017, 12:45 PM   #6
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Quote:
Originally Posted by TriFocal_Discord View Post
Nice start! I only have one complaint though. You did mention in the other thread that it's only this specific Gold Coast pulley you had figment issues with. It could very well just be a one off that slipped through QC. Just saying.. I don't think it's grounds for advising people to stay away from em.
True, however out of a fitement of 2 pulleys. The first pulley the bearing wallowed out the aluminum requiring replacement. The second pulley to replace it (this one) had fitment issues with hitting the valve time cover. I only discovered this because I assembled the whole thing back together with out the top timing belt cover. trying to put the middle timing belt cover to allow for as much clearance as possible. the pulley seized on the middle cover while I was hand cranking.

If this was not checked before start. Or if it ran and the middle cover slowly moved (there are no locking pins and it has quite a bit of movement) and it moved down reducing the clearance it could still start to seize. I have not approached Gold Coast about it as I have lost confidence in the part. I have technically gone through 3 pulleys:

1. Shipped when rebuild motor on the "Tick" it came with a huge dent on the side. Called them up after a week of trying to contact they replaced it (apparently the owner had his son do the shipping of orders while he was on vacation...)
2. Failed after approx. 30k miles due to wallowed out bearing. Was unable to give any details on failure or reason for it.
3. Had been installed on 2 Zetec blocks with clearance and fitment issues.
4. Also a local racer who has tracked out his Focus FULL track NASA spec had one seize / fail and cause full rebuild. He uses stock plastic on his full race built purpose motor.

3 strikes your out in my book. I Have the cross over tube and had quality issues with that (was not fully debured). I have looked at the coolant tube but am not sure about that.

I am happy that they make and support the aftermarket industry and make parts still for the MK1 focus. However, I have had to many "slips in QA" to recommend or try to buy another item.
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Old 01-11-2017, 02:39 PM   #7
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Quote:
Originally Posted by Magus2727 View Post
True, however out of a fitement of 2 pulleys. The first pulley the bearing wallowed out the aluminum requiring replacement. The second pulley to replace it (this one) had fitment issues with hitting the valve time cover. I only discovered this because I assembled the whole thing back together with out the top timing belt cover. trying to put the middle timing belt cover to allow for as much clearance as possible. the pulley seized on the middle cover while I was hand cranking.



If this was not checked before start. Or if it ran and the middle cover slowly moved (there are no locking pins and it has quite a bit of movement) and it moved down reducing the clearance it could still start to seize. I have not approached Gold Coast about it as I have lost confidence in the part. I have technically gone through 3 pulleys:



1. Shipped when rebuild motor on the "Tick" it came with a huge dent on the side. Called them up after a week of trying to contact they replaced it (apparently the owner had his son do the shipping of orders while he was on vacation...)

2. Failed after approx. 30k miles due to wallowed out bearing. Was unable to give any details on failure or reason for it.

3. Had been installed on 2 Zetec blocks with clearance and fitment issues.

4. Also a local racer who has tracked out his Focus FULL track NASA spec had one seize / fail and cause full rebuild. He uses stock plastic on his full race built purpose motor.



3 strikes your out in my book. I Have the cross over tube and had quality issues with that (was not fully debured). I have looked at the coolant tube but am not sure about that.



I am happy that they make and support the aftermarket industry and make parts still for the MK1 focus. However, I have had to many "slips in QA" to recommend or try to buy another item.


Fair enough.. I really hope I don't end up with a rebuild on my hands due to that pulley...
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Old 01-11-2017, 02:59 PM   #8
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Quote:
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Fair enough.. I really hope I don't end up with a rebuild on my hands due to that pulley...
Hope so as well. The only reason I found the wallowed out issue was when I was trying to source my ticking noise on that motor. Which turned out to be a busted piston. But in doing so I had the timing belt off looking at the buckets and cams and saw that it was moving around in ways it should not.

YouTube Video
ERROR: If you can see this, then YouTube is down or you don't have Flash installed.


It sounded like they had not see this before. Unsure if other conditions could have caused it. But I would keep an eye on it. Since I am keeping the SVT as a DD and want to keep it as clean and stock as possible I wanted to keep the upper valve cover on. I do not have it on the ZX3 - Tick. So its easy to inspect on a regular basis if on that vehicle. With the timing belt all sealed up on the SVT the effort to check the timing pulleys on a regular basis is to much for me.

Quote:
Originally Posted by IngotMK3 View Post
Congrats on the new daily, they never stay "stock" haha.
I know, already transferred my clear side markers over... Hahaha. Well with needing to do the Tick build that will likely take the disposable income for non-stock parts once I am done with the drivability stuff (control arms, suspension, etc)
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Old 01-11-2017, 03:03 PM   #9
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Very nice.

Sent from another garage.
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Old 01-11-2017, 04:00 PM   #10
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i'm jelly!
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