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-   -   Clutch, Rack & Pinion, and more (http://www.focusfanatics.com/forum/showthread.php?t=303208)

PLRX 11-28-2012 12:15 AM

Clutch, Rack & Pinion, and more
 
Few weeks ago I started to change my clutch on my 2003 ZX5 with 220,000 miles. This is the second clutch. It was spinning when cold, and before I needed to call a two truck I got busy.

First, I must say thanks to SPORADIC for his detailed DIY clutch thread[headbang]
http://www.focusfanatics.com/forum/showthread.php?t=163836


http://i275.photobucket.com/albums/j...12/Clutch2.jpg

http://i275.photobucket.com/albums/j...12/Clutch3.jpg

http://i275.photobucket.com/albums/j...12/Clutch4.jpg

http://i275.photobucket.com/albums/j...12/Clutch5.jpg

http://i275.photobucket.com/albums/j...12/Clutch6.jpg

http://i275.photobucket.com/albums/j...12/Clutch7.jpg

http://i275.photobucket.com/albums/j...12/Clutch8.jpg

This damn clip took three days to get.

http://i275.photobucket.com/albums/j...12/Clutch9.jpg

http://i275.photobucket.com/albums/j...2/Clutch10.jpg

http://i275.photobucket.com/albums/j...2/Clutch11.jpg

http://i275.photobucket.com/albums/j...2/Clutch12.jpg

http://i275.photobucket.com/albums/j...2/Clutch13.jpg

http://i275.photobucket.com/albums/j...2/Clutch14.jpg

http://i275.photobucket.com/albums/j...2/Clutch15.jpg

http://i275.photobucket.com/albums/j...2/Clutch16.jpg

http://i275.photobucket.com/albums/j...2/Clutch17.jpg

Dropped all components, and decided to give the cross-member a new look.

http://i275.photobucket.com/albums/j...12/Clutch1.jpg

http://i275.photobucket.com/albums/j...2/Clutch18.jpg

http://i275.photobucket.com/albums/j...2/Clutch19.jpg

http://i275.photobucket.com/albums/j...2/Clutch20.jpg

Part of the rivet came out and damaged the clutch. When? I got no idea.

http://i275.photobucket.com/albums/j...2/Clutch21.jpg

New Dual Mass Flywheel...NO MORE CHATTERING [strongman]

http://i275.photobucket.com/albums/j...2/Clutch22.jpg

http://i275.photobucket.com/albums/j...2/Clutch23.jpg

http://i275.photobucket.com/albums/j...2/Clutch24.jpg

http://i275.photobucket.com/albums/j...2/Clutch25.jpg

http://i275.photobucket.com/albums/j...2/Clutch26.jpg

http://i275.photobucket.com/albums/j...2/Clutch27.jpg

http://i275.photobucket.com/albums/j...2/Clutch28.jpg

This set the project back a week. It was very deep, and considered going to the hospital, but ah what the hell...

http://i275.photobucket.com/albums/j...2/Clutch29.jpg

...[drummer]

http://i275.photobucket.com/albums/j...2/Clutch30.jpg

PLRX 11-28-2012 12:20 AM

The old PS pump was making that infamous sound, and decided to install a "new" one.

Remove the belt cover, and remove the belt.

http://i275.photobucket.com/albums/j...ng/PSPump1.jpg

Remove headlight, PS pump line, and upper coolant reservoir lines

http://i275.photobucket.com/albums/j...ng/PSPump2.jpg

Use a pulley

http://i275.photobucket.com/albums/j...ng/PSPump3.jpg

http://i275.photobucket.com/albums/j...ng/PSPump4.jpg

Remove bottom PS line, then remove the four bolts.

http://i275.photobucket.com/albums/j...ng/PSPump5.jpg

Put it back on reverse order. Torque bolts to 17 lbs-ft

http://i275.photobucket.com/albums/j...ng/PSPump6.jpg

http://i275.photobucket.com/albums/j...ng/PSPump7.jpg

http://i275.photobucket.com/albums/j...ng/PSPump8.jpg

http://i275.photobucket.com/albums/j...ng/PSPump9.jpg

PLRX 11-28-2012 12:21 AM

New HID headlights

http://i275.photobucket.com/albums/j...s/HID/HID3.jpg

http://i275.photobucket.com/albums/j...s/HID/HID4.jpg

Merrigan 11-28-2012 12:29 AM

Jeeze. You were busy. But good work. Sorry about your injury :P.

How long did it take (labor wise) to change the clutch?

PLRX 11-28-2012 12:34 AM

Quote:

Originally Posted by Merrigan (Post 4473690)
Jeeze. You were busy. But good work. Sorry about your injury :P.

How long did it take (labor wise) to change the clutch?

I did it solo. It can be done in a day with four hands.

The broken clip alone pushed it 3 days.

Indy'sexclusiveZx3 11-28-2012 01:33 AM

What was the clip to

sleepyboy 11-28-2012 02:31 AM

Yeah what was that clip too? I wish I would have cleaned up my subframe now after seeing yours lol. I guess I'll do that the next time since I need to replace the clutch in my SVT again. Nice pics and injury, every job on the car requires a blood sacrifice lol

PLRX 11-28-2012 02:49 AM

Quote:

Originally Posted by Indy'sexclusiveZx3 (Post 4473793)
What was the clip to

It holds the power steering lines in place at the rack & pinion.

matmatician 11-28-2012 11:17 AM

very nice man. What was the infamous sound the power steering was making, for those who may be unfamiliar?

PLRX 11-29-2012 03:03 PM

Quote:

Originally Posted by matmatician (Post 4474167)
very nice man. What was the infamous sound the power steering was making, for those who may be unfamiliar?

The whining sound.


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