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Old 11-27-2012, 11:15 PM   #1
PLRX
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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
http://www.focusfanatics.com/forum/showthread.php?t=163836
















This damn clip took three days to get.



















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









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



New Dual Mass Flywheel...NO MORE CHATTERING















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



...




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Old 11-27-2012, 11:20 PM   #2
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The old PS pump was making that infamous sound, and decided to install a "new" one.

Remove the belt cover, and remove the belt.



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



Use a pulley





Remove bottom PS line, then remove the four bolts.



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







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Old 11-27-2012, 11:21 PM   #3
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New HID headlights



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Old 11-27-2012, 11:29 PM   #4
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Jeeze. You were busy. But good work. Sorry about your injury :P.

How long did it take (labor wise) to change the clutch?
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Old 11-27-2012, 11:34 PM   #5
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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.
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Old 11-28-2012, 12:33 AM   #6
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What was the clip to
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Old 11-28-2012, 01:31 AM   #7
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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
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Old 11-28-2012, 01:49 AM   #8
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Quote:
Originally Posted by Indy'sexclusiveZx3 View Post
What was the clip to
It holds the power steering lines in place at the rack & pinion.
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Old 11-28-2012, 10:17 AM   #9
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very nice man. What was the infamous sound the power steering was making, for those who may be unfamiliar?
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Old 11-29-2012, 02:03 PM   #10
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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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