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Old 11-21-2007, 01:50 PM   #1
tczx3
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Let the swap begin! ZETEC to SVT!

Let the swap begin! Well it's been a LONG time in the works but I think we finally have all the pieces to do the Zetec to SVT swap. Here's the starting pics!






Hopefully by the end of this weekend we'll have a running ZX3SVT!!


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Old 11-21-2007, 03:36 PM   #2
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i hope your going to give us a detailed list of every single part needed to do this!
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Old 11-21-2007, 03:59 PM   #3
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Photos of everything!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
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Old 11-22-2007, 06:14 PM   #4
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The swap is on! Yesterdays progress went well and we were ahead of schedule at 11pm when we called it quits. We started at 4:30 and at the end of the day the motor and tranny was out. The main problems in the removal were: a. Could not get lower ball joint bolts out to pull ball joint out of knuckle to remove drive shafts so we pulled the struts instead. No biggy but killed 30 minutes trying to get ball joints loose. b. Hard time getting LH drive shaft out due to retainer clip. Finally got slide hammer with claw behind the cup and popped it out. c. 1 stuck ATF line that we had to remove at cooler and unscrew hose and nut. d. Rusted nuts on flex pipe (go figure). Oxy/Acty to the rescue! We used a Motorcycle/ATV jack to hold motor up with car on jackstands, removed mounts, dropped motor as low as jack would allow and then lifted chassis up a foot or so with forklift to clear motor and rolled the motor out! Piece of cake!

Today was Tday and big feast at the inlaws so not much work but we squeezed in 3 hours this morning. Worked on stripping engine bay. This was a AOD to Manual swap so took a long time to tear out shifter and cables. Pulled both engine wire harnesses. The BJB harness was a pain because one wire went under LH fender to washer motor and that was a pain because of frozen bolt at rocker panel to remove inner fender liner to access.

Tomorrow we hope to detail engine compartment and complete interior work. We're swapping dash wiring harness also. This will allow SVT guages to work correctly. This swap is also 02 chassis to 04 motor so some wiring/connector issues to deal with. Will post lots of pics in the am to show where we're at. All things look good to have this done by Sunday eve! Motor install will start on Sat.

And for the nay-sayers, this can be done, buts LOTS of work. Is it worth it? Anything is worth it if it's what YOU want, right? The motor was a good deal and we wanted to go MTX so this gets us 40hp and the MTX. By the time everything is done we hope to have this project completed for $2000, less whatever we can get for the original motor and extras. Any one need a good used zetec motor????
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Old 11-22-2007, 07:15 PM   #5
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you ARE taking pics of everything right?!?!?! tons of us zetec auto guys would love a svt engine!
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Old 11-23-2007, 07:36 AM   #6
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The only problem I see you running into is the fact that you don't have the SVT block, head, or transmission in any of your pics.

Good luck with the swap, and make sure to keep this updated.
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Old 11-23-2007, 09:02 AM   #7
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As promised, pics of current status:

One zetec motor out of chassis!




Looks empty!



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Old 11-23-2007, 12:10 PM   #8
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Yes, the SVT engine exists!





Probably the nightmare- wires, wires, everywhere!

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2002 SVTF Infra Red! Stock w/ Dual oulet exhaust and rolling on Proxes 4
2002 SVTF Pitch Black-Dad's new ride!
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Old 11-23-2007, 08:54 PM   #9
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That a good choice bro. SVT is the way to go
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Old 11-24-2007, 08:29 AM   #10
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Well, the deconstruction phase of the build is complete.



Look Ma, No motor!
Took the time to thoroughly clean and detail engine compartment.




And no dash!



As it turns out the dash wiring has been the biggest pita! The harness could not be removed without pulling the dash- oh, well. What's another 2 hours?

It's been interesting as we've gone. Trying to check and double check components for interchange. It's the little things too. Found as we were installing the brake/clutch pedal assy from the SVT that the brake pedal didn't come up high enough to depress the cruise switch. After much comparison found both switches on the brake pedal slightly different. The plunger length on the AOD brake pedal/switch is 3/16" longer than the SVT. The switches look exactly the same except for the plunger length. Apparently the SVT has a different Brake booster/master cylinder and the pedal comes higher so the switches are shorter. Had we not found the difference now the cruise would never work because the system would think the brakes were always on.

Today we hope to have the dash wiring and interior completely put back together and start the engine install tomorrow. Trying to work out some issues with the head before we can put the motor in.

More later!
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2002 SVTF Infra Red! Stock w/ Dual oulet exhaust and rolling on Proxes 4
2002 SVTF Pitch Black-Dad's new ride!
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