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Old 03-03-2009, 02:25 PM   #1
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SVTF WorkShop Manual

WD40 referred me to http://www.helminc.com/helm/welcome_...R1WVL463NWC8XC to buy a workshop manual but I'm not sure which one to get. I have a 2003 does that make any difference? Right now I want to find instructions on how to replace a clutch and fly wheel but would like the whole manual if I can. Is the TSB instructions good enough? Thanks in advance for replies. I just want to make sure I buy the right stuff. I wonder if the 2001 special vehicle team (SVT) new model training distance learning pub would help me out. It's $110.

I'm at sea right now with a very slow satellite connection. If It wasn't for that I probably would have been able to come up with more info or a conclusion.


The following are TSB instructions I've found and seem to be complete but may be out dated:


Noise - Transaxle - Noise At Idle With Clutch Pedal Released


TSB 04-8-1
Article No.
NOISE - TRANSAXLE - NOISE AT IDLE WITH CLUTCH PEDAL RELEASED
TRANSAXLE - NOISE AT IDLE WITH CLUTCH PEDAL RELEASED

Publication Date: April 13, 2004

FORD: 2002-2004 FOCUS

ISSUE:
Some 2002-2004 SVT Focus vehicles may exhibit a clunking or rattling noise in the transaxle, mainly at idle in neutral. The noise can typically be reduced by slightly depressing the clutch pedal.

ACTION:
The noise may be caused by a dual mass flywheel issue, worn splines on the clutch disk, or by a transaxle misalignment issue. To service, refer to the following Service Procedure.

SERVICE PROCEDURE
Check transaxle fluid level. If low, fill to correct level and retest for noise. If noise is still present proceed to Step 2.
Remove the transaxle. Refer to the appropriate model year Workshop Manual Section 308-03C; Manual Transaxle/Transmission - MT285; Removal.
Inspect the transaxle slave cylinder assembly.
Inspect for leaks.
Inspect the clutch slave cylinder and bearing as follows:
Rotate the outer race while applying pressure. Inspect for roughness.
Inspect for any surface scoring or burrs that may impede the sliding motion of the clutch release hub and bearing. Any scoring or burrs should be polished off with a fine grade of emery paper.
Replace the slave cylinder as necessary. Refer to the appropriate model year Workshop Manual Section 308-02B: Clutch Controls - MT285/MTX75 Transaxle; Clutch Slave Cylinder.
Inspect the transaxle input shaft.
Inspect input shaft for damage, spline wear, burrs or rough surfaces. Any scoring or burrs should be polished off with a fine grade of emery paper.
Replace transaxle as necessary.
Remove the clutch pressure plate and clutch disk. Refer to the appropriate model year Workshop Manual Section 308-01C; Clutch - MT285 Transaxle; Removal and Installation; Clutch Disk and Pressure Plate.
NOTE: REPLACE THE CLUTCH DISK DUE TO POSSIBLE HUB SPLINE WEAR OR FRICTION MATERIAL WEAR.

Inspect the clutch pressure plate.
Check the clutch pressure plate surface for scoring, cracks or discoloration. Minor scratches or discoloration should be removed with a fine emery cloth.
Check the diaphragm spring fingers for discoloration, scoring, bent or broken segments and spring ends that are higher or lower than the rest.
Replace the pressure plate as required.
Inspect the dual mass flywheel surface with flywheel installed on engine for scoring, cracks or discoloration.
Inspect the dual mass flywheel with flywheel installed on engine for proper internal spring operation as follows:
Install flywheel holding tool 303-103 (T74P-6375-A).
Using a long screwdriver or bar firmly rotate the secondary mass clockwise. The secondary mass should begin to engage the internal spring past the free play movement of 19 mm maximum (.750"). The secondary mass should continue to rotate and engage the internal spring with increasing spring pressure (Figure 1). If the secondary mass does not rotate, replace the dual mass flywheel.

Using a long screwdriver or bar firmly rotate the secondary mass counter clockwise. The secondary mass should begin to engage the internal spring past the free play movement of 19 mm maximum (.750"). The secondary mass should continue to rotate and engage the internal spring with increasing spring pressure (Figure 2). If the secondary mass does not rotate, replace the dual mass flywheel.

Using a long screwdriver or bar rotate the flywheel back and forth until the friction control plate is centered between the secondary mass notches (Figure 3). Inspect the plate for damage or melting. If damaged, replace the dual mass flywheel.

Inspect the dual mass flywheel with flywheel installed on engine for proper secondary mass rotational free play as follows:
Verify that the friction control plate is centered between the secondary mass notches. The rotational freeplay check can not be performed if the plate is off center or damaged (Figure 3).
Place a reference mark on the secondary mass of the flywheel (Figure 4).

Rotate the secondary mass of the flywheel clockwise using light hand pressure until it stops. Use only sufficient force to take up the freeplay in the secondary mass.
Place a reference mark on the primary mass of the flywheel aligned with the mark on the secondary mass (Figure 5).

Rotate the secondary mass of the flywheel counter clockwise using light hand pressure until it stops. Use only sufficient force to take up the freeplay in the secondary mass.
Place a second reference mark on the primary mass of the flywheel aligned with the mark on the secondary mass (Figure 6).

Measure the distance between the two marks on the primary mass of the flywheel. The rotational free play spec is 19 mm maximum (.750") (Figure 7).

Inspect the dual mass flywheel on a bench.
Remove the dual mass flywheel.
Place the dual mass flywheel on a flat level surface. Blocks may have to be placed under the flywheel to prevent movement.
Inspect the dual mass flywheel for hub bushing wear as follows:
Place a dial indicator onto the secondary mass of the flywheel.
Using light hand pressure press downward onto the opposite side of the secondary mass until it stops. Use only sufficient force to take up the freeplay in the secondary mass. The secondary mass should not move more than 1.5 mm (.060") vertically (Figure 8).
Repeat Substep 10-c-2 in three places around the flywheel.



NOTE: AXIAL MOVEMENT OF THE SECONDARY MASS IS NORMAL AND THE FLYWHEEL SHOULD NOT BE REPLACED BASED ON THIS MOVEMENT (FIGURE 9).

Replace the dual mass flywheel as required.
Inspect the rear face of the engine block.
Ensure that the two required engine dowel pins are installed and are not damaged. If the dowel pins are missing or damaged replace as required.
Inspect the corresponding dowel pinholes on the transmission. Ensure the holes are not elongated or damaged.
Inspect the upper and lower plates for damage or warping. Replace as needed.
Inspect the crankshaft flange and flywheel, for residual thread locking compound or rust. Clean as necessary (Figure 10).

Install dual mass flywheel.
NOTE: INSTALL NEW FLYWHEEL RETAINING BOLTS.

Tighten the bolts in sequence, to 112 N-m (83 lb-ft) ( Figure 11).

Install the pressure plate and disc. Refer to the appropriate model year Workshop Manual Section 308-01C; Clutch - MT285 Transaxle; Removal and Installation; Clutch Disk and Pressure Plate.
NOTE: TIGHTEN THE PRESSURE PLATE BOLTS TWO TURNS AT A TIME IN SEQUENCE TO 29 N-m (21 LB-FT). REFER TO (FIGURE 12).

NOTE: ENSURE THE DISC IS PROPERLY INSTALLED WITH "TRANS SIDE" LABEL FACING THE PRESSURE PLATE.

NOTE: INSTALL NEW CLUTCH PRESSURE PLATE RETAINING BOLTS.

Install transmission. Refer to the appropriate model year Workshop Manual Section 308-03C; Manual Transaxle/Transmission - MT285; Installation.
NOTE: THE TRANSMISSION BOLTS HAVE FOUR UNIQUE LENGTHS AND WILL ALL FIT INTO ANY OF THE THROUGH HOLES OF THE TRANSMISSION TO ENGINE BLOCK. IT IS CRITICAL THAT THE PROPER LENGTH BOLT IS INSTALLED INTO ITS PROPER MATING HOLE (FIGURE 13).

NOTE: TORQUE THE TRANSMISSION BOLTS IN SEQUENCE TO 48 N-m (35 LB-FT) TO ENSURE PROPER TRANSAXLE TO ENGINE BLOCK ALIGNMENT (FIGURE 14).

PART NUMBER PART NAME
2M5Z-7002-BD Transaxle
2M5Z-7A564-AA Slave cylinder
2M5Z-7550-AA Clutch Disk
2M5Z-7563-AA Pressure Plate
2M5Z-6375-AA Flywheel
W702426-S303 Bolt - Pressure Plate
W701350-S309 Dowel Pins
F5RZ-6379-A Bolt - Flywheel



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Old 03-03-2009, 09:20 PM   #2
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I just spoke with a guy on my ship and told him that the SVTF transmission is from a ( shitt I can't think of the car right now cuz I've been up forever) (laugh) but anyways he said to look up the manual for that car. I guess the manual would only be good for the part where you uninstall and install the new clutch.

ANy thoughts on that?
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Old 03-03-2009, 09:30 PM   #3
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I think the SVTF trans is also in the Mini Cooper S....


Via Wikipedia:
285 — 6-speed
Ford Focus ST170/SVT, MINI Cooper S
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Old 03-04-2009, 08:49 AM   #4
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Actually the car I was thinking of was an audi A4. I don't know why that's in my head for the same type of transmission. I think i read that it has the same tranmission somewhere on the forum. But anyways it doesn't matter.

If I by a Haynes manual for the Mini Cooper S it should help me out when I get to the part of the job that involves replacing the clutch and flywheel, right? If I did that then all I would need would be a regular ztech focus manual then right?

This sounds logical to me. Any thoughts?
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Old 03-05-2009, 08:02 AM   #5
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What you need is the 2003 Ford Focus Workshop Manual Part #: FCS1294903
http://www.helminc.com/helm/product2...SG145B9F9NDKT1

there is the description:
Shop Manual has detailed repair instruction written by Ford. Information contained in each body type specific manual, has been developed to aid technicians in diagnosing and repairing vehicle components and systems. Each manual covers the entire vehicle bumper to bumper including specifications, diagnosis and testing, in vehicle repairs, component removal and installation and complete engine and transmission rebuilding.
Description:
Instructions And Procedures For Routine Repair Adjustments Maintence Work Diagnosis Testing And Removal/Installation Of Parts For Various Vehicle Systems.

I have a 2003 also but when I looked for a manual on e-bay the only ones were for 2002 or 2004 so I went with the 2004 one since it would include the 2003 info. I got it used for $45 which was a very good deal.
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Old 03-06-2009, 09:39 AM   #6
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Quote:
Originally Posted by bcvali View Post
What you need is the 2003 Ford Focus Workshop Manual Part #: FCS1294903
http://www.helminc.com/helm/product2.asp?class_2=FCT&mk=Ford+%26+Lincoln+Mercury&yr=2003&md=Focus&dt=Shop%2FService+Information&module=&from=result&Style=helm&Sku=FCS1294903&itemtype=N&mscsid=B354H9BH5FKD8JHENPSG145B9F9NDKT1

there is the description:
Shop Manual has detailed repair instruction written by Ford. Information contained in each body type specific manual, has been developed to aid technicians in diagnosing and repairing vehicle components and systems. Each manual covers the entire vehicle bumper to bumper including specifications, diagnosis and testing, in vehicle repairs, component removal and installation and complete engine and transmission rebuilding.
Description:
Instructions And Procedures For Routine Repair Adjustments Maintence Work Diagnosis Testing And Removal/Installation Of Parts For Various Vehicle Systems.

I have a 2003 also but when I looked for a manual on e-bay the only ones were for 2002 or 2004 so I went with the 2004 one since it would include the 2003 info. I got it used for $45 which was a very good deal.
Thanks for the reply. I had this thread posted for days but I guess nobody knows anything about this idea or if it sounds like it would work. I'll buy that 2003 manual but still want to get the Haynes books too for more reference when I do the project and write it up for sticky quality. Rep for you man, thanks for contributing to this well needed write-up.
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Old 03-06-2009, 10:19 AM   #7
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You are welcome! :)
I have the Haynes manual also since is less than $20 but you will surprised to see how well the procedures are presented in the workshop manual. I had a 1997 VW GTI and the workshop manual was from Bentley Publishers while very accurate and it wasn't for people who never worked on cars before but strictly for the techs. With the Ford one I feel like I start a repair job myself without too much of extra research.
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Old 03-08-2009, 08:01 AM   #8
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Does the ford manual have pictures of what your looking at?
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Old 03-08-2009, 10:43 PM   #9
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Yes it does but in black and white. they are actually very accurate drawings. get it, you won't be sorry especially if you find a used one on e-bay.
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Old 03-08-2009, 11:51 PM   #10
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Quote:
Originally Posted by domesplit View Post
Actually the car I was thinking of was an audi A4. I don't know why that's in my head for the same type of transmission. I think i read that it has the same tranmission somewhere on the forum. But anyways it doesn't matter.
Possibly because the South Bend clutches I believe use a modified Audi clutch. I think that's right? I donno, someone will correct me if I'm wrong I hope
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