My "new" Zetec S

Hi All,
well they say every day is a school day and I;ve learnt somethig today
If you need to press out polyflex bearings - use something a lot smaller than the bush ID or you:


Rip the flange off the bush - OOOps.
I never liked mauve anyway
So now I''ve got to clean up and paint the rear bush holders -



Then the yellow bushes can go in

Hi All,

Well finally a day with some limited success.
Managed to get the sheared wishbone pinch bolt with some heat and the remains of the snapped extension bar.
Seperated the ball joint and lifted the strut/hub out complete which allowd better access to the rear wishbone mount.
Managed to pry the subframe down just enough to get the wishbone free.
Dropped the subframe to access the rack nuts ( not looking forrward to trying to get them back in )
Only issue left, I can't get the lower engine mount bolts out.
To get the subframe out I only need to remove the rear bolt, but I'd like to get the whole bracket free as I am planning to polybush the mount in future.
Anyway loads of penetrating oil applied and I'll try again tommorrow


I am properly knackered now

Hi All,

Well finally, subframe out....


On Initial inspection the zetec subframe looks the same as an ST one, its got a 19mm ARB, but a 25mm lower engine mount as opposed to the ST's 30mm, so I'll be fitting an ST one when it all goes back together.

As you can see from the pic, theres no bracket on the lower engine mount, I could not get it off, maybe I missed a bolt

Tommorrow I'll measure it up against the refurbed ST subframe to make sure the new one fits

Al

Hi All,

Well, after measuring both the subframes the only differences I can find are the exhaust hanger ( as zippy mentioned ) and the bracket ( red circle )



As I've gone to the expense & trouble of powder coating the ST subframe above, I'm not going to start hacking it up, so will refit the zetec one ( until I can modify and powder coat my spare ST subframe )
Now I've removed a subframe, I'm not concerned about doing it again and as I've fully cleaned all the bolts am confident I could do the swap over in a day, I supose like most jobs on a 15 year old car, its not a difficult job as long as nothings siezed,
I'm going to try and grind the exhaust hanger off the ST subframe carefully so theres as little to repair as possible on the subframe
Found this, which I should be able to bend to make the new hanger


Its only £6, and mild steel, so I can weld it on with the welding kit I have available

HI All,

I ache like hell aftr the last couple of days crawling around under this car !!!
Limited success today, fitted the struts, AR bar links, had a job getting the ball joints in but finally succeeded


Gave up fitting the strut top covers as even without the struts in place I couldn't get under the scuttle panel.
I'm thinking of spraying them to match the car so will have another go in future.
Big set back:
I could not get the zetec S calipers to fit the focus carriers, I don't know if its me or they just dont fit, but reverted to the refurnbed ST calipers which went on fine.
I had planned on fitting these but not yet.
Anyway, all the brake unions are soaked in penetrating oil now. I've got braided lines and new solid pipes so will have a go at getting the brake lines changed later in the week.
Only other thing left to do is to try and get the lower engine mount bracket off the zetec and see if the powerflex unit thats on the ST will fit.
I'm off to spend the rest of the day soaking in the bath

Hi All,

Had a go seperating the caliper flexi hoses from the solid brake pipes.
Initially I din't think I stood a chance as everything was heavily corroded, but managed it on both sides.


looking at the state of the solid pipes I'm thinking of replacing to the next connection.
I don't mind doing a job once, but, if it mails an mot on these pipes I won't be impressed
The o/s didn't look as bad when I was doing it, but, if I'm going to change 1 solid pipe I might as well do both sides

Al.

Hi All,

Well for a change I'm happy with progress today and thanks to LloydST for all the likes
Pleased to say lower engine mount on the zetec S and ST are exactly the same.
There is 1 small differnce in the way they fit:
An ST has 3 bolts going through the front bracket and into the gearbox
A Zetec has 2 normal bolts and 1 that is a kind of stud ( the top one) it uses this to hold what looks possibly like a lambder sensor multiplug in place.


So now the front end is fully polybushed.
Gonna fit the exhaust rubber and bleed the brakes tommorrow, then replace the rear springs, get it tracked and hopefully "jobs a good un".
I'm properly fed up with getting the bus to work

Hi All,

Bled the brakes tonight,
I admit I wasn't looking forward to it as I've done dozens of bike brake hose changes and it can be a nightmare purging the air, especially after fitting new braided hoses, but it went a dream, start to finish in under 20 mins.
Great pedal so very happy.
Managed to get exhaust rubber back on without too much effort, then wheels off and off axle stands.
Annoyed with myself that I didn't take some pictures before I changed the shocks as with the 35mm lowering sprngs it dosn't look that low.


And. looking at the pictures I just realised I forgot to fit the springs to the calipers before putting the wheels back on - doh.
Weather permitting, tommorrow, I want to get the rear springs changed over,
I've got the abs light on atm, hoping that when I drive the car it will reset ( fingers x'd)
Al

Hi All,

Made a start at doing the rear springs, bottom bolts were properly siezed, but with a bit of persuation got them out.


Was hoping just to do the springs, but both struts are totally knackered.

As I've got new struts, carried on, and bow to @Marv_st knowledge, the top mount bolts are accessable without removing the liner, but I'm having a pig of a job getting a socket to locate - tried 10,11,12 & 13 and cant get any to go properly onto the bolt head.



Taken a break as I'm getting annoyed with it now

1 last thing which I would appreciate some advice with, which way up should I fit the yellow spring, tight coils to top or bottom ?


Many thx - Al