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Okay so this for all the ZX2 folks out there. First off this is my first time doing a clutch job and let me tell you it is thoroughly kicking my butt! The transmission is next to impossible to drop with both CV axles in it. Even with the drivers side installed it is still very hard to drop it. So word to the wise take both CVs out before dropping the trans. Also the bolts are tight. I had a few that wouldnt come off with an impact wrench. Also another note is that the passenger side CV is actually 2 parts and it is very hard to separate them. So take that whole thing out as a unit if you are going to do the CVs. Also another note worthy of making is that the lower ball joints if they are original will SPLIT on you. However all is not lossed go to Napa and buy a 3/4inch boot and that will cover them. Just make sure to pack them full of grease. Umm so, so far that is the most advice I can give you. Oh and one last thing as usual parts are hard to get for these cars so anticipate around a week for the parts to show up depending on where you are vs where the parts are.
So ill update this one more time once the car is driveable.
-NickQuoted From ytram:
The only difference from the Focus to Escort will be the Escort has a cross member (for lack of a better word) from the front to just about under the drivers feet that also has mounts for the motor and tranny to keep from rocking forward or back.
Now does that mean the engine will be better supported and maybe i wont need that engine holder for the zx2 to do the clutch?
Okay sounds like a plan. Also something weird happened today… The sound of that throw out bearing that has been there for the past few days has now silenced out….. I dont know if that means this is the calm before the storm with it or what. Any ideas?
UPDATE: sound came back randomly after I had ordered the parts for the car…. Ironic much? Anyways just figured I’d update the post and keep you folks up to date on the ford. And also when I do the shift linkage ill be sure to try and a post a how to for the ZX2s seeing as they differ a little bit from the ZX3’s/focus’s.
Okay ya Ive heard that and possibly my clutch flywheel has a hot spot on it…. Does the flywheel also sound like it? Heck either way though it sounds like Im going to end up replacing the clutch either way.
Okay to all those 1998-2003 Ford ZX2 5 speed owners, I finally have a complete answer to solve the issue with our cars grinding 2nd-3rd. It turns out that the bushings in our shift linkage wear out over the years and cause the gears to “miss align” when we are shifting. So where do we get the parts you ask? Well I hate to say it but you have to go through ford. There are no two ways around it. Now the part number you will be looking for, for the bushings that you can actually replace is 7A133. If your parts person looks at ya like a moron, tell them the part number has recently been changed. Also if replacing the two vertical bushings does not work you will need to buy a whole new shift linkage which runs around 380-400 USD. Also beware our cars are becoming real pains to get parts for because ford is stopping the production for parts for our cars.
So in closing I hope that since I have done all the back work for you, that this will make your life alot easier. And also a trick to getting those vertical bushings in is to take off the rod next to the shift rod itself. Dont worry any back yard mechanic can do this. Its not hard at all.
-Nick
Does anyone know where in the world I can find the parts for the above stated questions? Oh and dont say advanced or Ford… Already tried both.
Okay I checked the shift linkage sunday and found it to be pretty dang loose. It seems that most of the slop is starting from the stick its self. Its almost like theres a bushing underneath of it that has gone bad. Also in addition I did find a huge difference between the ZX2 and the ZX3 aka the focus and that is my shift linkage consist of two metal bars. One goes to the transmission and the other to a side mount looking thing on the side of the transmission. The bar that goes to the transmission has a joint and that also seems to have quite a bit of play in it to. So is there a bearing/bushing underneath the stick? And if so what is the part name and also where the bar meets the joint is that also a bushing????
Okay Ill see if I cant find the linkage on the ZX2 probably over sunday this weekend and update ya’ll. Also ill check those bushings cause a buddy of mine remarked to me about the amount of play in the shifter itself by saying that it felt like it was in neutral when it was in a gear. So maybe itll be shift linkage…….
Quoted From dreamer2355:
I would not attempt to do any type of R&R work to a transmission without having the correct tools and service information. I just rebuilt a manual transmission from a Toyota and it was not a fun experience at all.
If your grinding when trying to change gears, do you even look at your clutch hydraulics to make sure there is no issues there?
How does the clutch pedal feel and does it stay depressed when you use the clutch? Any other issues with any other gears?
My co-worker who passed away in August of this year had the exact same vehicle as you. He would grind gears due to worn out bushing near the shifter.
I would do some more investigating before condemning the transmission synchronizers.
Okay thank you dreamer… I know these zx2s are real dang finikey and some of the things they do just dont make sense. Now where would I be looking for the bushings at? Are they near the transmission its self or are they right up near the shifter its self? And thank you for suggesting that again. And im sorry about your friend that passed away.