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Old 12-20-2011, 08:41   #1 (permalink)
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Clutch change on 2002 Ford Focus 2.0 zetec Auto

Hi guys,

I need to change my clutch on a auto zetec engine, well remove and replace for a manual setup.

I'm faced with this big drum and unsure what to do with it.... any ideas??

I've tried smacking it a few times with no luck





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Old 12-20-2011, 08:52   #2 (permalink)
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Re: Clutch change on 2002 Ford Focus 2.0 zetec Auto

"BIG DRUM " is the torque convertor and is held on to flywheel by bolts at rear .
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Old 12-20-2011, 09:17   #3 (permalink)
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Re: Clutch change on 2002 Ford Focus 2.0 zetec Auto

Logan!! You the man!!

Gonna go remove the other clutch setup off my broken manual engine and swap it over and hopefully get the engine placed in tomorrow during day light.
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Old 12-20-2011, 09:21   #4 (permalink)
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Re: Clutch change on 2002 Ford Focus 2.0 zetec Auto

Hope all works out o.k for you and you get it finished / sorted out .
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Old 12-20-2011, 12:35   #5 (permalink)
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Re: Clutch change on 2002 Ford Focus 2.0 zetec Auto

Going from a auto to a manual eh?

I plan to do this myself in about a year, did you grab the manual wiring harness and ECU, and drive axle's?
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Old 12-20-2011, 13:07   #6 (permalink)
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Re: Clutch change on 2002 Ford Focus 2.0 zetec Auto

Remember and fit bearing for spigot shaft / input shaft into crankshaft ( flywheel ) .
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Old 12-20-2011, 15:51   #7 (permalink)
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Re: Clutch change on 2002 Ford Focus 2.0 zetec Auto

Pilot bearing
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Old 12-22-2011, 18:59   #8 (permalink)
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Re: Clutch change on 2002 Ford Focus 2.0 zetec Auto

The Duratec 2.3l didn't have bearings for the input shaft of the trans. It was just CNC'ed a certain way to cup the shaft, that is why they tell you to put some bearing grease on the end of the input shaft, but just a very light coat, or it will cause a lot of slipping if it gets on the clutch plate.

And I am 99% sure the Zetec is the same way. Easy enough to find out, look in the hole, if there are no bearings then it's the same as my D23. But I'd bet it is the same.
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Old 12-23-2011, 04:15   #9 (permalink)
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Re: Clutch change on 2002 Ford Focus 2.0 zetec Auto

Well that's a new one on me but always willing to learn something new . First time I've ever known there to be no bearing / bush for an input shaft . How is it supported and what does it run on ? I know there was a special grease we used to put a little on splines of input shaft which was to help the clutch centre plate slide. This cured the clutch drag , gear crunch you sometimes got on 1st and reverse .
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Old 12-27-2011, 13:19   #10 (permalink)
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Re: Clutch change on 2002 Ford Focus 2.0 zetec Auto

I wish I would have took a pic, because your reaction is just about the same as my pops when I told him there was no bearings for the input shaft.

It is just drilled out so that the shaft of the trans just slides right in, it must be a tight fit to the hole though, because I was able to pull the trans out a half inch before it felt like it was out the hole and coming out the clutch plate splines.

EDIT: Here I cropped and zoomed in on this pic of before I pulled the DMF off, you can somewhat see how it is.

It's just a smooth drilled hole, no bearings, or seals. All they say to do is put a very light layer of bearing grease on the end of the splines for the shaft.
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