Hi
I have not worked on the Zetec engined 4/4 , but a few pointers about general engine removal from the Morgan.

First I would double check (with others here) that the symptoms are indeed a clutch slave cylinder (otherwise you are going to do a lot of work for nothing!) and that there is no way to effect the repair without removing the engine and bell housing/gearbox assembly . There is often a trick access to these parts via a route that Ford trained mechanics know, but I have no idea of this is the case for a Zetec.

If you are familiar with pulling an engine on a Caterham , you will find the Morgan similar , a bit more cluttered with parts in the way perhaps, but if you work in a similar methodical manner labelling bits as you go , then it should be quite straightforward.

First drain all the coolant. I would also drain the engine oil , although that might not be strictly necessary and also the gearbox.

Take the seats and gearbox trim out first , then remove the gearbox casing.

Now start at the engine end, I would remove the bonnets, cowl, the tie bar bar behind the radiator , then the radiator.

Disconnect all hoses and electrical connections (being especially careful with any connections into the ECU and ensure you do not bend any tabs) and fuel lines/cables from the engine, and break the exhaust after the manifold but before the down pipe. Pull the down pipe away to one side (you might need to release some mountings to get it to move sufficiently.

Now remove the panel in the bulkhead which seals the bell housing, this may involve more electrical connections.

Remove the handbrake and the gearbox from its mountings and then the engine from its mountings.

Remove the clutch linkage.

I don't know if there are lifting hoops on the Zetec , but if there is use these . You might need a load speader to get the engine at very different angles as you extract it.

Once on the deck you can break the engine from the bell housing and set to the work on the slave cylinder.


Andy G
1999 +8 , Indigo Blue.
Ex-John McKecknie/Mike Duncan 1955 +4 racer.