Talk Morgan Forums Morgan Sports Cars Maintenance & Servicing 1999 4/4 1.8 Zetec Clutch replacement

Good Morning
I live in France and have just agreed to help a French friend with his car. As I understand it he has problems with his slave cylinder (which I believe to be concentric with the gearbox input shaft). This means the engine must come out I think. I have a Caterham and am well used to pulling the engine from that but I'd appreciate some pointers on how to attack this job. In general, which bits need to come off and which can I leave ? Any advice gratefully received ....

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.

Hello and welcome Roger. I thought I recognised your 'handle' from the other side. I can't be much help in your specific inquiry, but hope you might continue to join in and contribute here, they are a very varied and mature bunch most with something interesting to say.

Currently 'Brexit' is proving facinating on here.

easy, take the motor out! i have done it!

Andy, thanks for that, just the sort of info I was looking for !
Hi Paul, they're very friendly so far .....
Sukram, Nice to know it's easy !

Andy
I take it from your post that it's normal to pull the engine with the gearbox still attached ?

I've taken engines out of a crossflow 4/4 many times. There is no way you'll take the gearbox out first on one of these.

Can be done without a load spreader, but a heck of a lot easier with one as there isn't much space under the bonnet.

I am faced with the same problem with the Zetec and T-9 transmission in My DHC. Yes pull the engine with the gearbox attached. Mandatory IMO to use a load leveler. This unit must be tilted quite a lot to clear the front cross bar. Watch out that the gearbox oil does not come out the back when tilted. Drain gearbox.

Button
Seattle - Love France

Yes, familiar with the gearbox oil problem, it's the same on the Caterham. I have a purpose made cap that I slide over the shaft before I finally lift it out.

Whilst the engine and box are apart, its probably a good idea to replace the clutch as well as the slave cylinder! Saves a job in the future!

Cheers

Arwyn