I know I will have to drop the box at some stage to replace the cradle bushes (I know, should have done it before it went in!)

Anyway, would it be an idea to replace the clutch while it is out?

Apart from the sloppy change I'm having no problems with it, but the engine and box went in as a unit so I don't know what meat is left on it and if it makes sense to replace, I'd want to have it on hand when I do my dismantling.

Anything else that should be done at the same time?

 

As you've got the box off just take the clutch cover off and have a look at the condition of the plate and cover..

Sods law you'll put the box back in and 3 months down the line it'll start slipping!

 

Kind of think I'll buy a clutch anyway because, knowing me, if I take the box out then find the clutch is shot, if I don't have the parts to hand I'll use that as an excuse to avoid putting it back together for months!

But it looks like I may be doing this sooner than I thought. I took the car to Crail today and it wasn't great fun.

Big judder when pulling away and a noise like having a wee guy underneath, tapping with a hammer the whole way. It got worse when on the throttle and completely goes when coasting on a slack throttle.

I think (hope?) the noise may be a reverberation from the exhaust hitting the gearbox crossmember - I was tight for clearance so not sure if something has slipped/moved or what.

I'll need to get underneath for a looksee but may try and borrow a ramp to take the box out - I'm getting too old for rolling around on the floor.

 

The noise sounds like it is the front prop hitting the downpipe, just adjust it by slackening off the three nuts that hold it onto the back of the turbo , reposition it, and while a mate/mrs/passer by you have grabbed to help holds it, retorque the turbo nuts.

You don't need to remove the gearbox to get the cage out, just drop the rear box mount, & that gives you enough room to get all the bolts out, a ratchet spanner for the front ones helps lots. You will need to remove the small roll-pin that holds the main gearstick to the knuckle to get enough clearence to get it all out, but much easier than dropping the whole box

 

Mine is just a 2.9 so no turbo to worry about.

It's all very non-standard underneath and I had to machine an elipse in the gearbox crossmember for the exhaust which is why I think the gap has closed somehow.

If I can do the cradle without dropping the box it would be a bonus, but I'll take some advise on the possible state of the clutch first - this judder has me worried.

 

Well I never...

Got the car up on the jack this morning (which is a mission itself because it sits too low for the jack!) and the exhaust is still close to the gearbox member but seems to be clearing ok.

The problem is the donut - completely split and one of the nuts has been tapping on the spider so I know what my noise of a guy with a hammer was, but I now have a worn bit in the metalwork!

I have a spare donut from a 2.8 XR4i but it has a different part number for the 2.9 one which is common with the Cosworth and the Granada. Anyone know if it will fit?

Just in case, I called the local Ford garage and the donut is still available, but expensive - will try Partco or similar before I commit myself.

 

No huge progress on the replacement donut, but I found an easy way to change the cradle bushes:



You can just about see the donut here:

 

You want to fix that, or this will happen

 

put an escort cosworth donut on. expensive but stronger than standard.