Zetec in S4

[gav]

Andrew

It is worth checking the ratios of the 6 speed boxes - a number seem to have a very high first gear that isn't much use, then a nest of close ratios that with a really flexible and torquey engine like the 2l zetec aren't really needed.
My next change (but not this year !) is to drop the rear diff ratio to reduce the cruising revs.
Quaife do an interesting box that seems to have a drop gear lever so you can effectively use it in sport or cruising mode from the cockpit. No idea if it will fit but I think the concept is great. The only problem with Quaife gear is that it is so expensive. I think it might be cheaper to use an Elite box which is sequential (and probably a little over the top) - but you can pick ratios and I think you would be able to put the gear lever where you want. That box is really small.
One further thought to consider - my competition car uses a 5 speed ZF S5-18 box which I used to run with my twincam and a 4.1 diff in the roadgoing car and which was absolutely fantastic - there are different versions and the one I have is perfect - only snag is that the turret and gear lever are too tall for the Elan tunnel so when I ran it I had to enlarge the tunnel to fit it - hence relocation to the competition car.

Gavin

[gav]

One further point to think about on the 2l zetec is that we carried out a lot of work on the sump including adding a wing on the induction side to replace some of the oil that we removed by trimming it to clear the brace and anti roll bar (annoyingly not quite enough !)
To fit the engine, I found it easiest to lift it from the engine mount arms, remove the sump temporarily and drop the engine and box to the ground, refitting the sump before it lands.
I have the benefit of an overhead gantry and ramps and can easily control the process so a good set of equipment also helps. I could have lifted the engine and box out of the top but would still need to remove the sump because it is so boxy.
Because I fitted the engine and box on my own without a second pair of hands, I didn't want to risk the bodywork so I opted for the cowardly route.

Gavin

[RichardHawkins]

Gav,

Thanks for the reply and photos. The exhaust looks excellent.

Richard Hawkins

[Frogelan]

Interesting thread as I already think the standard gearbox is quite a tight fit. I'm very impressed by the re-thinking involved.

What I retain from this is the need to check any potential gearbox against the original.

I had a chat with Elite at Race Retro in 2017 and (if we put aside the cost), their ZF derived box has potential, especially as they are prepared to do machining modifications in order to widen their potential market away from the Escort fraternity.

With respect to Zetec, it looks a great engine, but some headscratching is needed to modify the pulleys.

I have a GTS project to finish first...

[gav]

Aha

Found a smaller diameter pulley to reduce the revs on the alternator and water pump and to provide more clearance to the chassis.
Am going to try a flywheel locking tool (fits onto starter motor mounting bolts) to undo the pulley nut. I'll measure the smaller belt and order it when the pulley is in place.

Perfect irony, I had to replace a hose in the cooling system which I did the other night. I am booked onto the rolling road on Wednesday next week so thought I'd run up the engine to bleed the cooling system in advance.
The irony? - the heater is working really well - with an outdoor ambient temperature of 34 degrees !
I suppose It might be helpful if the cooling is marginal but I have now switched to Evans waterless coolant (at huge expense) so I am not expecting a problem.

I hope I get to the rolling road OK - its my first long run for a while....

[gino1]

Very nice Gavin...
Lovely work,
Gino

[gav]

Thanks Gino

Hows your project doing?
Last time you showed us progress it looked spectacular

All the best
Gavin

[gav]

Cripes
Went to Emerald's rolling road on Wednesday to get the injection remapped.Had a deafening alternator bearing squeal all the way there and back. So much for sealed for life - so that is going back to be replaced but we ran the session anyway.
The figures for the engine were 222 BHP at 7550 with a pretty straight line up and 159 ft lb at 6770. I have an al steel bottom end and am safe to 8000 but i cant see me using that too much.
It was a quick journey home and I really wasn't pushing it.
My builder reckons that we will hit 230 comfortably when the engine has fully run in but to be honest I am more interested in the torque which makes the car so easy to drive.
Even though the Zetec is 15 kg heavier than the twin cam, the additional power more than makes up for it.
Very pleased - a very tractable solution - and I can always reinstall the twin cam if I need to.

[Frogelan]

Well done Gav.

The figures are indeed impressive - can you remind me of the capacity of the engine?

I'd be very interested to have a look when it might be convenient to you (am originally from Herts although I live in France now) !

Andrew

[gav]

Hi Andrew

It?s a 2 litre

Happy to show the instal when you are next over this way

All the best
Gavin

[gav]

Blimey - my cars famous (well among readers of Practical Performance Car) - it got a half page spread in Dave Walkers (Emerald rolling road) section

Never thought I?d make the press - but I suppose the mag is a little specific

I?m nearly ready for the oil change but the engine is running an absolute dream. And now I have the brakes sorted and cooling on the way I?m fast running out of jobs to do - hurrah...