What's a Seven?
Zetec vs. X-Flow
Conversion to Zetec
7's 50th Anniversary
Wide Track / deDion
2/2000 - 4/2002 , Crossflow bored to 1700, 244 cam
4/2002 - present - 2.0 ltr / 200BHP Ford Focus ZX3 Zetec
see Zetec conversion page
|Date / mileage||Event||Solution|
|3/26/99 130||#1 intake valve stuck in it's guide||recondition and upgrade head to XF1700 spec|
|4/20/99 130||first (re)start|
|4/21/99 200||15..20ftlbs of torque needed at the hubnut to turn either driveshaft (gear in neutral, brake pads out)||differential needs break-in. This goes eventually down to 1ftlbs at about 5k miles.|
|5/26/99 700||rear A-arm crunch noise||add washers at chassis mounts, relaxes tension on the A-frame|
|6/3/99 1600||transmission vibration/noise||I forgot to put in the pilot bearing - engine / xmission out - insert $9 bearing|
|6/20/99 2302||odometer broken|
|6/29/99 2xxx??||speedometer broken||get replacement (warranty)|
|7/20/99 2xxx??||distributor cap spring lost||drilled the cap and put in a pianowire
tied at the base of the distributor with a ty-wrap
|8/5/99 5xxx??||new speedo broken again||get 2nd replacement (warranty)
checked cable length to make sure it is not too long - seems ok. Bad batch of speedo's.
|8/6/99 5xxx??||Blinker relay stops working||open it up and clean contacts. Black dust inside.|
|9/1/99 7000||decide that 110BHP is not enough power||upgrade the XF1600 to XF1700 with
a Kent 244 cam this
coming winter, yes!
|9/30/99 7600||order pistons and 244 Kent cam from RMSCI and plan for the upgrade|
|10/17/99 8000||car is getting too cold to drive around 30..35F||order fresh air heater|
|10/20/99 8100||Radiator leak at the top 1" blanking nut||solder with silver solder|
|10/25/99 8500||Valeo voltage regulator goes out (on
rgenerating 20V board voltage, with very bright headlights. I did
replace the bulbs.
||redesign regulator (corrects field winding bias issue, causes after runs when the fan is running at shutoff), mount under carbs to avoid baking by header #1|
|12/26/99 10100||dismantle engine - prep for XF1700 upgrade||-- Hobbyist Wisconsin plates do not allow driving in January, also 0F/-18C weather makes driving less enjoyable|
|2/4/00 10100||1st start as a 1700/244 cam||noisy at startup, allow 500mi for
compression about 160psi, after break-in around 190psi (warm)
|3/5/00 10900||Clutch cable breaks far from home -
have to start
in 1st gear, shifting w/o the clutch is not too bad otherwise.
||Embarrassement at a couple of the
Get new cable and a 2nd as a spare in the boot
|3/24/00 11400||Install engine mount restraint plates as a precaution|
|4/2/00 11800||K&N airfilters self destruct||replace (blow back from carbs is desolving the rubber seals. 10% alcohol in Wisconsin fuel does that)|
|4/5/00 12100||A carb stud loosens - leans out mix on #2||loctite and center punch studs behind the manifold|
|4/6/00 12150||Radiator leaks again at the top||resolder again|
|5/5/00 13500||Radiator leaks at the bottom||resolder and hope for the best|
|8/27/00 17000||driver side floor fails (10 rivets lost)||drill out rivet remnants, re-drill and use 3/16" stainless rivets after epoxying floor to chassis|
|9/3/00 17600||Radiator leaks everywhere||resolder everywhere|
|12/16/00 19000||put it away - too cold (25F is the cut-off), also too much salt|
|2/4/2001 19000||2001 driving season starts - still cold, have to drive around the salt :-)|
|7/1/2001 23000||Junked the Heavy Duty Radiator, it's a sieve||get Alu radiator - much much better cooling and ... no more leaks... wow|
|10/30/2001 28000||thermo sender goes flaky||replace|
|12/18/2001 30500||Parked for the season. Just can't stop driving|
|2/1/2002 30,500||I'm back - Wisconsin Hobbyist plates do not permit driving in January. Normally this is ok, but this year there is no winter.||.|
|4/21-30/2002 31,500||Swap in 2.0 Focus Zetec||.- see XF-Zetec conversion page|
|5/2/2002 32,000||Remapping of GEMS fueling map continues. Mileage now around 17mpg, but a lot more power||Note: (5/03) - lean
out cruising map - AF approx. 13.5 -
23mpg freeway, 20mpg country roads
|5/30/2002 32,800||Running good, except odd event where revs limited to 4500rpm||The issue disappeared. ECU gremlin?|
|6/4/2002 32,900||(GEMS) ECU
overheats - 3000rpm
see near the bottom of XF conversion page
95F weather, sidescreens in, heater valve not completely shut off. ECU mounted on the Exhaust side firewall inside the scuttle. ECU too hot to touch. Issue resolved with added ECU cooling installed.
|10/25/2002 37,300||Clutch cable brakes again. Seems underrated. Too much force is required. Snaps off, 1/4" back from the eye in the footbox.||replaced cable for now - considering hydraulic. Craft something from Pegasus or Jegs parts.|
|12/19/2002 39,500||Weather perked up, so out I was, but speedometer failed again.||replaced 1" flexible cable in right angle drive at the gearbox. Also shortened both ends of the main cable to make sure it runs free enough to spin the speedo by hand from the gearbox end of the cable.|
|12/20/2002 39,501||Battery failed - low temperature starts killed it off. Fully charged, but capacity is not enough to crank a 10.5 CR Zetec at -0C /<32F temps.||New Johnson Control (aka Sears Diehard) sealed Gel battery ($45) is perfect. Slightly lighter, fits about in the same space and 340CCA ! Need to device pole caps for general & track safety.|
||Parked for the season
|2/1/2003 39,600||Back on the road|
|4/15/2003 40,100||installed adjustable Leda shocks and new springs - however 275 / 200 lb/in F/R is too stiff .||Handling improved significantly, but
a daily driver, I
ordered 220lb/in Front and 150lb/in Rear springs.
Running 275/150 F/R now.
sounds like a weld had given away
||lost 1 of 3 #4
header bolts, others loose. replace/retorque - fixed.
||deDion tube failure...whoOAaa
Left rear shock mount cracked, causing 1" left rear suspension drop.
|weld up the old tube
close the season, and ordered a new tube.
But..we're back on the road within 2 days, let's hope it holds up.
out again. 1" flex drive wire broken - this is fragile when it gets
cold and the bowden cable stiffens. This is Wisconsin, and it does get
||use a 1" x 1/8" square brass rod
section as a link between
right angle box and gearbox - no more troubles. Also, no more wavy
||new deDion tube received.
Also received hydraulic clutch actuation parts
||Mounted - slight adjustments
needed, for brake-T mount and Z-arm openings, otherwise fits fine
- snow and salt are here.... it's hard to stop :-)
on the road again of course !
||Starter solenoid keeps hanging up.
This is still the old starter from the Crossflow. It's a Magneti
||lubricate solenoid plunger. Dry
graphite works best. Also added heat shield wrap to the starter /
||brake pads glazed (still about 30%
||replace (original) brake pads
to report, just running
great, except the weather has been lousy here in Wisconsin, hence not
miles have accumulated this year.
Black Hawk Farms track day...
kinda washed out
has been very solid this year, but driving has been curtailed by THE worst weather we've seen here
in Wisconsin in a while, with perpetual downpours. Some rain is no
problem, but there are limits :-)
Fortunately the 2004 driving season ended with a perfect 45 degree F - blue sky day - I suppose global warming has even reached Wisconsin
on the road!
running good, but the weather has not cooperated. Cold is ok, but
rain is not great.
switch is out again... need to really fix this..
rotors, new pads
closed, early winter
30mile spin - 35F, but that's enough!
spin with the old gearbox - time to change!
1st / 1.81 2nd gear a 3.92 diff and a 2.0ltr Zetec does not work well.
Last year October visited Brian Hill and his team at BGH Geartech. He
put together an E7 kit for me, which I'm about to put in.
Original ratios: 1st - 5th 3.36 / 1.81 / 1.26 / 1.00 / .82
New ratios: 1st - 5th 2.75 / 1.75 / 1.21 / 1.00 / 0.85
much spare time, but, the box is done - time to put it back in the car
||See Gearbox upgrade
page for details
run with the uprated box
so good. Better put some miles on it.
I just noticed that the old T9 boxes actually used trust washers on the layshaft, hmm..maybe I improved it :-)
rotors and pads.
|5/22/2006 60,400||Lotus trackday at BHF -||Gearbox
worked great! No more 3rd gear crunch. The dreaded front wheel
lift-off due to the 3.36 gear has finally been put to rest. Last year
with 3.36 and the sticky racing slicks, the car did a mini-wheely on
leaving the pitlane and I almost hit the exit wall, close one that.
Clean starts now with these new ratio's.
in the driver side
footwell - heater hose split
overheating again after
coming of the freeway in 100F weather.
noise filter to 5V
regulator, increased cooling fan capacity - seems to work
cable frayed... hanging
up in the sleeve
it with the old
throttle cable I still had laying around from the Crossflow days.
ECU fails - replaced with DTA
DTA S60 PRO is DTA's latest development
DTA is excellent. Features, programmability, monitoring is quite a step
Combined with a WB02 (Bosch NTK) gives much closer tuning than the GEMS.
ends... it's very cold
in the car! It's 35F
and dry, some rain washed much of the salt away.
yes, this is Wisconsin, not
(normally 10..20F this time of year)
lower A arm balljoint needs replacement.
Locknut mysteriously loosened itself. Retightened for now, but need replacements. Not bad for 65k miles.
ones ordered - will install these when it gets warm(er)
lower rear shockmount bolt shears off.
Had to get tools from home (10mi's) and do a roadside repair.
all lower suspension bolts with Grade 8 plated.
Suspect this failure was due to trapping some piece of bushing rubber under the bolt washer, preventing proper bolt tensioning, causing significant bending stress.
full sequential injection mode causes cam sensor errors below 1200rpm,
i.e. idling >5 secs stalls the engine.
Ford's magnetic cam sensor with a Honeywell Halleffect device. The DTA
S60 ECU has both magnetic and Hall effect inputs. The Honeywell-IGT101DC
does not quite fit, thus a bushing is needed to fill the gap as well as
O-ring to seal it off. Bushing: L =
.5", ID = .705", OD = 1.01"
Zero cam errors now! Solid idle, smooth shifts.
cable is not fully returning
with 1/16" heavy duty mountain bike brake cable.
when sitting still in traffic jams in 90F weather
thermoswitch (in filler neck) with a 75C model (was 92C) - works
perfect even in super hot 90F (32C) weather with traffic.
wheel balance issues.
Haven't had this in a while. Proper centering of the rims is important
as I've noticed that with hasty wheel mounting (track days) the rims
may not be perfectly centered possibly.
session had 22 (!) stick-on pieces of lead on one of the
Back to traditional transverse and radial balancing solved the issue. Just 2 small rim weights / wheel. Wow.. now it's good.
Oh.. that's $12/wheel.
out again. - check
this eve, probably the cable at the right angle drive fell off.
The Oct 8 Road America track day was great, but new Avon's did vibrate slightly, causing things to come loose.
|The right angle drive had vibrated
loose.. no big deal. The high speed running at Road America probably
did that. Car still vibrates >100mph and power is off > 120mph,
due to having "lost" the ECU map after the TB issue... to be corrected
over the off-season months.
(see follow up 6/18/2008)
last night and a lot of salt. That's it then. It's early this
year, but given the length of the "to-do-list", it may well be a good
thing, as I can't stop driving this car.
It's a balmy 33F, almost +1C. Still sheets of
ice and snow, but no salt!! Salt ran out in January having
received a record 98" of snow fall.
||Car needs tuning, the TB's aren't
properly tracking since last year, drawing false air on idle...
I'll work on it, but I need to get some driving in first :-)
adjusting the TB balance, I noticed the top alternator bracket was
cracked. About 80% through.
a new beefier one from solid 6061 Alu. Note the crack in the original
still not balanced at idle. The Jenvey/Lumenition TB's are relatively
high tolerance items, and clearances for a good idle setting just
the last track session at the Lotus track day to collect some steady
high end (6000-7500rpm/100% Throttle) data. Thanks to Graeme for
fearlessly hanging onto the laptop and O2 electronics gear.
Updated the Fuel maps and balanced the TB's at quarter throttle. Wow, what a difference. "Z power is back"
right ball-joint creaks, also, the rear ARB drop links have developed
fresh ones from RMSCI.
Drop links are installed, but I need to allocate more time for the top ball-joints as it'll require re-alignment. (jackstands / strings & ruler method)
close. Snow is on the way. (12/6/2008 - 12" on the
ground already )
Certainly a good year, with some longer (700mile) trips during the past weeks - it's going to be 10 years with this car. Even past 77,777 miles, and it still make kids smile and it still gets greetings. I can still look ahead by looking under those silly King-Kong SUV's.
I should really do some work on the car, but at a sustained < 10F for weeks now, I wouldn't even try change the oil, unless I used a spoon.
I know there's se7eners further North of me, so I'll save my complaining. The weather forecast is showing a warmup to maybe the 20F's, the week after next.
And... the new local low-salt road-maintenance policies should indicate early clean roads! Keep hoping.
[ 10 years ] ]
|20's--30's--40's Mid winter thaw, and
some strategically selected salt free routes. Put the 1st 100 miles on
it. Started without trouble. Good to be
back driving. Got a few incredulous looks from the SUV parade,
hey, it'd be difficult to explain.
in the back
brake cable worked
itself loose. Sleeved it with 5/8" rubber hose and ty-raps to the lower
diagonal frame rail
||new pads (Mintek) and
standard solid rotors.
broken. This time it's the delrin slider. Too many miles I suppose.
Just wonder what it is with alternator brackets. The Valeo 45amp is very light, and the Zetec runs pretty smooth, maybe not at idle (light flywheel). So.. I dunno. Just replace it and see what happens.
I made the new one from delrin (as was the original from Raceline) a bit
thicker and added a "brow" hoping to help avoid
resonance (we'll see if it helps)
close. 24F and dropping rapidly. 12" came overnight, so that's
it. April seems very far away.
The car has been very good this year. Over the winter, when it's not too extreme, I plan to check the rear suspension, as I still heard something make noise, although it doesn't affect handling. Maybe it's something with the wooden floor board in the trunk.... yes, my car has a 'trunk' :-)
since Nov '09 leaves time for upgrades - Battery, and front
brake-line (too close to one of the primary pipes).
an Odyssee battery.
Looks like three resonable choices:
PC545, PC625, PC680. No need for the metal jacket or terminals.
Picked the 680 for it's very low internal resistance (7 milliOhm) and good capacity/volume ratio. Although rated at 17Ah, it can deliver over 500Amps for 20sec. (or 680Amps for 5secs). Odyssee specs (220CCA), or 220 cold cranking amps at 0F and for 30secs.
Starters can't run for 30sec without taking damage. In other words, more than sufficient cranking power.
lost left front bearing dust
cap during a trackday
2. Oil breather catch tank drain spigot plugged with emulsion
3. right front suspension crunching noise
replace dust cap - cheap at
2. Wash out the tank and filter.
3. tightened upper A-arm suspension bolt (wheels on the ground)
suspension noise over large bumps.
ARB drop link interference. I replaced these some time back and they
never fitted right... made a new offset interface.
Not pretty, but very effective.
On the left the original in actual orientation (angles), leaving no room for any deflection w/o interference.
Center is an intermediate version, which didn't work well.
Right is what I put on the car and this works well.
Overall weight left vs right is about the same (Alu block)
||Season end. 23F is too nippy.
Didn't get the tonneau cover to fit (yet). I'll figure it out next year.
I do have to fit those half side screens sometime before Spring.
is a more than balmy 37F for several days now. Heater full on,
throttle full on, sunglasses on and we're good to go.
errors after track day.
||reset to non-sequential injection
until I find a new cam sensor
||All fixed. Runs smooth again, zero cam
Digikey carries these (again) - straight swap, added ty-raps for the wires, which had broken due to vibration.
cable broke 20 mi from home, prompting another clutch free drive, and
reinterpretation of stop signs.
This is the 3rd cable to break in about 90k miles. I guess time's up for this archaic method.
clutch cable turned out to be 2" too short. The proper length isn't
available (supposedly it never was?? haha... funny).
Whatever, it's time to convert to Hydraulics at last : See below:
|Left pic: note rubber washers under
the slave cylinder to help clear the bellhousing edge (interference
spot not visible in picture)
||Center and right pics: hydraulic
line route. The line is a bit short actually, but it's not too bad.
Overall more linear operation than the cable.
washers under clutch
slave cylinder deteriorated (as anticipated)
cold, season end is
near. Drove in some <28F and thought it felt a bit cold. Aging
the hood up next time
shockabsorber has slight free play at full extension
having these dynoed and
rebuild. LEDA is unfortunately out of business - nevertheless excellent
Front top ball joint has developed slight play. Supposedly 7's are hard
on balljoints. Probably applies to any car driven quickly on crumbling
on order (backorder)
top RF balljoint -
sharp steering has returned
||seats and tunnel worn. Not bad for
this level of use.
The Odyssee battery didn't live as long as expected
Light slop in the front ARB
Alternator bracket cracked (1st time for this one)
|replaced seats, tunnel cover.
went with another pc680 battery
replaced front roll bar ball ends
machined / replaced top alternator bracket / accessory belt
||clutch slave cylinder linkage
failed -- too much stress
||repaired, added spherical
washers to accomodate the slight angular movement
winter is fiercly cold (a week below -25C), and taking the car
out is a ways off. Projects from last year have accumulated, and I hope
to get to them before the roads clear up.
||Driving season's a bit late this year. About
7C now. Not much time for driving in the past year due to personal
Redid the hydraulic clutch cylinder using pivot washers, accommodating the slight arc motion.
||Annual Lotus Trackday at Black Hawk Farms, produced
an 'off', which folded up the exhaust system. Yes, I went out in the
rain on semi slicks and had a lazy spin. The tailpipe tip just caught
the concrete curb edge, going backwards. So much damage in so little
had another set
of headers made, which fitted perfectly. #3/4 are 'standard' but
#1/2 are different for the LHD car, i.e. special order of the already
||Timing belt replacement
||No repairs - just driving :-)
||Weather is unseasonably warm (65F), and the
is approaching. It'll read 95,000
since there's the 5k unregistered miles due to a couple early failures
(see '99). Very Se7enEsque! Everything has a story and is
non-average. Who'd want to be average anyway.
||replaced rear rotors & pads
- 50% left, but crumbly
||I think this is it for the
season - 22F
in a Se7en!
On the way back from the Black Hawk Farms Lotus track day, it ticked over to 100k when entering the driveway at home. The odometer reads 95,001 as mentioned previously.
it's some form of affliction, no cure is anticipated or sought.
In summary, I recommend this car.
flow issues, limits top end (track day) . Inspection shows internal
damage (kink) from 2014 track mishap
||Replaced muffler, flow restored.
on battery only, alternator is not charging
of terminals. Cleaned alternator spades, replaced connectors, all good.
||End of Season - Salt on the road
= no more driving
|End of Season is nigh 35F,
but no salt yet!
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