JonB
New member
This is the second go at this as my original plans got scuppered when the insurance companies decided not to repair my old Puma.
The main trouble I had was not being able to do any more than a weekends work at any one time. Solved that by buying a car for the Mrs to drive once she passes her test (and me to use daily) then another Puma to work on.
Bought a rather neglected example that had been used as a fun runabout while the owner worked on his prefered drive, knew it needed a clutch, n/s front wheel bearing, had exhaust issues, ABS problems and the tracking redone.
This car was going to be perfect to fit my black and red half leather ST seats into, front and back. I am going to build a 5 seat Puma.
Got her home and started stripping to get at the clutch.
As I intended to replace all of the rubber underneath, and knew it was in the way, started with the front suspension. Soon as the wheels were off I noticed a bent steering rod, that would explain why the steering wheel was offset, someone had just lengthened the adjustment on the other side to compensate! I also found an ABS sensor wire tucked up the arch with the plug cut off, guess that might explain the ABS light being on.
Fortunately I was able to get another rack, along with various other parts from a guy breaking.
Next thing was strip all the bits in the way of getting the gearbox out, as I pulled the o/b driveshaft I noticed that the gear oil was rather red and foamy, I think someone had used ATF instead of gear oil!
Finally got to the clutch which was indeed knackered, then checked the endfloat at the flywheel and got 0.4mm. This is within specified tollerances but right at the top end, so decided to look for a lower mileage engine. I was willing to strip the one I had to change the slightly weepy head gasket and change the cam belt, oil seals etc, but bottom end is really out of my comfort zone.
Then I really blew my budget because I had fully intended to get a LSD for the gearbox to couple to a reconditioned engine via a Focus clutch, but bought the engine and LSD box from FRP336.
This is really going to be a Puma Plus now, plus one seat and plus 30HP!
Now I am looking for a heavier ARB to fit in behind the steering rack before the engine gets delivered to my work as I would rather not fit it from below as that entails dropping the subframe.
I also had time to wash the mud out from the engine bay where someone had been off roading!
Have given the 16" Mondeo wheels a coat of black paint as the silver was flaking off, and painted the calipers from the 300mm setup bright red.
Thats about as far as I have got, I will try to add some pics as I rebuild, but no promises.
The main trouble I had was not being able to do any more than a weekends work at any one time. Solved that by buying a car for the Mrs to drive once she passes her test (and me to use daily) then another Puma to work on.
Bought a rather neglected example that had been used as a fun runabout while the owner worked on his prefered drive, knew it needed a clutch, n/s front wheel bearing, had exhaust issues, ABS problems and the tracking redone.
This car was going to be perfect to fit my black and red half leather ST seats into, front and back. I am going to build a 5 seat Puma.
Got her home and started stripping to get at the clutch.
As I intended to replace all of the rubber underneath, and knew it was in the way, started with the front suspension. Soon as the wheels were off I noticed a bent steering rod, that would explain why the steering wheel was offset, someone had just lengthened the adjustment on the other side to compensate! I also found an ABS sensor wire tucked up the arch with the plug cut off, guess that might explain the ABS light being on.
Fortunately I was able to get another rack, along with various other parts from a guy breaking.
Next thing was strip all the bits in the way of getting the gearbox out, as I pulled the o/b driveshaft I noticed that the gear oil was rather red and foamy, I think someone had used ATF instead of gear oil!
Finally got to the clutch which was indeed knackered, then checked the endfloat at the flywheel and got 0.4mm. This is within specified tollerances but right at the top end, so decided to look for a lower mileage engine. I was willing to strip the one I had to change the slightly weepy head gasket and change the cam belt, oil seals etc, but bottom end is really out of my comfort zone.
Then I really blew my budget because I had fully intended to get a LSD for the gearbox to couple to a reconditioned engine via a Focus clutch, but bought the engine and LSD box from FRP336.
This is really going to be a Puma Plus now, plus one seat and plus 30HP!
Now I am looking for a heavier ARB to fit in behind the steering rack before the engine gets delivered to my work as I would rather not fit it from below as that entails dropping the subframe.
I also had time to wash the mud out from the engine bay where someone had been off roading!
Have given the 16" Mondeo wheels a coat of black paint as the silver was flaking off, and painted the calipers from the 300mm setup bright red.
Thats about as far as I have got, I will try to add some pics as I rebuild, but no promises.
Not sure that sandblasting and powdercoating is going to be enough, so ill just buy another good condition one, and refurb that instead! It needs to be good condition because ive got to weld a a bracket for the rear engine mount to it, the standard puma gearbox rear mount wont fit the duratec box.
