Merkur Scorpio Restoration Project & other trivial pursuits

May 2nd, 2013

Got the clutch fork boot today from the UK. Looks like it is going to work. I have included some pictures of the original one alongside the replacement. Not exactly the same shape on top, but the same dimensions on the bottom, so I think it will work fine.

May 1st, 2013

Clutch fork bushing/space issue solved. Made a trip to the Ace Hardware store and found a couple of options for replacement.

I used the one that was on the left. It was a little shorter than the original, but it had the correct I.D. and the pin is just tapped into the case, so I was able to adjust for the 1/32" shortness.

More progress, shifter is finally out. That was a pain!

I had to take both front seats loose so I could remove a couple of screws that were holding the console in. No fun at all.

Got the pedal box removed last night. Not too hard, but did take some time.

The one hiccup I did have, is that I discovered the clutch quadrant had broken at the tab that holds the return spring and the spring was MIA. The incredible Jeff Herson already has a new kit on the way.

I am just waiting on the clutch fork boot to show up from the UK, and with that and the quadrant, I may have this all back together by Sunday! Fingers Crossed

April 28th, 2013

Made progress over the weekend, and had one set back.

Progress: Took the flywheel to a machine shop to resurface it. Always a good idea, the flywheel was slightly warped. Looks much better now.

Installed the pilot bearing and the flywheel on Saturday.

Installed the clutch and pressure plate today.

I have to say, I like this much better than working on the A4LD.

The one setback of the weekend. The Clutch fork pivot bushing gave up the ghost when I removed the clutch fork.

Should have this attached on the shaft.

I pulled the piece out. I am hopeful I can find a suitable bushing to replace the one that failed.

April 22nd, 2013

More progress on Sunday, got the flex-plate removed, replaced the rear main seal, started to remove the shifter assembly. One small snag, the clutch fork boot doesn't look like it will be usable. It has seen better days and it is missing the clip to keep it in the bell. Hopefully have it resolved by later this week. I also am planning on getting the flywheel resurfaced. Just to make sure there are no issues with install.

Rear main seal, new and old:

View of the new seal installed, I hadn't had a chance to clean up the rear of the engine yet. I think I have a leak coming from the Distributor.

April 20th, 2013

The A4LD is out! :headbang

What a pain in the a**!

I'm about halfway done. Still need to remove old flywheel, replace rear seal, install clutch in the T-9. Fill up with liquid gold, aka Ford Fully Synthetic Manual Transmission Fluid. Install pedals, install clutch cable, Install new flywheel, pilot bearing, transmission, driveshaft, heat shield, exhaust. Then FUNTIME!!!!

April 15th, 2013

Made some progress yesterday on the swap. Got the exhaust removed, driveshaft removed, transmission drained. Hopefully I will find an hour or so tonight to remove the coolant lines and maybe the starter. Sorry no pictures, nothing dramatic yet. Definitely helped that I have removed the transmission before