MXT-75 (Duratec) clutch/flywheel/FD/diff questions

[carlfreddy]

Since I've stopped autocrossing for 2 years now I'm finally getting around to doing the mods to my car that I want to do versus those I'm allowed to do in lieu of class rules.

The first of those mods are some transmission mods (truth be told, they are pretty much the only mods I'm interested in, more on that later). I'm interested in upgrading my clutch/flywheel and installing a torsen and possibly the FRPP FD. I'd like some input from Duratec folks who have actually done any combo of these.

My questions;
1) I don't ever plan on doing any power mods beyond intake and exhaust. However, I'd like my car to rev faster. Is there any reason not to just put a lightweight flywheel on without getting the stage 1 clutch (or whatever is on Focussport's site)?

2) Since I'm already going to have the transmission out and taken apart to install the torsen is it worth it to go ahead and install the 4.06 FD? I do no motorsports competition with the car whatsoever, these mods are just to address the short-comings that I encounter driving my car on a daily basis. With that in mind, I'd like to not jeopardize my lifetime average of 30mpg for the car. I do roughly a 50/50 mix of highway and city driving, and I'm afraid that the combo of a light flywheel and shorter FD will just kill my mileage.

3) Anyone actually installed the torsen themselves? I'm considering tackling the job (I'm no stranger to turning wrenches, I've built race cars and crewed for a Spec Miata team in the past, but I've never actually taken apart a transmission). The only tool I don't have is a lift. My other option is pulling the transmission and taking it somewhere to have them install the diff. Basically, I cringe at the thought of how much labor would be if I just took my car to a shop and had them do it all, but I'm not completely opposed to having a pro do it. I've been known to forget a bolt or two on reassembly.

Basically I want to address 2 areas of the Focuses performance that need improving; effectively putting what power its got to the ground, and freeing up more hp's by making the engine work less.

[brads03zx3]

Exedy OEM replacement. I'd recommend that over the stage 1 unless you are totally obsessed with the slight weight difference. The OEM replacement kit includes a flywheel that is much lighter than stock. You would be very happy with it. The stage 1 exedy has a pretty harsh engagement.

4.06 or 3.82 gears are great. It is really up to you. My duratec car has 3.42 gears and are way too long. If you can, drive a car wtih 4.06 gears. It may not be worth it to you.

Have a shop install and setup the torsen. Save yourself some money by delivering the tranny out of the car.

[carlfreddy]

Originally Posted by brads03zx3

4.06 or 3.82 gears are great. It is really up to you. My duratec car has 3.42 gears and are way too long. If you can, drive a car wtih 4.06 gears. It may not be worth it to you.

I think only the PZEV duratecs got stuck with the 3.42.

I'm almost certain my 2.0L Duratec has a 3.82 FD.

[brads03zx3]

Correct...I am agreeing with you. Your car does have 3.82 gears. I have driven cars with all 3 ratios. I really like the 3.82 gears. There are very few instances where I would rather have 4.06 gears. I am still trying to decide if I will go 3.82 or 4.06 in my track car.

[carlfreddy]

Originally Posted by brads03zx3

Correct...I am agreeing with you. Your car does have 3.82 gears. I have driven cars with all 3 ratios. I really like the 3.82 gears. There are very few instances where I would rather have 4.06 gears. I am still trying to decide if I will go 3.82 or 4.06 in my track car.

I wasn't sure since I didn't specify which duratec I had.

[brads03zx3]

It's in your sig and I know the 2.0 was offered in 2006

[FocusSportVP]

Originally Posted by brads03zx3

The stage 1 exedy has a pretty harsh engagement.

Having driven stock, Exedy OEM, Stage 1, Stage 2, and the Hyper Single...I'd have to say the Exedy Stage 1 has a smooth engadgement - as you'd expect from a sprung solid organic disc. The pedal IS stiff, however. Maybe that is what you meant. In contrast, the Stage 2, which comes with a sprung cerametalic 3 puck disc is not as smooth and feels like you'd expect from said disc. Stage 2 also has the same stiff pedal feel as the Stage 1 since they use the same pressure plate.

[OmniFocus]

After having done 4.06 gears, I probably wouldn't do them again... though maybe with a 2.0L Duratec they'd be a little more appropriate than a PowerWorks car.

[carlfreddy]

Originally Posted by FocusSportVP

Having driven stock, Exedy OEM, Stage 1, Stage 2, and the Hyper Single...I'd have to say the Exedy Stage 1 has a smooth engadgement - as you'd expect from a sprung solid organic disc. The pedal IS stiff, however. Maybe that is what you meant. In contrast, the Stage 2, which comes with a sprung cerametalic 3 puck disc is not as smooth and feels like you'd expect from said disc. Stage 2 also has the same stiff pedal feel as the Stage 1 since they use the same pressure plate.

Actually, just the person I was hoping would chime in.

Could you shed some insight regarding the differences between the stage 1 and OEM replacement Exedy clutch kits?

Is the included flywheel in the Exedy OEM kit the same flywheel that comes with the stage1 kit? How much lighter is the flywheel versus the OE flywheel?

[FocusSportVP]

No, the FW from the Exedy OEM and Stage 1/2 are not the same, nor are they interchangeable.

The Exedy OEM FW weighs about 15lbs. The Exedy FW from the Stage 1/2 weighs about 12lbs.

I don't recall the Ford OEM FW weight, but the entire clutch/press. plate/FW package was about 36lbs.

I have stated a ton of facts about Exedy and our clutch kits in the past. If you search for my posts here and in the FocusSport form you'll have plenty of info. Sorry, I have to do a grip of stuff right now, so I can't make huge informative posts.

[Egz]

Originally Posted by carlfreddy

I think only the PZEV duratecs got stuck with the 3.42.

More accurately, 2003-2004 Duratecs got the 3.41 gears. 2005+ got 3.82, because there are still PZEV Duratecs with 3.82 gears.

[carlfreddy]

Originally Posted by FocusSportVP

If you search for my posts here and in the FocusSport form you'll have plenty of info. Sorry, I have to do a grip of stuff right now, so I can't make huge informative posts.

I must suck at using the search function because I can only find your thread about the Exedy OE clutch kit for the Zetec.

[FocusSportVP]

If you search with "Exedy" in the "Shift it" forum you get 110 thread results: http://forums.focaljet.com/search.php?searchid=446091

If you search with "Exedy" in the "FocusSport" forum you get 49 thread results:
http://forums.focaljet.com/search.php?searchid=446093

[carlfreddy]

Originally Posted by FocusSportVP

If you search with "Exedy" in the "FocusSport" forum you get 49 thread results:
http://forums.focaljet.com/search.php?searchid=446093

I forgot about the FocusSport forum.

[illinipo]

im installing the torsen myself next week or the week after, it doesnt look too bad especially if you have that much experience. No point in paying a shop for it if you can figure it out...

[jsundelin]

Originally Posted by carlfreddy

With that in mind, I'd like to not jeopardize my lifetime average of 30mpg for the car. I do roughly a 50/50 mix of highway and city driving, and I'm afraid that the combo of a light flywheel and shorter FD will just kill my mileage.

Just an aside... A lighter flywheel should improve your gas mileage, but probably not enough to notice. Less rotating mass = less energy to get it up to speed = less fuel consumption.

See the thread "Installing a Torsion Diff" for some info on changing it yourself. The gear swap is quite a bit more complicated.

--
John

[blueovaldave]

Originally Posted by OmniFocus

After having done 4.06 gears, I probably wouldn't do them again... though maybe with a 2.0L Duratec they'd be a little more appropriate than a PowerWorks car.

I was going to post the same thing.

I put the 4.06 gears in when I was NA and 161 hp and loved them. With the PWSC and 245hp I really don't like them that much. Too short in 1st and 2nd gear.

[netdragoon]

As I recall, the stock duratec flywheel is 22.5lbs.

[carlfreddy]

Originally Posted by illinipo

im installing the torsen myself next week or the week after, it doesnt look too bad especially if you have that much experience. No point in paying a shop for it if you can figure it out...

While I've swapped many transmissions, I've never actually been inside one.

I've made my decision; Exedy OEM kit from FocusSport.

But not this month, bicycle racing has my budget on lockdown.

[CTZX3]

Thanks to all who posted info, it helped me too