Jesusfrk611 Midnight Blue '03 worklog

[Jesusfrk611]

Sedan 5th gear.

As a disclaimer, don't use this picture as a reference. The drive gear is on backwards. I noticed it when I was putting everything back together. When doing the 5th gear swap, the reference pictures in the 5th gear swap how to are good.


Thanks for the comments on the trunk lid cover. It turned out pretty decent. I was worried the push pin things would be too short with the thickness of the cardboard. But it manages to stay in there. I just used those same pins used to hold up the trunk carpeting on the sides of the trunk. I wanted to put on in the middle as well, but I only had two push pins.

Trunk lid is now back on the car. Pulled the splash shield for the serpentine belt and pulled off the serpentine belt. Timing belt soon, not looking forward to it. RTV'ed the 5th gear cover and put it back on. Pulled the passenger door panel and replaced the door lock actuator. I just remembered that I didn't bother to test if it works. lol More Dynamat on the door is next. Probably tomorrow morning. I started pulling the steering rack out, but I have to take that arm off to get it to come out, or drop the subframe. I already need to drop the subframe for the front sway bar bushings replacement and to replace the rear transmission mount (the one that's actually bad), so might as well drop the subframe for the steering rack as well.

[Jesusfrk611]

Just an updated list so I can keep track.

-find clunk in driver front end and fix - Found to be ball joint
-5th gear swap - Done
-Curt hitch install - Done
-swap LED reflector for unLED reflector - Done
-trunk lid interior cover - Done
-passenger door lock actuator replacement - Done
-more dynamat in the doors - Done
-fix up some wiring - Done
-fog light condensation - Done
-replace battery terminals - Done
-timing belt and pulleys - In Progress
-Esslinger UDP and Gatorback belt - In Progress
-steering rack and bushings replacement - In Progress
-ball joint replacement - Old ball joints off
-lower transmission mounts replacement - Front mount replaced
-front sway bar bushings
-hood struts
-detail clean interior
-fix tachometer
-19mm RSB swap
-Water pump replacement

[ARIO98zx2]

wow nice work. I have a long list of stuff I have to do on mine buuuut I gots no time working 12hr shifts 6 days a week. then, as always, no money right now
but good job nate

[Jesusfrk611]

-find clunk in driver front end and fix - Found to be ball joint
-5th gear swap - Done
-Curt hitch install - Done
-swap LED reflector for unLED reflector - Done
-trunk lid interior cover - Done
-passenger door lock actuator replacement - Done
-more dynamat in the doors - Done
-fix up some wiring - Done
-fog light condensation - Done
-replace battery terminals - Done
-timing belt and pulleys - Done
-Esslinger UDP and Gatorback belt - In Progress
-steering rack and bushings replacement - In Progress
-ball joint replacement - Old ball joints off
-lower transmission mounts replacement - Front mount replaced
-front sway bar bushings
-hood struts
-detail clean interior
-fix tachometer
-19mm RSB swap
-Water pump replacement

I got my swaybar bushings and endlinks for front and back. Of the major things to do left, dropping the subframe for the swaybar bushings and getting that transmission mount replaced will be next. Bought a water pump to do as a maintenance item since the serpentine belt is off anyway.

New battery terminals.


Working on timing belt.


Fog light wiring rerouted, cut off butt connectors and soldered/heat shrank, and tied it all up.



Little bit more Dynamat. Still need to test for rattles with the door panel on, I don't like to do that when the parents are home though.


Timing belt installed. That sucked. I hope I got it right because I don't want to do it again for quite some time. My dad made a timing peg for the crank TDC. Made it a lot easier.

[Jesusfrk611]

-find clunk in driver front end and fix - Found to be ball joint
-5th gear swap - Done
-Curt hitch install - Done
-swap LED reflector for unLED reflector - Done
-trunk lid interior cover - Done
-passenger door lock actuator replacement - Done
-more dynamat in the doors - Done
-fix up some wiring - Done
-fog light condensation - Done
-replace battery terminals - Done
-timing belt and pulleys - Done
-19mm RSB swap - Done
-Esslinger UDP and Gatorback belt - In Progress
-steering rack and bushings replacement - In Progress
-ball joint replacement - Old ball joints off
-lower transmission mounts replacement - Front mount replaced
-front sway bar bushings
-hood struts
-detail clean interior
-fix tachometer
-Water pump replacement

Although it would be nice to have, I think I may end up giving up on the hood strut idea. Still can't really find what I need to mount it to the hood.

I broke the head off my dipstick, so I gotta grab a new one of those.

Swapped on the 19mm RSB. It's amazing how much lighter the 19mm is than the 21mm. Hopefully that should stop the snap oversteer. 21mm RSB is for sale if anyone wants.

[Jesusfrk611]

-find clunk in driver front end and fix - Found to be ball joint
-5th gear swap - Done
-Curt hitch install - Done
-swap LED reflector for unLED reflector - Done
-trunk lid interior cover - Done
-passenger door lock actuator replacement - Done
-more dynamat in the doors - Done
-fix up some wiring - Done
-fog light condensation - Done
-replace battery terminals - Done
-timing belt and pulleys - Done
-19mm RSB swap - Done
-front sway bar bushings - Done
-lower transmission mounts replacement - Done
-Esslinger UDP and Gatorback belt - In Progress
-steering rack and bushings replacement - In Progress
-ball joint replacement - Old ball joints off
-hood struts
-detail clean interior
-fix tachometer
-Water pump replacement

Got the subframe down and got the transmission mount replaced and did the bushings and endlinks for the front sway bar. Now I need to get my tie rods off the old steering rack and get them on the new one and then get the subframe back up somehow... My dipstick broke somehow as well, so I got a replacement.

[Alwayssideways]

break the nuts off the rear trans mount and tack them on the other side. That way you wont have to raise or lower the engine to get that mount in and out .

[Jesusfrk611]

I thought about it, but it sounds like too much work now. If I ever do replace that mount again it won't be for awhile and by then I might have my own house and a garage and a daily driver so the ZX2 can sit around undone for awhile. I'm ready to get the car back on the road soon now. My left leg and right hand are both getting bored of driving an automatic.

[Alwayssideways]

lol ,, ok . Im glad I did it because I pulled the es insert out of mine when I swapped in the mfactory, and ended up wanting it back in after the fact and it made the swap in pretty easy

[Jesusfrk611]

Yeah, I won't be putting inserts in anytime soon. The car vibrates enough. Again, maybe when it is no longer a daily driver.

[Jesusfrk611]

-find clunk in driver front end and fix - Found to be ball joint
-5th gear swap - Done
-Curt hitch install - Done
-swap LED reflector for unLED reflector - Done
-trunk lid interior cover - Done
-passenger door lock actuator replacement - Done
-more dynamat in the doors - Done
-fix up some wiring - Done
-fog light condensation - Done
-replace battery terminals - Done
-timing belt and pulleys - Done
-19mm RSB swap - Done
-front sway bar bushings - Done
-lower transmission mounts replacement - Done
-steering rack and bushings replacement - Done
-ball joint replacement - Done
-Water pump replacement - Done
-Esslinger UDP and Gatorback belt - In Progress
-fix tachometer

Got the subframe back on Sunday evening along with the steering rack. Balljoints are on, they were being a pain... Had to find the washers for the steering rack hoses so it won't leak when I put new fluid in. Finally got those today. Drained the coolant and replaced the water pump. Got the cross brace back on for the transmission mounts. I was missing a stud for the manifold to cat I noticed when I went to remove the cat. I have no idea how it didn't have an exhuast leak. But I found a stud that threads onto it and a nut that was on the stud. Soaking them in PB Blaster. Had a hard time finding a new cat to exhaust pipe gasket. Mine has been taken off enough that it got mangled. AutoZone didn't have it listed under any year ZX2, so after ordering the wrong part the first time and then having them look around to find it, I finally told them to loo under Escort and there it was...

Need to hook up the hoses for power steering and hook up the steering column to the steering rack. I should have done it with the steering rack unbolted...so now I have to pull the steering column to connect the two. Not hard, but something extra. Once that's done I'll get the cat and crossmember back on. Need to put the pulley back on the water pump.

My shifter stabilizer bar got broke where everyone else's falls through. I left it in there and it got pulled too far down when we were getting the subframe back in. I put some JB weld on it and then put a small hose around the inside and put some RTV on that. Letting it dry and hopefully that will stay. I didn't want to make another 45 min -1 hour drive 1 way to the junk yard and back for a part that was just going to eventually break anyway.

I changed my oil the other day and noticed a small puddle of oil under the transmission and engine. Rear main seal or oil pan seal I think. I figured I had an oil leak somewhere. Looks to be coming out kinda faster than I thought it was, but maybe it's because the oil is new. Car hasn't been turned on since I parked it in the garage. But no time to get that fixed now. Especially if it's the rear main... I never had any problems associated with the oil leak, so I'll just check the level every so often and add oil if needed. I hate having leaks, but I'm kinda tired of working on the car. I want to drive it again...

I think I've always had some kind of coolant leak since I bought the car. One was at the sensor on the thermostat housing, probably at the housing to block as well. Replaced those awhile back, but coolant still vanished. There hasn't been any coolant in the overflow bottle in awhile now. Never had an overheating issue (one of the gauges on the scangauge is water temp so I can see exact temp). But there was a definite leak at the water pump. So hopefully replacing the pump fixed that leak as well.

All I really have left to do after finishing up the small stuff is the Esslinger UDP and belt and replacing the tach. Almost done. Hopefully no more goofy issues come up that keep me from finishing soon.

[Jesusfrk611]

-find clunk in driver front end and fix - Found to be ball joint
-5th gear swap - Done
-Curt hitch install - Done
-swap LED reflector for unLED reflector - Done
-trunk lid interior cover - Done
-passenger door lock actuator replacement - Done
-more dynamat in the doors - Done
-fix up some wiring - Done
-fog light condensation - Done
-replace battery terminals - Done
-timing belt and pulleys - Done
-19mm RSB swap - Done
-front sway bar bushings - Done
-lower transmission mounts replacement - Done
-steering rack and bushings replacement - Done
-ball joint replacement - Done
-Water pump replacement - Done
-Esslinger UDP and Gatorback belt - Done
-fix tachometer

Shifter assembly put back on. Serpentine belt on. Power steering lines hooked up to rack. Catalyst back on car with removed cracked heat shields, no more rattling ftw. The oil leak seems to have stopped, or at least it isn't anything that's leaking quickly enough to show on the ground. I haven't started the car since I did the timing belt. While I'm pretty sure I did the timing correctly, I will see tomorrow when I start the car up again.

I'm still detail cleaning the interior this summer, just not right at the moment so I took it off the list. Only other things I need to do is cycle power steering fluid and coolant, reinstall all splash shields, swap the tach, and put the interior back together.

Sorry I've been too lazy to take any pictures right now if anyone is still watching my thread. Been kinda slow about getting stuff done this past week anyway. Mostly just getting stuff put back together.

[EnergyBlue98]

u seemed to have forgotten the turbo on your to-do list.

[Jesusfrk611]

Nope. That was purposely left out. I need a reliable daily driver. Very few turbo ZX2s are reliable. Turbo will never be done to this car. I'd like to grab an NGP0 and with 2 recently in the for sale section I almost bought one, but I can't spend any more cash on my car at the moment.

[Alwayssideways]

Nope. That was purposely left out. I need a reliable daily driver. Very few turbo ZX2s are reliable. Turbo will never be done to this car.

Quoted for troof. Nate I am on the same page.