Monday, December 15, 2014

204E / 206E Replacement Gaiters

Applicable to the MK2 Zodiac, Zephyr, Consul '56-62.

English Ford p/n: E 125-GD-2. Inner dimension: 2 1/8" x 2 1/8" x (1 11/16" fork cut-out).
Ford p/n: C30Z-7513A. Inner dimension: 2 1/4" x 2 1/4" x ( 1 1/2" fork cut-out).

These Gaiters are used in the English Ford made Dagenham 4 speed transmission for the "62-'65 Ford Fairlane, Falcon, Mercury Meteor, Comet 144ci / 170ci 6 cylinders  64 1/2- 65 Ford Mustang 170ci / 200ci. 6 cylinders.
U.S. Ford offered three types of Dagenham transmissions which are L/H side-loaders p/n: 212E-7006F.
Dagenhams are similar to the English Ford 211E/213E and U.S. 3 speed 2.77 / 3.07 trans  ( designations are not gear ratios).

Replacement Gaiters are easily sourced from Ford parts suppliers, or ebay. $15-$24. They fit tightly in the Bell Housing and Fork. Smear vaseline on the Gaiter for easier installation, being careful not to poke thru the rubber. Use a worn, wide-blade screw driver to help maneuver the gaiter into place.

This replacement Gaiter may not work on the EOTA / EOTTA and 211E /213E Bell Housing. Measure the Bell Housing opening and Clutch Fork. I don't have access to these types.
Left hand E 125-GD 2 / Right hand C30Z-7513A

Left hand E 125-GD 2 / Right hand C30Z-7513A

Installed C30Z-7513A Gaiter in 206E bell housing

Sunday, November 30, 2014

Vented and Non-Vented Gas Caps

 There are two types of fuel tank caps that are available: vented and non-vented.
A non-vented cap will cause fuel feed problems if your fuel tank is not vented. So you must use a vented gas cap, otherwise it will put a strain on the fuel pump, particularly compact solid state electric fuel pumps will fail in no time. Vented caps let in air to take up the used fuel and relieve internal pressure build up in non-vented tanks. Use the correct cap for your particular model.

Vented systems are ones that vent fuel fumes to the outside air thru either a vented cap or vented tank.
Modern closed systems are ones that reuse the vapors that fuels put off by recirculating it back into the fuel system by ways of an inline purge valve, or a type of a carbon canister system, or any other means in a closed  system thru an internal fuel vent. In 1970, Cortina MK2 in North America came with non-vented caps for a closed evaporative emission system.

Below is a list of English Ford vented and non-vented caps:

100E series:  Non-vented tank. Vented caps: EOA-9030 or Locking cap: E493A-9030.
105E series:  Non-vented tank. Vented caps: 105E-9030A or Locking cap: 105E-9030
105E Estate: Vented tank. Non-vented caps:  400E-9030A or Locking cap: 400E-9030B
307E series:  Non-vented tank. Vented cap  : 307E-9030.
109E Capri / Classic Consul.  Vented tank. Non-vented caps: 204E-9030A or Locking cap: 204E-9030B

EOTA / ETTOA: Non-vented tank. Vented caps: EOA-9030 or Locking cap E493-9030.
204E / 206E: Vented tank. Non-vented caps: 204E-9030A or Locking cap: 204E-9030B.
211E / 213E: Vented tank. Non-vented caps: 204E-9030A or Locking cap: 204E-9030B.

Cortina MK1 sedan: Vented tank. Non-vented caps: 400E-9030A or Locking cap: 400E-9030B.
Cortina MK1 Estate: Vented tank. Non-vented caps: 113E-9030A or Locking cap: 3014E-9030C

Thursday, October 16, 2014

Kent Engine series Water Pumps and W/P Pulleys

Two types of water pumps (w/p) : 105E and uprated Capri / Pinto 1600.

105E type:

W/P: Ford p/n: 105E-8501A. Quinton Hazel p/n: QCP-181.
Dimensions: Hub 2 5/8". Center of Hub 3/4". Hub bolt holes 3/16". Shaft diameter: 1/2".

W/P Pulley:  single groove w/o emission p/n: 105E-8509B. double groove w/emission p/n: 2737E-8509B.
Dimensions: width 4 1/4". height 1 7/16".

All U.S.A. EnFo imported models are equipped with the 105E type w/p's:
Anglia 105E, Prefect 107E, Consul / Classic / Capri 109E, Cortina MK1/2.

Cortina MK2 Master Parts Catalog lists W/P p/n: DORY-8501A and with DORY-8509B W/P pulley.
This is an uprated W/P version ( and matching pulley ) of the 105E W/P and not supplied on smog equipped models.

Uprated 1600 type:

W/P: Ford p/n: DORY-8501A. 691F-8501AA. 682F-8501A. Quiton Hazel p/n: QCP-730.
Dimensions: Hub 2 5/8". Center Hub 15/16". Hub bolt holes 5/16" Shaft diameter: 5/8". Heavy Duty Casting. On 711M block and after.

W/P Pulley: p/n: DORY-8509B
Dimensions: width 4 1/4" height 1 5/8".
Left to Right: p/n 2737E-8509B, p/n 105E-8509B, p/n DORY-8509B

Left to Right:  p/n 105E-8501A, p/n DORY-8501A

Water Pump Spacer p/n 2730E-8A645A

105E Pump with Spacer

Uprated W/P can be a replacement for the 105E W/P. You would need to use the matching DORY-8509B
pulley and enlarge the center hole of the fan blade to 15/16" and increase the bolt holes to 5/16".

A fan blade spacer p/n: 2730E-8A645A provided for the Cortina MK2. This part is not listed in the Cortina "C" Master Parts Catalog. The spacer should be installed on all MK2 105E type W/Ps either for metal or plastic fan blades.

All impellers should be made of metal, cast iron or steel, some after market 105E type W/P's had plastic impellers-don't use. They will come loose or melt from high heat.

Friday, May 30, 2014

204E Fuel Sender Units

EnFo p/n: 204E-9275A/B/C

For:    '59-67 Anglia 105E sedan
          '61-64 Consul Capri / Classic
          '56-62 Zodiac / Zephyr / Consul sedan.

Unit Manufactures / Type:   Float Sender Unit. Resistive wire wound Bobbin, Single Sweep.
    - Smiths T.F. 1000/23 WET   EnFo p/n: 204E-9275A
    - AC  7228816 12V D5         EnFo p/n: 204E-9275B
Replaced by 204E-9275C. I assume that T.F. means mounted on top of fuel tank-WET, submerged.
AC/Smiths units are interchangeable.

Rebuilt 204E Fuel Sender Unit
Unit Manufacture specs:    Resistive range: 12-22 Ohms to 240-290 Ohms (depending on the # of wire turns on bobbin and condition of the unit)                              
Wire type: Nichrome #34 .006 diameter. approx. 20 Ohms per foot non-magnetic.
Wire length: 14 ft. 200 turns.

Typical failures: Intermittent, corrosion, worn or damaged, and unit not grounded. Check that the unit is properly grounded to the body (there should be a ground wire from the sender unit mounting screw to the body/chassis) before removing the unit.

Removal:  Remove unit from fuel tank. Remove the access plate from the unit (two screws or two tabs) Corroded/stuck units should be soaked in a cleaning solution ( DO NOT SAND-BLAST). Discard units with excessive corrosion on the aluminum body that has worn thru. Units in decent shape with moveable parts are more desirable. Check the float for small holes or fuel inside. Repair holes with silver solder and flux, if necessary.

Corroded Unit but bobbin in good shape
Condition: Check the condition of the wire-wound resistor, sweeper contact, wire connection to the terminal. Clean the face surface of the wire-wound resistor with a cleaning solution/acid brush.

Connect a digital Ohm meter, one probe to the body of the unit the other probe to the spade connector. Move the float arm slowly from one end to the other end. A steady reading of approximately 12 ohms to approximately 290 ohms.

Corroded terminals should be removed by drilling out the rivet on the top connector side. Replace worn parts. Re-attach with a 1/8" x 5/8" long aluminum pop rivet.

Re-Winding Resistors: This procedure will require a NZ-1 winding machine. NZ-1 has been modified  to accept a bobbin. It's nearly impossible to re-wind by hand. I will show you how I accomplished this.
NZ-1 Manual Winding Setup
Mounted Bobbin wound with Kanthal
Arm removal with punch and hammer
Installing arm. Place arm in vise. Tap on sweeper stud.
Remove the arm/float assembly as shown (mark the position of the arm).
Remove the sweeper assembly (detach the braided copper ground strap, if there)
The bobbin is safety crimped in its guide. Carefully remove the safety tabs. Cut the wire to the terminal. Carefully remove the bobbin. You may have to move it back and forth until loose. Use WD-40 if needed. Remove the resistive wire. It may come off in sections. Total length 14'.

Alternative Resistive Wire:   Kanthal A1 #34 gauge (.006 diameter ) 21.1 ohms per foot. Magnetic.
Kanthal resistive wire: chromium, aluminum, Iron.

Nichrome and Kanthal cannot be soldered with a typical soldering iron, unless excessive heat was applied. So, wrap the end of the wire a couple of times around the interior terminal. Apply electrical solder to the terminal covering the wrapped wire completely with solder.

Result:  165 turns on the bobbin and installed in the unit came to 22 ohms to 242 ohms.
I sprayed some EL601 Red Insulating Varnish on the coil but the fuel washed it off. So leaving the wire bare did not effect the resistive range. Also, I didn't attach a braided copper wire from the sweeper rod to casing ground as i figure that the cover plate notch should press against the top sweeper rod for grounding. Some units had the ground strap missing or broken in that case the unit still worked properly.

Friday, August 23, 2013

Lucas Reproduction Distributor Rotors

Beware of Lucas reproduction rotors that have the troublesome rivets that holds down the brass contact to the plastic body. These are known to short circuit causing misfiring or complete ignition failure. There is insufficient insulation ( on some versions only 1/16" plastic material ) between the bottom of the rivet and distributor shaft.
The original Lucas rotors brass contact was recessed or molded into the plastic body which did not provide a rivet.
I cut a few rotors in half along side the rivet and found that the distance between the base of the rivet to the distributor shaft was only 1/16". In that case, high voltage ignitions would easily short circuit across to the distributor shaft. Most reproduction rotors do not have an inner spring clip and could fit loosely on the shaft causing it to wobble. This will make contact with the distributor cap contacts, assuming the shaft bushing is not worn.

There are quality reproduction rotors available i.e.

Tuesday, April 9, 2013

Crankcase Ventilation Separators

Positive Crankcase Ventilation before 1963 was through a draft tube.

The following year a separator to remove the engine oil and return the blow-by gases back into the engine via a PCV valve.

Between 1964-1967, there are two types of separators and matching fuel pumps  for the Kent series engines:
1) In/out baffled internal drain separator and AC fuel pump with non-drain tube.
2) In/out baffled separator with external oil drain outlet and AC fuel pump with oil drain tube.

Internal drain separator can be used for either AC fuel pump. Just plug the AC pump drain tube.
External drain separator is only used with an AC pump with a drain tube. Do not plug the separator drain tube when installing a different fuel pump. This will fill the separator with engine oil thus making it dysfunctional.

An excellent explanation on Engine-Breather Systems by Burton:

Monday, March 4, 2013

Speedometer Cable Housing - Plastic End Fittings

Some English Ford speedometer housing cables have plastic end fittings which attach to the transmission by a metal fork. The plastic fittings will eventually warp by heat and pressure from the attachment fork.
( Replace speedometer cable assembly if the plastic fitting is loose around the cable housing )

Warped plastic ends will cause oil leaks even silicon sealant won't solve the leaking problem.
To resolve this defect without replacing the housing. Use a 1/16" thick washer 1  3/16" x 5/8" cut off a 3/8"
section so it would slip past the housing. Apply a bit of sealant to the plastic fitting face.  Place the washer
cut out end up, against the plastic fitting and tighten the attachment fork.