Gearbox

 

Any ford box will fit, ideally use a 2.8 Capri/XR 4 box (5 spd) because the ratios are fantastic (just drive a 2.8 Capri and you will see!), but first gear may not be ideal. This box has a slightly longer input shaft that will need shortening to fit (same dimension as the shaft from a 1.6/2L Type 9). If you use the Raceline kit there is space to fit a 30mm spacer which will allow an unmodified V6 gearbox to fit and should also line up perfectly with your existing mount and lever hole.  The Capri box is used to 160 bhp (205 bhp on the Tickford Capri) so should be strong enough. 

 

You can use the later sierra/Granada MT75 Gearbox or Cosworth T5 but you will need to enlarge the gearbox tunnel and the Granada MT75 (and Granada type 9s) use electric speedos!

 

You can use the lighter RS2000/Mk 2 Mexico bell housing to save weight, but it isn't essential.

 

Gearbox Tunnel

 

If you are going for a 5 spd Type 9 I reccomend fitting a larger gearbox tunnel.  You don't have to but it will really help and you and you will be really glad of it when you come to change the clutch.  Large gearbox tunnel cost approx £40 from TJ Motorsport and I fitted mine in an afternoon.  You will have to adapt the gearbox mounts regardless for a 5 spd conversion.  Using a Sierra or Granada gearbox crossmember helps.

 

Quick Shift Kits

 

Most people say you should fit a quickshift kit with a 5 Spd as the normal lever clashes with the handbrake.  I'm not sure if it's true or not but a quickshift is a good buy regardless.   This one was from Rally Design  and was just over £40, you can't go wrong.

Flywheels 

There are kits from Dunnell, Burton, Tiger and Raceline amongst others involving different lightened fly wheels that except Pinto or CVH clutches (cheaper, lighter and more upgrades available). Lightened flywheels do not add power, but do allow the engine to pick up revs faster.  For road use a lightweight flywheel will probably give you more idle problems than is worth. 

All the ZETEC flywheels fit each engine, with the 1.8 flywheel being the lightest so a worthwhile swap.  Beware, some companies sell so called lightened flywheel, they are just 1.8 flywheels!!

The fly wheels can only bolt on the in one way so make sure you put each bolt in a few turns before tightening them up as sods law the last one wont fit.

Always use new fly wheel bolts and use a small drop of loctite to be safe.

 

Clutch

 

You can hybrid a Mondeo/Escort clutch with a pinto clutch if you are on a budget.  Remember that ZETECs have hydraulic clutches so they will be heavy if converted to cable operation.  RetroFord offers a modified ZETEC flywheel re-drilled for a pinto clutch. 

Flowtech and Retroford offer an alloy mount (fits to the spare starter hole on an RS2000 bell housing) for the clutch cable.  The 1.8 ZETEC flywheel is the lightest and a quick and easy swap for your 2 lt and 1.6 lt.

Apparently you can use the 1.8 ZETEC flywheel and clutch cover, a sierra 1.8 CVH friction plate. Then use a ford spigot bearing, and by changing the clutch release bearing to a capri part CT133 Quinton Hazel it will all work fine with a Type 9.

Pinto clutches are approx half the price of a Zetec clutch so make sense as the money saved will pay for your flywheel to be re-drilled.

Starter Motors

 

The original starter will not fit  a RWD bellhousing so you will need to adapt a pinto starter or use the Ford DOHC starter.  If you go for a lightened flywheel from Raceline, Tiger or Burton you can choose the ring gear to suit any ford starter.  CVH, Pinto and Crossflow ring gears are all the same so you can use your existing starter as long as it is a pre-engaged type.