Here's the story:

I bought a 1999 Escort ZX2 on Craigslist. All that it needed was the timing belt replaced (so he said).

Long story short is that I have replaced:
- timing belt
- timing belt pulleys and adjuster
- passenger side CV axle
- coil pack
- spark plug wires
- cam position sensor
- crank shaft position sensor
- battery

It finally starts and runs, but here comes the rub. Whenever I push the clutch pedal down, it bogs the motor down and sounds like something is rubbing. I'm assuming that something is wrong with the clutch, but I don't know what. It will shift into reverse and 1st gear for sure. I'm too nervous to road test it yet.

Any suggestions. I have already invested more money into the car than I paid for it...

 

One of the things that is involved when the clutch is depressed is the clutch release bearing and that could very well be the cause of the noise. A close inspection from under the vehicle with the lower flywheel cover removed may make the diagnosis a little easier. Depending on just how bad the noise is may allow you to drive it around the block a few times to test all your other work.

 

I agree with Hanky.
Does the noise go away when you get off the pedal and come on as soon as you step on it? That would indicate that the release bearing makes the noise. If that is the case you certainly can go further than just around the block, but don't get into stop and go traffic.
It looks like you bought a project but these cars are tougher than they look and you took care of a lot of basic maintenance.

 

There is no noise as long as I'm not pushing on the clutch pedal. As soon as I start pushing on the clutch, it starts making the noise. If it is the clutch release bearing, how big of a job is it for a "shade tree mechanic" such as myself?

 

Depends on what you would call a big job.
The trans has to come out to get to the clutch assy. If you have all the equip it isn't too bad. Otherwise consider having it done by a shop with the equip.

 

I finally got it running...as you can imagine, I found more than I bargained for. I ended up pulling the motor and transmission out to make it easier to work on. I found the throw out bearing bad, the pilot bearing was totally disintegrated, the clutch plates were pretty worn, etc.

I sunk a good chunk of change into this car, but it runs pretty good. Just ran the 1st tank of gas through it and got 31 MPG. The only thing left to get fixed is the AC, and I'll hire a professional for that.

Thanks for the info gents.

 

Update:

I just got the AC recharged yesterday, it only needed to be vacuumed down and then recharged. Everything is holding so far. Things are looking up. Thanks for the information.

Gas mileage on 2nd tank is 33.5 MPG.

 

Glad you were able to do what needed to be done.
You didn't provide the present mileage, but it has to be up there. From the sound of all the work you had to do so far , don't forget to check the lube in the trans, I would almost bet the former owner never did. At least now you know what you have and can drive without concern as to what will go next.

 

Mileage on the car is 152,250 miles.

In addition to the original parts list, I replaced:
-serpentine belt
-radiator fan motor
-valve cover gasket
-spark plugs
-thermostat
-water pump
-all the radiator hoses
-power steering pump and high pressure hose
-all but 1 motor mount
-shift rod bushings
-clutch plate and pressure plate
-pilot bearing
-throw out bearing
-front and rear main seals
-both ball joints
-front brake pads (turned the rotors)
-air filter
-oil filter
-wiper blades
-ALL new fluids (oil, coolant, transmission, etc.)

It still idles a little rough when it gets warmed up, but I have a few more things to try to get that smoothed out.

Other than that, I have a practically a new car (under the hood). The outside is not so pretty, but I bought it for the MPG and not the looks.