Ford Focus Forum banner

1 - 20 of 20 Posts

·
Registered
Joined
·
721 Posts
Discussion Starter #1
Introduction:
Okay, so I have just fallen victim to the infamous busted DSI Clip. The part costs $9 bucks and wont be available till Sept...mine is on order. Other than that, you can buy a whole new $260 manifold to get the $9 part. Ummm...no.

Thanks to a thread posted on FocusFanatics, I got some direction on how to fix this...but it had no pics. So with camera in hand I did the job to keep me happy till the new part shows up. (oh yeah, this is my first post of a new thread, and a how-to...go easy on me)..also, my server is gettig a lot of traffic these days, so the imgs may take a minute to load, or a refresh maybe in order.

Lets Go!

First thing is first....grab your tools and take out your intake...meaning your filter box/short ram/etc. NOT the entire intake just the filter and box or heatshield.

If it is stock, you will need to take the entire box out...open it up, take out the filter, unbolt it from the car and pull it up out. You may also want to take the MAF off the side of the box as well so you can just move the hose out of your way and not have a huge plastic POS hanging on it. In my instance, I had to take out the heatshield from my short ram and remove the maf from the side of the shield to pull it out.

Amongst a set of sockets and a screw driver or two, you will also need a dremmel or drill, a set of pliers/vice grips/vice.....I used a pair of needle nose pliers.



Once you have that outta the way, stand on the drivers side and look down in at the side of your manifold, right around where the Throttle Body sits...you should see the DSI "Actuator" and a dangling cable w/clip.

See how that cheap crap broke? [:0]
You should see a dot at the top of the actuator, where the post once was....the clip snaps onto the actuator right there.

Here is a pic of the broken post...I popped this out of the clip on the end of the cable using a flathead screwdriver:


and this little gem will be it's replacement:

check that it is the same thickness on the post.

Now grab that screw with a pair of pliers/vice grips/vice and grind it down with a dremmel so that the head of the screw matches the same diameter and thickness of the posts head....go a little at a time and check to make sure it fits snug, not loosely, into the clip.

Here is my grind on the screw head...I also cut it shorter so it didnt hang out too far from the side of the actuator:


If you dont have a dremmel, you should really buy one..they rule. But you can put the screw into a drill chuck and use a file to "lathe" it down. [;)]


Almost there, can you feel the suspense?!

Aight, now you gotta go back to the actuator and pilot a hole for that screw...and make sure its not a bigger hole than the the screw with wide...duh. I used a dremmel cause it fit nicely in there and I didnt have to try to wiggle that actuator out of its home.

Lol, here's a picture of my hole...



I am sure you can see where this is going....screw + hole =



If you did it right, the screw should go in snug. You can reinforce it with some epoxy if you like. But now all you have to do is rock the actuator forward a little and snap the clip over the head of the screw and you are done! Drive your car around and enjoy the satisfying sound of your dsi switching over again. [thumb]

Hopefully this helps ease your frustrations while waiting for those parts to become available. Hell, you could also use this as a guide when you go to replace the part!

Happy motorin'
 

·
Registered
Joined
·
674 Posts
Nice how-to! If mine ever breaks im sure i will be using this.
 

·
Registered
Joined
·
3,022 Posts
Hmmm...interesting idea. I wonder what the longevity of this fix will be.

Relatively off topic, but someone definately needs to get some more of those aluminum DSI clips made. I'm kicking myself in the head for not getting in on that at the very last minute.
 

·
Registered
Joined
·
1,874 Posts
Most excellent post. Folks should note that this was done while the new part is on order. I don't think sleestak is claiming to have engineered the part the way Ford shoud have done it.

May I suggest a clarification?
First thing is first....grab your tools and take out your intake.
This could be construed as meaning the whole intake manifold (since that's what the Ford service department is instructed to do). It's pretty clear to me that you mean the air filter box. You might want to clear that up, up front.

Thanks for the great pics on an important topic; this is why FocalJet is such a great resource!
 

·
Registered
Joined
·
1,874 Posts
just a bump to put all three DSI threads next to each other
 

·
Registered
Joined
·
721 Posts
Discussion Starter #8
thanks all...glad I could contribute. I will make that change, as requested MCSguy.

PhocusZX3 - I was wondering about th longevity of it as well, but if you drill your hole the right size and screw that bear in there tight, I dont think its going anywhere...if anything the plastic would break again. I mentioned using Epoxy to top it off and strengthen it a bit, if you are concerned, but it seemed pretty sturdy to me. Once you get in there and actually flip over the dsi by hand, you realize that it moves with relative ease.
 

·
Registered
Joined
·
721 Posts
Discussion Starter #9
Got the new part from ford today... Its STILL PLASTIC!! lol, dontcha love ford?

Anyways, it will sit on my shelf till mine breaks. To be quite honest though, I think my fix will last longer..haha. I may actually take the new one and put a metal post on it as well.
 

·
Registered
Joined
·
19,113 Posts
That is almost exactly what I did to mine several months ago.

The only difference is I used a machine screw and I filled the hole with two part epoxy before putting the screw in.
 

·
Registered
Joined
·
167 Posts
Thank you for this write up, This is the second time this has happened to me, however, unfortunately I'm not under warranty this time. It's a big help, you are the man.
 

·
Registered
Joined
·
246 Posts
Thanks for the great post. Mine broke recently. I printed out your post and my brother helped me machine a new stud very much as you wrote it up. Repair made and so far it's holding up


Thanks again- very, very helpful!

Dave
 

·
Registered
Joined
·
4,662 Posts
I dunno about the whole screw thing. I think they started selling just the one part for like 7 dollars. Call steve at Tousley Ford!

You have intake runners that open at 5000 or 6000 rpm. It opens them. I will let you find out what it does once you get it fixed
You will notice a difference
 

·
Registered
Joined
·
200 Posts
I just ordered one from Sunnyvale Ford for $9.42 The guy told me it will be there tomorrow morning!

Apparently the DSI Lever on my SVT has been broken since I purchased it. Can someone please explain what the DSI lever does/How it works? I never had the pleasure of driving with one on my SVT.
 

·
Registered
Joined
·
19,113 Posts
I just ordered one from Sunnyvale Ford for $9.42 The guy told me it will be there tomorrow morning!

Apparently the DSI Lever on my SVT has been broken since I purchased it. Can someone please explain what the DSI lever does/How it works? I never had the pleasure of driving with one on my SVT.
I hope it really shows up for you, They are on national backorder with an estimated release date of 11-15.

The DSI (dual stage intake) basically uses two different sets of runners in your intake to optimize the airflow for high and low rpm operation.

At low speeds the DSI holds the intake in the low speed position, once you get past 5000 or so it switches to the high speed runners.

When the DSI lever breaks the intake defaults to the high speed runners and kills your low end power.

You will be amazed at the difference when it is working.
 

·
Registered
Joined
·
200 Posts
I read a post on ff that said on early model SVTs you can't just replace the broken DSI lever. Instead you have to replace the entire intake manifold, newer models got a different intake manifold that made it so you could just replace the DSI lever if it breaks. Is this correct?

Can I use the DSI lever I ordered on my '02?
 

·
Registered
Joined
·
19,113 Posts
I read a post on ff that said on early model SVTs you can't just replace the broken DSI lever. Instead you have to replace the entire intake manifold, newer models got a different intake manifold that made it so you could just replace the DSI lever if it breaks. Is this correct?

Can I use the DSI lever I ordered on my '02?
NOT TRUE,

As far as I know all SVTF's use the same DSI lever.

I drive an '02 and mine looks exactly the same as the replacement levers.

It is true that up until about 3 months ago you could not buy the levers from Ford, They only came with the intake manifold.

It took Ford a while to figure out they were losing thier butts replacing complete intakes because of this little lever, but they finally figured it out.

Now if we can just get them to provide the DSI lever spring that people now seem to be losing.
 
1 - 20 of 20 Posts
Top