I have a manual transmission in my 2002 Ford Focus.  I've read many of
the postings on this newsgroup about how difficult it is to remove the
pin.

I purchased a new VSS to install it.  I have the factory manual and two
third party manuals: Chilton, Haynes.

The problem is I cannot find any information on what I'm supposed to do
with the flat metal clip that goes from the VSS pin to what looks like
a hole by where the VSS plugs in.

Question: Does this flat clip actually go into the hole to keep the pin
in place?

Question: Do I simply pull the pin out from where the VSS plastic hook
meets it and yank the flat metal clip with it?   I'm asking, because it
looks like the flat metal clip will prevent me from pulling the pin
out.  And so do I need to first bend the metal clip up and then pull
the pin out?

The Ford dealer wants between $100 and $200 in labor to remove this
pin.

If this is going to be a massive pain, I would rather just be robbed by
the Ford dealer.

You have me worried, I have a 2002 Focus also ,Question what is the VSS?
And where is it located... ? thanks SF

VSS = Vehicle Speed Senor

Located on the transaxle (transmission).

VSS = Vehicle Speed Sensor

Located on the transaxle (transmission).

Hopefully you got a new pin when you got the VSS? If not I would advise
getting one before you start as the chances are you will destroy the old
pin during removal.

Using a pair of pliers, bend the flat clip out of the way. (It does not go
in to the hole; it just presses on the casting.) It will probably detach
itself when you do this. Grip the pin with a pair of side-cutters close to
the transmission housing and then use the side-cutters to lever the pin
out. You will have to keep repositioning the side-cutters along the length
of the pin as it gradually moves.

Others have suggested clamping mole grips on the pin, then tapping the mole
grips with a hammer. I tried that, but it didn't work for me. YMMV.

Once the pin is removed the VSS is still a bit hard to get out. It has two
O-rings on it that make it a tight fit in the housing. DO NOT be tempted to
try to knock it upwards with a drift and hammer. This might result in the
sensor breaking, leaving half of it in the hole!

In the limited space available wrap a piece of rag around the sensor and
rock it GENTLY from side to side and twist it as you pull upwards. Take
your time and it will eventually come out.

I agonised for ages before tackling mine, but once I took the plunge I did
it in less than 20 minutes.

Post back to let us know how you get on.

Chris

--
Remove prejudice to reply.

Thanks.

Would you happen to have the Ford part number for the VSS pin?

I got a pin, it was the only one in the Ford parts picture for the VSS,
but it doesn't match what Chilton indicates it should look like.

It is just a rolled up sheet of metal (a rolled "U" shape), while the
Chilton drawing makes it look like something more substantial.  The
number for the pin I have is W525729*S300.  This for VSS part number
YS4Z-9E731-AB.  I have a manual transmission (Ford Focus SE - 5 speed).

It's a roll pin AKA spring pin.  They're supposed to look like that.
I'd be very cautious when thinking of putting my trust in a Chilton's
manual over the Ford parts fiche.

I replaced the VSS, and that was the problem :)