This may be an old thread, but I must say that it is a very useful one. My number 2 project has had a dodgy clutch since the day I test drove it, engaging immediately the pedal was moved from the floor. I knew it wasn't right, and figured it just needed a spacer block put in, as it was orginally a 1.6L car and now has a Pinto in it. Well last week it completely died, and after towing the car home I started pulling the gearbox out using the long bolt method described above.
What I found inside the bellhousing surprised me, and some of it I would not have known to look for but for the contributions of others here. The clutch fork was bent (handy having a spare to compare it to), some plastic parts of the throw out bearing were broken (tip - always use an all-metal bearing), the bearing itself was the wrong type for the fingers of the pressure plate (learned that here), and the spacer block used with Pinto motors looked home made and was extremely loose (bolt was practically free).
While the gearbox was out I figured I'd drain the oil seeing I had no idea how long it had been in there. It was grey and miserably looking, so I'm glad I did, but I nearly blew it by using GL-5 spec oil. Never use GL-5 oil in a Type 9 (or Type E etc.), even if it is marked as GL-4/GL-5; read this for why:
http://www.widman.biz/uploads/Transaxle_oil.pdf. I eventually found a correct GL-4 spec oil at a local distributor, which was a pleasant surprise. I'm hoping it also improves the shift quality when the trans is cold.
The new Cortina speedo drive made by First Line is the prefect length to use with a Type 9 in an Escort, but the flange is too thick to use the factory retaining circlip, so a bodge was needed to stop it falling out (cable ties to the rescue). I also found a split steering gaiter, so had to replace that and refill the rack with fluid. Of course the tie rod end was practically welded to the strut, so I had to destroy it in the process of getting it off. The radiator was pretty worse for wear, so a quick sandblast of the frame to get the rust off and a new paint job later and it at least looks better. I also put in a new gearbox saddle bush, which tightened up the shift a bit and reverse is now finally locked out. The cheap bushes on ebay are likely to have flashing on the bottom like both mine did, so if you buy one be sure to check and cut it off before fitting.
Everything apart from the radiator is back in, and a quick test of the clutch has revealed that it feels completely normal now, with take up somewhere in the middle of pedal travel. What started off as a fix for a dodgy clutch sure consumed a lot of time (and curse words seeing I did it mostly single handedly), but it's a relief that it's done and has been done right the first time. So thank you to all the contributors to this thread, which helped me enormously. A special thanks goes to Ash who graciously welded a strengthening plate to my replacement clutch lever, thereby eliminating another bent fork in the future.