Alias, thanks again for the info. Today I had the car parked and running and I finally remembered to hang my head out the window and play with the clutch a little. Could hear the TOB for sure due to the difference in noises made when clutch pressed and not pressed.
The engine still makes a weird bucket of bolts coming to rest kind of noise when you shut the engine off, both when clutch pressed and not pressed, but it could still be related to TOB. The nice thing was that with the clutch pedal held in, and light revving, I couldn't hear any noise except the normal Zetec noises. Clutch pedal out with light revving, could clearly hear the TOB.
I wonder when this thing will crap out. I have noticed that the clutch feel is not what it used to be, but it is still working ok. If it goes will it go suddenly or start to slip and become more and more obvious? I don't want the wife getting stranded in it somewhere before I can get around to fixing.
BTW, how much for the clutch kit?