wheel FORD CAPRI 1974 Service Manual

)8 Chapter 10 Suspension and steering
Power steerin g gear Type .. Steer ing wheel turns (lock to lock) lubrican t Iype, Lubricant capacity . Fluid Iype .
Fluid cilpacily: Sepilrilte reservoir . Integli!1 reservoir .
Front wheel alignment C",nbc, M;lXll11um dlffcrence side \0 side C<lSlor M,.xirnunl dtffcrence side \0 side . Toe·in
-yres SllC . <;JSsu,es Illl/m' (~(Jflclll&#39;). 185170HR13: Up to 3 persons . More than 3 persons. 1 B5170VR13: Up to 3 persons . More \h,1I1 3 persons. 205/60VR 13: Up \0 3 persons . More (h,m 3 persons .
195/50VR15: Up 10 3 pe.sons . Morc th(ln 3 persons.
Torque wrench settings Fran! SIIS{!cl!siotJ Stlut upper 1110untrng . P,ston rod nut Suspen Sion &#39;)~&#34;,{Jont St;rhiliscr birr mount"'lt . Stab iliser h;rr to track control ,)In,
Track cOIHlol ~rrn p,vot
,H'o1( slIspCIlsion od abso,bcr lower mountH'g .ock absorber upper mounting Stabillser bar to axle .. St;rl.lIlIscr har 10 underbody
U ·bol . Sprinu I.ont mount"'g . Spring rear sh;rckle
SINNing Steering gear (m~nual) Track rod end uall,oint Coupling shaft to pinion. Coupling shah t o column . Steering wheel.
Steering column.
Roa(/wiJec/s Wheel nuts/holts: Conicall;rce . FI(lt face.
General description
, -'The flonl suspension is of Independen t MacPherson Strut Iype incorpotating inleglal telescopic shock ~bsorbers and a stabilisel b~r. The ,eal suspens ion is o f semi ellip tic leaf spring·with· 'l ive ' axle Hydrau
l
ic assisted rack tlnd pinion 3.25 SAE 40 oil 0.20 litre (0.35 pint) AulOm<ll ic transmiSSion lIuid to ESWM 2C 33E. SaM 2C 9007 AA. or D2AZ 19 582 A
2.2 litre {3.9 pint} 0.5 lure (0.9 pinl)
1- 0 ' 30' I" O· I l' O' O ' 45' 01070 nun (0 !O 0 28 ",)
185170HR13. 185/70VRI3. 205/60VR13 o. 195f50VR15 Front Rear
23(1.6) 23 (1 6) 28 (20) 28 (20)
2<1 (1 7) 28 (2.0) 28 (20) 32 (22)
28 (20) 28 (2.0) 32 (22) 32 (22)
26 (1 8) 26 (1.8) 32 (2 2)
32 (22)
N'H Ibl It
20 to 2<1 151018 40 to 45
30 to 33 <11 to <18 30 to 35
28 to 33 21 to 211 21 to 61 15 to <15 25 to 30 18 to 22
53 to 63 39 to 11 13 27 to 33 20 to 2<1 40 to 50 301037 35 to 41 26 to 30 25 to 36 181027 35 to <11 26 to 30 11 to 14 8 to 10
20 to 24 15 to 18 24 to 30 18 to 22 16 to 20
12 to 15 231030 17 to 22 27 to 34 20 to 25 17 to 20 13 to 15
85 to 115 63 to 85
115 to 140 85 to 103
type, incorporating telescopic shock absorbers and ;l stabdiser bill. The steering is of rack and pinion type, but may be either m(lnual or power·assisted . The steering wheel incorporates 11 convoluted cam which is designed to collapse rn the event 01 (In accident to prevent
injur y to Ihe driver. It is not reco mmended that the power steering gear is dismantled on Ihis work is best entrusted to a specialist.
procarmanuals.com

162 Chapte r 10 S uspension and steering
)
Fin· 10.6 Front
@",.,i
, 5
Y 6
hub cOnll)oncnts (Sec 3)
12
1 0,1 seal 7 Diller be,?li/!{J Iwck 2 IIIlIcr bcaring wee 8 GUiN Iwmitlfl filct' 3 Inner bemiJlg /I,?ck 9 ThlllS! wilslwf 4 Screw 10 NIII 5 Disc 11 Sf"il (lin 6 H", 12 01151 C.1jJ
4 Remove the split pin frorn the nul rC\;linCf and undo the adluS\ing nul from the stub a xle. 5 Wilhd,nw the thr ust washer and the outer tapered he,..ing. 6 Pull off the complete hub ;111(1 disc ilsscrnbly ffOIl11hc s tuh tlXlc. 7 To refit locale the huh tlSscmb ly on the stub il~lc <'Ind slide on the outer hc"rinu nnd II1<lI5 washer. 8 Fit Ihe nut tlwn \,uh1en il to a lor que of 20 to 25 Nm (1510 1811>1 II) while <I\lhe same tlillC IUfllinu the huh <lilli-clockwise. 9 Luosen lill! nlll by 180' (hall a turn) Ihen rc\i\)loIen usinU only the
IIngurs ~&#34;d Ihun1l),
1 0 Rei" the nut ret;)u)Cr SO th~t the spill pUl holes ~re ~lIg&#34;ed. Fit a
v split pin <Ind ref,t the d( ,st c~p. ,I Hellt the front br~ke c;!hp er wllh reference to Ch<lplcr g, ,~ Re"t the ro~dwheel and lower the cm 10 the ground
4 Front hub be<lrings _ renew<ll
1 Remove Ihe Iront hub as described in Section 3.
2 Cmelully prise out the gre.lse senl Irom the b~ck 01 the hub <Isse01bly <In(t remove the inner wpered be<1rlllg 3 Using a brass drift. or beming puller. remove the bearing ouler !racks from Ihe ends of the hub.
4
Scoop out the grease 110m inside the huh imd wash clea". S Drive the new bearing tr<Jcks into the hub wilh thell tapers la cing outwards usin g suitable metal tubing,
5 Working the
glease well into th e beiu ings. lully p<lck the bearing cages and rollers with whcel bearing Qre<lSe. Note: Le,1Ve Ihe hub cavity half emply. to allow fOf subsequent e"p,1I/sion of tfle gIC{JSe, 7 Fil the inner wpered bearing in ils track then press il new grease se<J1 squarel y into the hub using <I piece 01 wood, S Refit the front hub with reference to Section 3 .
5
Front Suspension strut _ renl0v<li and refitting
Apply the handbrake then jack up the Iro"t of thc car ilnd SuppOrt r ViC S\Jnds, Remove the roadwheel.
.lel1love th e front hub with referen ce to Sec lion 3,
56 Front SllSI&#39;,,&#34;~&#39;nll Slrut uppe, moullt"l{j
5.7 Lowellnl) 110" f'o"l SUSrlt''' S'OIl ~lr&#34;tlro&#34;&#39;ll&#34;der the wheel a,ch
I !:&#39;~
!; ... ~
-;;
3 On e~rly n,,,dds. Icmove the "\lI d brake p'pu ""d dew ch Ihe flex'hle hose 1,0 '" the br.1ckct on thu strut (, f neccssilry ruler to Ch"p ll'r 9 ).
4 OlsconneClilHlu.u:k rod l'nd from the steer;ou n'm (Sect ion 14) 5 Extrncllhl' spirt p,,' <lnrl unscl ew Ihe nut securing Ihe track corlllol
arm bali,ornt 10 Ihe SI,ut. ScpnralC the ,oint using n hnilioiol sepnrator
tool.
6 Workrng Ul1d'; r Ihe bonnet. un screw the three mounting nuts sec(Jl iog the 51'Ul 10 the wheel arCh (photo). Where applicable note the location 0 1 Ihe ilce ele r" tor cnble Slipporl bracket be ne3th one of the
nulS .
7 Lower the stru t ~ssembly from undl'r the wheel arch (photo).
8 Refll,!n\) '5 i' reve rsal 01 removal. hut ti\)htcn all nuts 10 Ihe
specified torq(,e fl"fe r 10 Section s 14 and 3 as necessary.
6 F ront coil sp ring - removal and refitting
Note: In Off"" /0 ,(:mo ve Ihe corl .~&#34;{!finy ffOIl! the strut it writ be neccssa,y /0 ub/."" .1 sui/able sP"".<J (;u"'p,essof ro ol 1 Remove Ihe f,ont suspension str,,1 JS descrrbcd III SHt,on 5 ,
procarmanuals.com

Chapter 10 S uspension and steering 163
~~--,,$iJO
~~\~
Fig. 10.7 Coil spri n g compressor lOo ls (Sec 6 )
\.
FiU. 1 0 .8 C o rn pressi nu the frOllt Goil spring ( S ec 6)
~ " / ron t stobiliser bar clamp mountrng
2 Mount the strut firmly i n ~ vice .
3 Fit t he spring compressor tool(s) to the coil spring and compress the spring until it is juSt clear of the upper mounting. Milke sure tho t the
1001 is f ully engilged with the spring.
4 Prise off Ihe plastic cap then unscrew Ihe pis ton nut ~nd remove
t he cranked
retoiner .
F ig . 10 .9 CU\·
ilWilY view o f th e front coil spring nnd strut mountin g compo nents (Sec 6)
A Shack absorbfN pis/ull B 51,,11
5 Remove Ihe upper 1110unling lollowed by Ihe corl spring. rebOllnd
rubber and lowe r sprrnU seal. G The coil springs are colour· coded ,1nd II a new sprong 's being I,!led
il muSI hilve the same colour code.
7 Ref itting is a reve,sal 01 removal. but il Will be neceSS<lry 10 I"S I fll the compressor 1001 10 Ihe coil spring. Where a dished washer is I ,tted 10 Ihe piSlOn lod. Ihe convex Side must foce upw<llds . Fn II new piston
nlll _ using locking fluid on its thre<lds. Do not fully tighlen the piston
nul until Ihe weighl of Ihe car is on the suspension and. when l ightening il. posilion the cranked retainer wIth ilS twO ears al 90' to
lhe centre.line of Ihe CM. Where the p iSlon rod incorpor<lleS a slot.
crrmp the nut
II~nge into the 5101
7 F ront stabiliser bar -removal <lnd refitting
Apply t
he hand brake then Jack up the front of the car and supporl
on axle stands. Remove Ihe fronl roadwheels.
2 Working under Ihe CM at the Irani. knock back the loc king tabS on the four baits securing tile two f,ont ct~mps Iha t hold the swb,hser ba r
t o the frame and then undo t he four bol tS and remove lhe clampS <lnd
rubber insulJtors (phOIO). 3 Remove the split pins 110m the cJstellated nu ts rewin in g the stabiliser bar to the Irack control arms, then undo Ihe nu ts and pull off
,
I " I , ,
j
!
procarmanuals.com

Chapter 10 Suspension and steering
~ l"Nfl> BUS"'''G
~ TRACK CONT~O~ AIIM
Fig. 10. 10 FrOllt st<lhiliser bar and trilck contro l <lrlll componcnts (Sccs -, <ll1d 8)
7.3
Front Slilblliser bJr iltlilchmCIll to tr<lck control <lrm
tile l<lrge w<lshcls. cilrefully 110tln\[ the way III winch they nrc fined (photo).
1 Pull the stilbiliser bilr lorw,lrd uut of the two tr;rck control MillS ilnd remove from the cm
5 With the stilbiliscr bilr out of tire Cilr. rernovtl the sltltlve Jlld lilrge wnsher from each end 01 the bar. <lgilll' nOllno till} cotrect Illling posItions. II l1eCCSS(lry renew the nlOunlH1\J rubbers 6 Reassembly is <l reverS<l1 of the nbove procedule. but new 10ckin\J tilbs must be used on the Iront crmnp bolts and new spht pins on the cilsttlllated nuts. The bullS on the cl<lmps ,'lId Ihe c<lstellnted nuts on eilch end of the s1.ll>d,ser bar l11u5tnol be fully tiuluened down unulthe cm is resting on its wheels.
7 Once the car is on its wheels. the c(lsteli,lted nUlS on Ihe ends olthe st,)bifiser bar should be tl\[htened down to the specIfIed torqlJe .. nd new spill pinS filled The four cl(lmp bOilS on the IranI mountinu poinlS must he tluhtened 10 the specliled torque and tile lockIng whs knocked up.
P
Front truck conlro l ;lrm -removal alld refitting .
Apply the h'lIldl.>r<lke then Jilek up Ihe fronl 01 the Cilr and SUPPOlt
8.4 Tr(lck COIIIIOI ,lim inner pivot bolt
on a~le swnds. Remove the roadwheel. 2 Working ullde! the C(lr. remove the spirt pin (lnd unscrew Ihe cilslellmed 11111 Ih"t secures the trilck coniroi <um to Ihe stabiliser bar. 3 LIft aWily the I"rge dIshed wJsher. notrng which w~y fOund it is fllted.
4 Remoye Ihe self lock nut ilnd tiM wJsher from the bilek of the track control nUll P,yot bolt (photo) Release the inner end of the tr[lck control Mm.
5 WithdrJw the split pin [lnd Ullscrew the nut securing the trilck control Jflll battlOIl1 10 the base 01 the suspension unit. SCpar[lte the joint. using n ball,oinl Sepnr[llo,. or wed(Jcs 6 To ret, I thc lI"ck conlrol arm . fllsl JsscOlble the track conlrol [lrm bJIl stud to Ih(~ bilse of the suspenSIon !m't 7 Reflllhe nu! ilnd tighten to the speCIfIed torque. Secure with a new spirt pin.
S Place the track control (lrill so IhJt il conectly locates over the sliIbiliser hJr nltd then secure the iIlller end.
9 Slide Ihe pivot bolt into pOSItion "0111 the "onl and sccure w ith Ihe flat washer Dud il new scll.lock,no nut. The nut must be to the rear . Trghten the nUl to Ihe specified torque. when thu car is on the ground. to Fit the dished washer to the end of the stabll iscr bDr. making sure it is the cOllect way round and secure wit h the cas tellated nut This must
-------------------------.. procarmanuals.com

Chapter 10 Suspensio n and ste e ring 165
he IllJhlCned when Ihe em IS on Ihe '1IOUI1(1. \0 Ihe speclhe(1 100quO Lock Iho cnSlC\lnlCd I1UI wllh n new spill pin.
9 Renr shock nbsorbcr -rClllovnl nlld rofitting
Early models 1 Remove Ihe bnck sent. <Iller hnvll1g lenlOVe( J Ihe IWO sClews hom
th~ lIoor ns~ombly crossmemher. 2 Remove Iho screws secIIIlllg Ihe SO,1 !Jell 10 Ihe lap o f Jl1() B ·pllI"r 3 Dowcll Ihe B·pllf<lf cover (2 sClews) 1 Remove Ihe lOp (11111 from Ihe sIde wmdow (4 screws) 5 Remove Ihe IWO scrows f,om (1m rocker panel ill (he ren, end and pull off Ihe door wea(helslllp. in (h e ,e!lIon of Ihe ~Ide Ilim 6 T., ke oul Ihe hool s,de 111m (2 $C'('ws) o1l1(llho ca,pel 7 Re&#34;&#39;ov&#39;~ the 1m mIl of the 'f)n, pn,,,:1 (5 screws) nnd oj Ihe SId,! panel (1 0 ~news). foldlnu Ihe IC," Sf),11 f"rw.ud for ilC(.ess
Liller //lor/cis Remove Ihe cover hom tl,,~ :l,:c,,~s hole III Ih e rea r srdl! H un
.pholo)
. models ~, CIlr:ck the front wheds Ihun F":k up th,) rca r olthc (:;" and SUPI"lI l on "xle swnds. tCmovH Ihe ,o.ldwlwel 10 Unsc,ew Ihe nu(S Iron' tim lOp 01 III" ~hock ilhsnrhe, ilnd ,,:move the wa~her and ,nsul"l!)r rllhh,,,. 11 Unscrew nllll ,emove Ihe hollom IIH)l1ll1l&#34;~1 holl and wllhd,.lW Ih(, shock nhsOliJer trom the cnr. Now tlw 100:"t,on of Ihe Sllacr:, '" II",
1110ul1lll1g lubber. 12 If nocessmy (he moun(lng lUhbers IIlay be relwwed sepal;l1cly 13 Relittinu is il reversal of refllov<ll I>lIt l<!JhtCII Ihe IHOUIIIIII!J "Ills to the specified torque.
10 ReM leaf spring -rell1ovnl. bush rellewnl "nd refiltin g
C
hock I hl) hOI1l whl)l)ls then Inck up Ihe rl);11 of Ihe cm nntl SliPPOlt
98 Renr shock ilhSOlbel upper mOIJnlln\j
nccess hol e
"
-----------_.-
II 2 Re~, stabi llser b ar mountinu on Ihe rear a xle
on <lxle st",1IJs posllionod on the hody Inc kln\) pOItlIS . Remove Ihe roadwheel 2 Place a llOliny lack underne<llh the dlf fe'en(lnl housing to support the re,lr a~l&#34; "sstHllhly whe n the spllng is removed. 00 not raise the Inck IJmlel Ih!! dlll",entlill houSln\j so thnt the SPlinl iS are lIallened. but r<llse It )lISI nnOu!lh 10 lake the full wel\Jh t ollhe axle with the springs
fully eXlClld"d 3 Undo till: "';11 sh;,ekle nUIS ilnd remove the combined shackle boll lind plill0 asse,"l>lrus. Ihon removo the rubber Ilushes. 4 Undo lh" InJl Iron , Ihe honl mounlln\) and tilke oultho bolt runnltlg Ihrough 1111, ""'"lllmn (l'hO(o) 5 Undo Ih" lIul<; on Iho ends of Ilw fOIll U·bolts ilnd remove the
U ·lJol ls. 10'1",1"., WIth Ihe all.lchment pl,110 ilnd fubber splinf)
Insulatols (1,1",11') U The I(lhll'" Ilu~h&#34;s C;\l1 be p,es'>vd 01 dl1ven oul. lind new bushes fllted ns {I",.( ·"l,,·d 11)1 Ih" hushes OIl Ihl! s!ahd ,se r bnr lind end pieces in
SectIon 11 1I1r1l1t~ !lIY CI;"nc. or I,,"kr, flUId . WIll <lllow the blJshes to he plessvd III nil "" "."., Iy No!!) Ihilt til" lIOn I huShes ~ue 11 mm (0.43 In) rhnl1lelt" ;111<1 II,,: 1( :.11 IJlJshvs ilr!! 8 n1l11 (0.31 III) d,<lme ter. 7 f\efI1l1l1!1 Ih" ~P&#34;I)(I IS tho 10vr:rS<: 01 I he removnl [)foce(Jure. Tho "ulS on II", U Ilolh. spnn!J hOllt "'OlIlIIIIlO <lnd rear shackles rHUst he IOI(juod 10 Ihr: I&#39;!IIJII)~ (lIven In the Spf)clhcnllons ilt the be,Jinflltl(J of tlus Ch"pt", IJlrly .111", Ihe CM h,lS bor:1l low(:!()d onto Its wheols .
11
R eM st"hiliscr har -rcmovnl ,,"d refitting
Chock tlr" from WIH&#39;t:I~ Ihen Jack up (h o ron, 01 the cal ~nd ~Hpport 011 nxle stands il"I1love Iho rear whet:ls fo, holtcr ilCCeS$ 2 USlnO :1 11111111 !J"P wlCnch. 0' sll1>llnr tool. to hold the swoiliser b,'r IOwa,ds 11r" <I.h) Illhel. remove Ihe IWO bolts nt eneh stnbiliser l)iH·IO·~.h: 1"1),, h,;r<.;ket (pholo).
3 D'SCOJ111"ctlhc l1ul and uolt ilt ench end of Ihe stabiliser bar. whefe It IS allached to Ihe floor ilssembly. lind WIthdraw tho bnr (photo). " To fenow a stablilser bill mounting bush. ,emove lhe locknut <It one end ;rnd lIllSC!eW Ihe ond piec e. Remove Ihe nut nnd withdrnw uoth ruhbcr hushl!s 1101>1 the stnhillse r bar
5 0'$1 Ih(~ new ruhber bushes III olycelll1e. 01 hrake lIuld. ensure that tho stabIlise, b.H ~(JIlnce is clc<ln and n"t score d. Ihen slide on the
10 5 ReM sprinU U ·bolts <lnd plil1C
11.3 Re<lr swulhser bal mounting on the underbody
i:
procarmanuals.com

,6 Chapter 10 Suspension and steering
A
l
I Lr;=::;;r&#34;&#34;~Jj&#39;Q l
G-cc;;;;-~---~~~~~
, " I : I 'II
'I' , ,
, ,
FiU · 10.11 Fl(Wr stniJiliscr b;H flnd piece positioning (Sec 11)
A IJ 2620 I J!J 111111 (/03 101m) 100111111 (0·1 mJ
1"'5 ;",(1 ,0.:1'1 tile t;1\{1 sHoec When l ilted. the wHip'cec should he 1&#39;&#39;&#39;~&#39;ll&#39;&#39;&#39;H,,1 .15 shown III FlO 1011 DIIIlCIlS'Oll A should he betweell ?!.i 59 nlld 2Gtl 5 ""ll (102 ami 104 JI') :lnd Ih" (h(fmcncc IWlwr!f!1l IllI! two s"I"5 IIll1S! nOI he \l'catc, th.1rl 2 5 nUll (0 1 m)
(l II Ihe IJl,~hcs "' II", (,11(1 11".:';'$ "''1''''<) """,wi,I, II 'llaV I", found "'O'e COI1V"Il<t:IlI 10 ICIIlO"C tin: elld I)leces hom lin: ~1 .. IJllrs"l hal. "l1hough tillS IS nO) eSSen(,nl. Thp. bushns C,l" he p",ssed OLlI liS"'!! <l sU'I;,blc dllft whilst Ihe end piece IS SlJPPOllcd on ,I ~lIIt;)hh, d"IIlH:Wr Ivbe. Filling is s!ln'!Jhtlorw<lrd. the rww hushes helllU p,essed III ul1ul the steel c~se on the Oll1side of the hush is flush WIth the InsIde of tim end piece. Note the position of the semi·cilcliioll lecess III the hus h ilS shown ill Fig. 10.12. 7 Whell refming the swbilisel hill. ,t should he fitted ilt the I loor end l"s1. with the w1)shers and self-locking nuts loosely IIIs1<lllmi 8 The har is then fitted 10 (h e <lXle tlille. lISlng a sUllo1lJle tool to pull It tow;IJds the axle The hrnckets. clamps 1)ml ruhher IlIslitntors should now I,e 1I11.-:d and the hOlts tl(lhtelied to the speCIfied torque. 9 luwI" thl~ v"hiclo to the UlOllnd. then 10,1(1 the veillde so that Ihe
C"'IIJ(.' 01 till: axle tulle ilnd the sprlllO .em eye ,lie Oil the sarll e
h",,/.ul1,11 h.'vel (the wUIOht ",qlllred IS dpp'ox,m<ll!!ly thilt of two adults) The l1uts "nd holts seclIJlliH th,~ Slilb,hser 11.11 10 the lIuor Gill now 1m liUhlc l1ed to the speCIfIed torque
17 Steering ge<l r (malHlal) _ femoval and refitting
Ll..,tore st;IItlnl) set the f,ol,t wheels In the s[ro1lght ·ahead pOSlt rOll
J.!Ck lip the front 0 1 thn C,lr and place s1<Inds unde, the tra ck control 'IIms Lower the CM shl)htly on the Jilek so th,1I Ihe Ililck rods <Ir e III a
IHlill .hOfllonwl posltioll, Apply the han(lhlilke 1111(1 remove the f,ont ro,l(lwheels.
2 Remove tile nul ~lId holt from the elnmp at the front of tile fleXIble COllpll ll(1 on the steerm!j colllllln, Tills cl,IInp hOlds the couplln(J to the pillion splines.
3 Working on the front crossmemlier, knock hilek the lockmg wbs orl the two bolts on each IJck houslllg U ·C lillllp. undo the bolt ~nd remove tbe locking tabs ~nd clamps
4 Remove Ihe split pillS <lnd cnslClialed nuts f,onl the ends of each tlack/od. where they join thn steerlll(J a"IlS Sepmate the Ir~ck rods from Ihe steering mms. using 1) bl1liloint sepJra to r or wedges. and lower Ihe stee.ing ueor (IOWnwillds Ollt of Ihe Cilr. 5 Before lehlting the steer ing gen!. make sure thaI the wheels have rCllll1l1led In the strillght'ilhead posit Ion, Also check the condition of the mounting rubbers lound the housinu and If the y appeM worn. or damilged, rellew them
G Check that the steCflng \jeilr IS also III the sJraiuh t'ilheild POsl\ion.
Th iS cnn be done by ensuflng that the d,swnces hetween Ihp. ends oj bOlh trllek rods 1111(1 the Stec1inu geilr hOllslng on both sides ~re the same .
7 Place the stee"ng Uear in it s 10c<I11on on the crosSlllemher ilnd ill J lll1le tune 1ll<1t!: II p the splmes on the pinion. with t he splines in the cl<lllll) on the steering colulllll Uexible coupimg 8 Relit Ihe two U·cl1)mps. using new lockmg tabs under the bolts.
--
-,
Fig. 10,12 COfrect position o f stnhiliser bar ruhher bush {Sec11 )
T'!jht(:n the holts to Ihe speclf,(:{! to"lne, 9 Relit the I.,lck rod ends into the stO)(:IIn!) illluS. refIt (he I:a';[ellolted nllts and II!Jhten them to the slleclfl{)d tOlque Use new spill pillS to '!:t.nn the nuts
10 T'!lhten tho I:I,II"P bolt (HI the steeru'!J COItIllHI lIex'hle couphllU to 1f1n spec&#34;&#34;~d torque. h,)vIlI!) fll~t rnil(\e SlJlOl tholt tlul pin lOll is cOlfecily 10(;"101(1 III t he S"III1CS 1 1 Lower the cm to tho urOllnd. thcn check nrld If neceSSo1ly ildJlIst the front whlwl ;III(J 'Hncnr 015 descrd)ed in Sec lion 20.
13 Stcerinu geM (Illanual) -overhaul <111(1 adjustment
Remove tlllltr ilc k rod nnds (Section 14) then .elllove 1)nd discard the Wile retalnlllg cliPS. remove the hellows and drall1 the I"hricant 2 Mount the stee"ng Ijear in <l soll·j;&#39;wr~d vice and drill olltlho pIllS sec""nU Ihe uack rod housin(Js to IIHI locknuts Celltre'punch the pIns bciore dllll",O thern Use 11 4 111m (0 1 (; lIloh or No, 22) d"lI. but do not d,,11 100 deeply.
3 It IS now Ilecess,l'y to unSClew the housmgs from the IlnilIOUl1s. so IhJt the tr~ck rods. hOIlSUlgS , locknuts. hall se<lts. w"shers Jlld sprinUS
C,IIl he removed. Idenlt y tJIIS rcqUlles the USIJ of spec;al 1001s which should he aVaIlable IrOlll ol Fo.d De;1ler. hu t II implovised grips or wrenches ;lie used. lilke care thnt no p,IIts Me dalllalled (If pa rtS ille darllaUed. "ew Items must be oblall1ed). 4 Remove the rilck slrpper cover pl~le, slliln pnck. (Jasket and shpper. 5 Remove Ihe pUlIon i>enring Ilrelo~d cover pl;1W, slum pack. g<lsket
1)nd lower beilJlnU {; USlIlg a serewdllver. or sinlllill tool, pnse out the pUllon oil seal 7 Clean all d'll <lnd pollnt from the p,nion Shaft. then push tim p'nion out of the housing Withdraw the rilck from the pll1 10 rl end of the sleerlllg ge~r hOUSing 8 T,lke out the p,nton upper beallng ilnd w<lsher, 9 Cleall omJ IIlspect nil the pans for damilge and weJr. Exallline the bush In the end of Ule r;1ck tuhc lurtheSII.om the pinion If worn. it can blJ prnssed out and ~ new hush Iitted. 10 Commence reJssernbly by f ,tting the pinIon UPPIJI be<Jring <lnd waShel II1to the hOllsmg. 11 POSition the r<Jck into the housing <Jnd leave 11 in the centr~1 pOSItIOn,
12 FI t the pinion. ensuJlng thm. after fItting. the lI~t is towa.ds the Jlght·hand side of the vehicle ( " respeCtIve 01 right or le/1·hand drive vehicles). 13 Fit Ihe pinion lower be,lling cover plate. 14 Assemble the rack shppel. SpIIIlg. uasket. shim pack nnd cover plaHl,
15 LubrientIJ the ball Seilts. balls and housings. with the specified gear 011 Screw the locknuts OntO the ends of the steeling (1)ck. 1 G Assemble t he sprlllgs. waShers. bJIl seJts. track rOd ends and housing. Tighten the hOllsmgs. to obwin a rowtionnltorque of 7 N m (5 Ibf It). then lock them w ith the locknuts. Recheck the torque alter tiuhtening the locknut 17 Drill new holes (even If the o ld holes Jre in aliunment). 4 mm {O, 16
______________________________ .1
procarmanuals.com

)8 Ch apter 10 Suspensio n and steering
\0 the SI(lcring Mill (photo) 4 USlIlg" 1)[lIi)onH SCpilriltor tool (photo). reh:o,lS(l the ['ilek rod end from the Slc(!rino ""m 5 Unscrew the h,"'IOlilt hom the ['<lek rod, notmg lhc C~ilCt number of turns required 6 SC!( )w the new 1m ill Oint 01110 til(! 'rac k rod the SilnlC number of turns . 7 FIt the (.<le k lod end In the steering [I,m, SCI(!W 011 the nut illld lighten 11 to the specIfied torque AII\)11 the holes nnd IIlscrt il new spht pin
8 T'Uh!C1l th e h<lIl,DUlI locknut whde holdlrlU the unck rod end hOrllon\<1I, {) ReIn the ,oailwhc()1 ilnd lower the C,l' to the wound. 10 Check ,1(1(1 ;ullllsl til" f,ont wheel ""onmen! <1S desCllhcd ,n Section 20
15 Power steering -hlccdinU
The power ~1P.elln\J SysHllll WIll only need blc",rhnfj Ifl the even! of . .., hell1\J Il1tl<)(hu:ed ",to the system. cu whcn: IH llI:S h;IV() IW(}1l dlscoI1l1cc«:d or whel() J Ifl.lk"(Je has occlUfed To hleed the system ···ocp.ed ;'s (1<,~<:&#34;I)Cd III 1(11) followlllU l),l';)\J,,1I)hs
I Open llH~ hO'Hl()1 ,111<1 cl\p.(:k the Il",d h:v el "llhe Il'Sl'IVi'" Top·llp.t llucess;IIY IIS"'!J (Il<) spe.:II,ed lype of 11(11<1 3 11 11."d IS added. allow two "'''HlWS. th"l1 lUll 11m I;I\U"W at apPI{)xIIllntnly 1500 rp'" Slowly \illll lhe st'!""Il(! wheel 1,0m lo,:k to lock. wlllisl r:l\.,,;klllH and WPP"'!I up Ih e Ihlld unlll th" l"v,,1 ",m;II11S
Stf),li1y ;1<\<1 no molC hubhl"s ilPP":U I II tlw I"S,,,V,,II
" elc ;,", and refn Ihe r"servoll cap ami close II,,, 1>0"",,1
16 Power steering gear rellloval and refittinu
The p'ocedure IS Sllml", to thilt descrd)<)d III Sc(:t lon 12 10' th" m,10u,,1 steeling gC,lf NOlO. how"ver. lhm tile 111011111(1)(1 1)I)Its (jo cOllipletely tl1(ouyh lhe front e,ossmflmhe,. "nd the II.),,, nil IS a,e
I()(;ked wllh sphl pillS. Add,llon"lly lhe lIuld IIIH)S rnu~;t Iw lhsc.onnec · l"d. and atln' ,uI,Um!J the system ~hollid he loppud III' ,lnd Illed wllh lui"",,,!:,, 10 $"(;tl{>n 15 (photos)
17 Power steerillU pump remov;ll "lid rcfil1 ill\J
Loo~&#34;n tl", «II.." Iwlley 1",lck,,1 b"lts. ,el..,ase Ih" d"ve!Jclt lellSlon. Ihcn ,emOVe II", dllvelu:lt I,,)m the P"'''I' pulley Oil 3 0 101", IIIO<il:ls , FI(:k up the tro"l 01 tlH~ ~&#39;&#34; ;lnd support on "xlu SI;IIHis. Ihell 'e"'ove tlll~ ""\llnU spl,'sh ~llIeld Belllove lhe tuul pump , 'Ill til() U"U"U, (Ch;,ptc, 3) lIul 1,,;IVIII!1 th" fu el trncs (;oIHu )Cled .
O ,sc<)nll,,(;1 Ihe IIlIal hnes hom the pump ~nd <1,,111 Ihe IIUI(III)to" sultahl" (;Olliall'", The pIIISS(lIe I",e h,15 .1 sell)w"d (1111011. hul the lehlln Ime 1 5 ,1 ,ulJhCl hose connecl'on (pll()I&#34;~) " Ulliloit (111) powe,· steuIIIIU punlp. (o\Jelhu, WIth thn IllOUnllllU
h,;lc.k(,t ~nd st;)y. wlw,e ;1j)1'11 <:;,I)I". ,!Ill! ","'ove f'DIII Ihe CII!) "le (photos). The "",d..,1 C;'rl lh"" 1m (lnl)nlt"d flOm Ihe pUlllp of nccess;"y, 5 RellltlllU IS .1 ,ev,,&#39;~al 01 I..,moval. "ul l&#34;&#39;Il~lon Ihe lhlvehelt ~Ild "Iced Ihe sy~IC&#39;&#34; wllh lek'e'll:tJ to Sec;1I0ns 2 ,!Ild 15
&#34;V&#39;,~, , .,' , -t .~/ ,.
~
&#39; ---... . . ' .. ' , "
A-i·J<&#39;~ r~ _ I' .' If! h \l:: fITI \~, . '''''
~
•• :. ' 10)",', / )
. .. 'I.· L../,
'": .. ':;' ., .... ---,.
. .. .
18 S teerinU wheel removnl nnd rIllittinu
1 Dlsconneci the lodlielY nCU~lIve le,,(1, 2 PIISC Ih" mOllf hUIll Ihe celn,,) o f Ihe stcclln(j whc,,1 (photos)
15.1 A Powef SICCIIIl(j (je,, ' showUlU pinlOrl and lowe, coupl",U ~h,,11 un,vcfsnl lo;nl 161 B Power steering ue", mountUlg bolt (,,"owed) 1 G 1 C "nd nul (""owed)
.' ---------------------------------procarmanuals.com

,~
1 Unh"'I"'!lllo" pow,,, ~I&#34;&#34;&#34;&#34;!I pUIIlP "''''''''OI'!! bracket
18 2A Rr,mOVII\!llill] st(;c:rOll\) wlu,cl mOI,f (emly models)
17.313 Rl]rtlov"'!III,,· ,,,1,",, Ion,· f'ol1llile I&#39;OW~&#39; step- r'll!) pump
,
" , " ,
I
,1 , :ii~ ,
~i( '1 .-
~(
&#39;.~ .&#39;~&#39; ,
, " L -17 dB olnd ~I,&#39;y
a
~.&#39; , 'II;.:" " . . ~ ....
,
,
----
18.2
8 Relllov",!) lil(: SWcnll'J wheel m01l1 (lalCr models)
&#39;,.~ ~ , ;,
r i.
procarmanuals.com

Chapter 10 S usp en sion" and steerin g
c
D
A
E
Fig. 10.14 Sleering column componenlS (Sec 18)
A Rllllbcl f/IOIIIIIICt n OutCI CO/U/IIII E Simll H SWill!! J W.n!u :, K Ci,cflfl C fmhC,ltOI ,1Ctuol(iIJ.II C,/11I o Upper f)CMIllf/
F lowt'l /)f:;lIiIlY G W.lslrtH
3 Wilh Ihe iron! wheels sl/aigh13he,ul, unse.ew Ihe nul from Ihe lOP of Ihe column. <1 Mi"k Ihe s!Celinu whecl and column m .eliliion 10 eilch olhe. Ihen 1".11 Ihe SI~&#34;ng wlu • .'ci from thc spllncs. lilk",!! C illC nOI 10 cxtend Ihe ~pcclill convoluled SCC\lon which ;'CIS ilS it Si.rtlly d<!llU;e 10 m"lnlllS C
dllVCI "'J"'Y II, IIHJ evenl o f 01" lIccldelll 5 nel,!!",\) IS a revClsal (ll "''''(lvill. m;lklllll su'e Ih;11 Ihe Jucvlnu sly mndc marks ... c ilhUned T'\Jhlell Ihe nUllO Ih\! spc,:l1lod torquc
1 9 S leerinu coilimn -remov,,1. overhaul (lnd refitting
1 Remove Ihe Sleer'n\J wheel ilS descllhed III SeCllo n 18-2 Remove Ihe upper and lowe. slee.lI1\J coupllll(l cl;Jmp 1)0115 ;Jnd 131) Ihc coupling sh;Jh down Ihe pinion shah 10 rhSC(lnneCI Ihe cO\lplin\J
sha ri f.om Ihe column (pholo).
3 Remove Ihe direCllon in(hcaIO' aCIUillOI C(lm 4 RemovC Ihe stee.ing column shroud (2 screws <lllhe bOllom. Ihen pull out al the lOp) and lowel Ihe d~sh panel lIun (pholos).
5 Oisconncci Ihe d"CCllon "lIJ,ca lo ' SWit ch hom Ihe col"m " (lw<I holls). 6 O.seonnCCllhe loom w.llng hom Ihe '!lIlItIOIl SW it ch (phnln) 7 Remove Ihe lwo sWCling colum" 'CI;1II'"'\I h o hs ;11,,1 pull Ihe column ilssemhly hom Ihe vehicle (pllolo) Push Ill,! ![wm"H:1 OUI 01 Ihe 1I00rpail . 8 01111 off Ihe sICC""!) colull1lllocklloll &#34;e;J\I~. or lilp 111(,111 round Willi il pili pUilch. Ihell usc sUitable U"[)s 10 pull oul the holl Shanks Remove Ihe Slc crlilg lock (u)lcrl() Chaple' 12. II IlI.&#39;ces~;IIY) 9 Rcmove the CIIChl). washer and sPlinU from Ihc towel l!!lel 0 1 Ihe column. 10 Tap Ihe lowc. end of the shaft wllh a SOft·filccd hall""C' 10 ICIl'OVe Ihe shar t ilnd beall('Y flom Ihe lOp of Ihe column 11 USlI1g the shaft as a dlilt tal) the 10wcI hCillll1!J Otll 01 Ill(! COI"I1111 12 InspeCI illl the paris lor WC<"lf ilfl(f (fnm~ge. reneWIIl!) " IlI&#39;C(&#39;~~;Jly 13 Commence rensscmbl y by posilioning Ihe sh~ft III Ihe COI\II111I. Ihen assemblc the 10wcI beallng (small (j,nmClel IOwa,ds Ihe COhlllll1). spring. washer and circlip 10 the shaft. PUSh Ihe t1ssl'n,l>ly 11110 Ih\.! column to locale Ihe bearing againsl the stops. 14 P. ess Ihe upper bearing onto the column.
"J . "\/ . ..::..J. \..
19 .2 S leering coupling shall (ar.owed) 19.4A Remove Ihe se,cw ... 19.48 ... and lower the bOllom slecring column shroud
procarmanuals.com

Chapter 10 Suspension and steering 171
19 4C Removinu the top steering column Shroud 19 G lunitlon SWitch ,1nd wirlllU (A). also COllll'lII upper mOlUllnl!J holt (0) 19.7 Removing the steering column uppcr mounlul(J holt (arrowed)
'5 Secure Ihe SIt:(;(1I1(1 lock 10 Ihe colulIlIl ,lIal ~heil&#39; the h eads I,om ,he m:w holt~ 11) U~e the stecrin\J lock to locate the shaft in Ihe column. then III Ihe )ct,on mdlGltor OICIlJalinn GUll alld Stecrmn wheel. CtlCC~ that Ihe ruadwheels afC st,lIln the 5trai\jht·ahead P05,110l1. 17 Install the Stce!Ul(J column orommet Oil the lowm en(t. 18 LOCille the column assembly ami sr:c",e It wrth the Iwo mOllrlllng bolts. 19 The ((,milliuler of the rellllUI\J proccrl",e ,~ th" reverSI! of lhe removill procedure,
20 F ront wheel alignment and steering ilngles
Accurate front whcel alignment IS essential lor good stoer"'g and lyre WOiJr. Scion) cons,dering the steering angle. check Ihat Ihe tyres
are correctly inflated. tllnt the front wheel s arc nOI IJlJckled. the hub hea"nns arc not worn o r mcorrectly adjusted und thilt the sleflr"'g IlIlkaUfl is in IJood order. wllhout slackness or we,ll at thu Jo,nls
2 WIH;f; 1 "I'!JIununt co&#34;s&#39;st~ 01 loUl I"ctors, C;"lliJcr_ IS the ""Ule "t wilich the front whet:ls ,lie sci from Ihe
verllcal when v'ewud 100'" the IrOnt 01 the c"r 1'0sIt,ve camber 's Ihe .. mount (111 de\J&#39;ee~) th"t til() whucls ,ue toited outwards at the lOp 100'"
thu vert,c;,1
Castor. ,~tho i&#34;&#39;~Jlu between the SIl,erlIlU ,,~,s OIrld.1 v..,'I,e.11 lone len viewud IrOIll p,lch ~,dfl 01 the C,lI 1&#39;0~;llIve castor 's when the ~tcermu ",x,s 'S ",cloned rUiHw,,,ds ill the top jStcerinu ilxis inclin,,{ion 's lhe illl\Jle. when VIewed frOI11 the .It 01 the Cilr. bel ween the verltcal and "n 1Il'''U>I1.1ry hne drawn betwCl)n the upper ilnd lower suspensIon strut p,vots, Toe-i n IS the ilmoUl,t by wh,ch tlte dl5li"'Ce helween the frOrlt
IIlsuJu ed\Je~ 01 the rOildwhecls ('He,lsu1ed m huh heiuht) ,s less thiln lhe d'sWrlCI) &#34;,e<l~ured between the rca' Ins,de edges 3 The imUleS of c"mber. c,l~tor "nd slCe''''g ax,s ilIe SCI ,n produCI'On ~n(1 nre not <ldluswble. 4 Front wheel aliurUlll)n t (loe·"I) checks ilIe best camed out wl\h nlodern set!lIlg equ'pment. but il fC,lsonahly acc1llate alte rnative is hy nle<lns of the following procedure.
5 PI"ce the Cilr on level ground WIth the wheels 111 the sualghl·uheild pos' lion,
6
Oht"in or m"ke <I loe·in unuge Onu IHay eas,ly he Ilwde from it lenyth of rod or t ubinU. cr<lnked to clear the SUIl'P or bcllhousing and h~vmy il setscrew "nd locknut ill one end 7 W'lh the gnuUe. measure the d,stilnce IJetween the two IIlner wheel IIrns M hub helUln ill the Iron I of the wheel. 8 flowte the roadwheellhrough 180' (hillf il tU1[1). hy pushinU or pvlllllg the CM and then me,lsure Ihe d'Stilnce ilgaon at hvb height bel ween lite inner whee! (In,s <It the reil! of the roadwheel. Th,s meaSurernem should eIther he t he Silme as the one Just lilken. or greilter hy no! Ino,e lhan 7 mrn (028 in) 9 Where the 1O~·1II IS founoJ to be ,,,correcl. sla~ken the 10cknuiS 0[1 each tr,lck rod. also t he I lex ,ble bellows clops and rOWle each tr~ck rod . XII equal ilrnourl unlll the correcl toe·,n ,s oIJW'''ed . T,ghten Ihe .k rod ~nd 10cknulS. whole the !JilIIJo,nts ille held III the centre of lhe" ilrCS of trilvel II'S "npcrilllve lh~11he len\Jlhs of 1he trilck ,ods are ~IWi&#39;yS equal 01herw,se thu wheel ilngles on turns WIll he ,ncorrect. If
ne:w components have heen I'lted. set the ro"dwheels ,n the stral\jht·ilheil(f p05otrOn and also cent",lrse the steering wheel. AdJ"st the len\Jths of the track rods hy lllll1ing tltem so th,,! the track rod end IJ,litJoinl studs w,11 drop eils,ly onlO the eyes of the steer inu ilrlllS Measllfe the dislilllces between the centres of the hilllfOllllS illld the grooves on Ihe inner ends of the track rods and ildjust. ,r neceSSilry. so Ihiltthey me equ,ll Thl~ is all lII,t,,,1 sellinlJ only and prec,se ildillstmellt mu~t he carried oul as descrrhed earheL
21 Wheels and lyres -uonNal care and milintenl1nce
Wheels ilild tyre~ shOuld give no reill problems in usc provided thm ,1 close eye IS kept on Ihe", with re\janlto excessive weilr or dilmilge To llns end. the following pOllltS should he noted Ensure thm lyre pressures ",e checked re\Jularly ami ma,ntallled correctly. Checklllg should be c,Hried out woth the tyres cold alld nOI IIlHlledialely alter the vehicle hilS heen "I usc. II the pressures are checked w'th the tyres hOI. iln ap(l,Hently hi\jh readmlJ w,1l be ohw'lled OWlnH to heilt expJnsron. Under n<) Cllcumst<l"ces should ,III ,!lWlllpt he lIlildu to reduce the p,essu,es to Ihc quoted cold r eildlllU ,II thl~ "Ist,once. or effect've undcrinlliltlon w,1I result Undc""f)"I'o" wrll Ciluse ov(;rheiltu\lj 01 the tyre OWin\1 to excn ss,ve fluXlIlU 01 the casin\l. and Ihe Ire,ld w,1I not S,I correctly on lhr! road surfilce ThIS wrll cause it cOllsequent loss 01 adhcs,on alld excess,ve weilr. IlOtto '\lention the danncr of sudden tyre fadwe due to hea t bluld U), Overonfiil t,on w,11 Ciluse rap,rt Wear of the cell Ire part of Ihe lyre tread coupled w,th reduced ndhesloll. hiusher ride. and lhe dan\je, of shock dilmilge occw"ng in the lyre Cilsin\l Heg"liloIy check the tyres lor dilrno1\je 111 the form of cuts or !>"Iucs.
eSpecii\lIy 111 the s,dewalls Remove any na,ls or stones ell\bedded 111 the tread hefore they penetr"te lhe tyre 10 cnuse dcfliltlon If remov,,1 {)i <I nad docs reveill thai t he tyre hilS been punctured. relIt the "JlI so thill ,ts point 01 penelrat,on is Illilrkcd Then inHlled'illely change the wheel and have the tyre repimed by il tyre deiller, Do no/ drive on il tyre in such il cond,"on In lIlilny cilses a punClUre C~ll he sunply repa"ed by tile use of ilil IIlner tube 01 t he correct size ilnd type. If In any doubl ilS to the poss,ble conS<lquences of ilily dlll11ilge found. conSult your locill lyre defiler lor adv,ce Periodically rcmove Ihe wheels and clean any dirt or mud from the 'Ilside ilnd outs,de SUrlilCeS. Ex~mine the wheel rims for signs o f (listing. CorrOSion or other dilmilue. Light alloy wheels "rc eusily
dilll1i1ged by ·kerbing· wh,lst par king. and simililrly stee l wheels may hecome denIed or buckled, Renewnl of the wheel rs very ohenthe only course of rellled'ill ilct,on poss,ble, The balance 01 each wheel Jnd tyre ilssembly should be mainta,ned to ilvoid excess,ve weilr, not only 10 the tyres but illso to the s teering and suspension components. Wheel imbillilnce 's normilily S'\ln, f,ed by v,i)rilllOn through the veillcle·s bodyshell. illthouUh III many c~ses it IS piullcularly nOliceahle Ihrouoh the steenng whuel. Conversely. it ~hould bc noted thilt weilr o r dilnlaUc 111 suspellS IOll or steer ing components may '.:ause e~ceSSlve tyre wear. Out·of·round or out-of· t!Ue lyres, damaged wheels and wheel !leafing weilf/ nlilladJustntent also lilll into th<s Cille\Jo ry Billancing w ill not usually cure v,bration caused by such wear
,.
:.
procarmanuals.com