lock FORD CAPRI 1974 Manual PDF

) Chapter 9 Braking syste m 155
20 Hllndbrake ctlble(s) and rod -removal and refitting
I Chock the hon wheels Ihen jack up Ihe rea, ollhe car and support on a~le stands. Release tho handbfilke .
p,imary cable 2 Disconnect \heCllble flom Ihe lower end of Ihe handbrilke lever. On
c1'IIIy mOdels back 011 the cable ad,ustment and unhook the clevis . On latcr models remove the split pin and withdraw the clevis pin. 3 On early models, unscrew the locknut and adjustme nt nut hom the rOlll end 01 Ihe cable. disconnect the cable Irom Ihe lever, and withdraw it Irom the underbody guides and pulley.
4 On l F ig. 9. 18 Handbra ko components on Iille r models (Sec 20)
•
I HaN/brake lever 2 Clevis pin lIml chi) 3 Prif!!lIfY clIble
4 Gllidc 5 Clevis {lin illld r:hiJ 6 TWf/sveISC lOti
3
, , ,
, '. , /
·f
! I i ,
I:
!
1 1
i 1·
!
j j
procarmanuals.com

,
156 Chapter 9 Brakin g syste m
Secondary cc1ble (early models) 5 Loosen 1I1c lock.nut ~nd unscrew the adju stment ferrule from the right-hand rear clevis.
6 Remove the split pin and clevis pin securing the secanda.v caulo \0 the left-hand Icar operating le ve l. 7 htrac the clip, remove the clovis pin. and withdraw the pullcy wheel from the lever on the Ical a~le. 8 Remove Ihe cable from the lever.
Transverse rod (later models) 9 Disconne ct the cable from the righi-hand rear opCfating Icvcr by
removing the split pin and clovis pin. to Uncl.p the cable hom the 'Hlnsvcrse rod . 11 Remove Iho spli, pin and clevis pin securing the fod 10 the Icft·h~nd le;!1 operating lever . 12 Slide the transverse rod Irom the guide on the rOM axle . 13 Check thO {luide bush lor wear and dama ge and renew It il necessary by prising il oul and pressing a new bush irllo POSilioll.
All models 14 Refining is a r e versa' of removal. but lubr icllto the lin kage as )scflhed in Section 2, and atljl' stthe cable as (fescri bed in Section 18.
21 VilCUUrll sorvo unit -dosCrilHion
A vacuum servo unit is linod Into the lir,lk e hydrallirc cil cu il. 111 series with I he 111,1S ler cylinde f. to provide assiswnco to the dllver whlln Ihe brake pedal is depressed . Thi s reduces the eHolI le{luired try the driller to oper,lIe the brakes, under all brak ing condi tions .
This unit operates by vacuum, obtained from Ihe indu ction mnni rold and comprises basicall y iI booster diilphragnl and check lIallle . The servo unit and hydraulic master cylinder are connected
t o gether so that th e serllO unit piston rod acts as the master cylrnder pUShrod. The driller's b rilking ellon is trilnsmitted through allot her PIi ShlOd 10 the serllO unit piston and ils built-in COmrol system . The scrllo unll pislon docs not fit tightly inro the cylinder. but has a strong ,lltl flhril!Jlllto ke el) liS edges in COllst ilnt COntaCI with I he cylinder Willi_
23 rilult diagnosis -hrilking system
~ylllptom
-'ceSSllle ped,,1 u;tllel
nrakcs pull 10 ono Side
Or;tke ludder
E~cessive eHor l to stop car
so ensuring an i1inigh t seal between the two parts, The fo rward
chamber is held undelllaCUUm condi tions cleilted in the inle t manifold of the engine and during periods when the brake pedill is not in use, the controls open a passtlge 10 the rear ch ambe ., so placing it under lIacuum conditions as well. When the b.ake pedal is dep.essed. the lIacuum pass.Jge to the rear chamber is CUI oH and the chamber expos ed to atmospheric pressure. The consequent rush 01 ail pushes
the servo piston lorward in tile lIacuum chamber and operates the main push rod to the m.Jster cylindcl. The controls are designed so that assistance is given under all condllions. When the brakes are 1'101 requ ired, vacuum in the rear chamuer i s .e -es tabl ished when the br.Jke ped.J1 is released . All air Irom the atmosphe.e entering tho rear ch.Jmbe. is passed through II sma ll air trlter. Und er normal opcr.Jting cond itions tho IIflC(IUm serllO unit is lIery relraule and does not require ollerhaul e~cepl at IIcry high mile,1geS. In this case it is far bcner 1 0 o bta in a serllice e~hange uni l. r,1the, than rcp;ti . the o,igi'lo11 unit . Although inlernal components we,e once .Jv'lIlaule 10 ' ovcrhauling purposes this service has no w been
d,scont,nue(t .
22 Vacuulll servo unit _ remOlla l MId re filtillg
I RemOIlO the master cylinder as desc.ihed In Section 10. 2 D,scolllwc l thc vacuum hose from the non·return lIalve on the serllo \lI1it. 3 Work i,,!) insido thc cal. remOlle th e lower l;t cia panel below the stccring column. 4 E~tractlhc clip and l)ul1 outlho clellis pin attaching Ihe push.od to the l ootu .ake ped;t!. 5 Unsc.ew the nuts securing thc mount ing b.ack.et to the bulkhead.
then withdraw thc serllo unit and bracket from the engine COlllp,lJtlnen t, 6 UnSClew th e nuts ar1(1 serlar,lle the braket 110m the SCIIIO uni, . 7 netrning IS;t rell e.sal 0 1 remOllal w ith leference .Jlso 10 Section 1 0 when retrumg Ihe master cylrnder.
Renson(s)
RC.Jr blake self adju sting mechanism faulty All i n hydrilulic system
WOIll or cont,llllina led /rnin{Js Seized Caliper or wheel cy linde r
E~cessille run-out or distortion of discs o. drums
Worn Of cont aminated linings Brake backplate or caliper l oose WOIll suspensio n bailloints
SerllO unit faulty
Worn or conwmin.Jted linings
I
J
procarmanuals.com

rhapter 10 Suspension and steering
F Specificatio n s
Front suspension
Rear suspension
, . , enflg gear (manual) Type ................... ....................•................ Steeling whecl turns (lock to lock) .. . LUbrican t type ............. ................. ...... . lUbricant capacity _ ............................. .
" G 3 ,
7 ,
• 20 1 15
"
Powel stCCIlIlg Ilump .. remOllal ,111(1 fcllting RCiU leill SI)II119 . emoval. bush renewal .1nd Iclottlng Flo;"), shock iJbSOfOO' removal ,m(/ felUtlng , ............... , Rein sl ROlltlllc m"IIH ennncc .
Steering column -rCmov Slecrong gear (manual) -overhaul and adJustmcn t .. Steeling ge'lf (manu"l) -removal and relrn ing •...•.•...
Steeling wheel -rCfllov Track rod and baliJoll1l -renewal
Wlleels nlld lyres -uencrill CilfC and maintenance ...................... .
17 10 9
" 2 19 13 12 ,.
" 21
Independent. MacPherson strutS with Integral telescopic shock
ab sorbers Seml·elllpliC leaf springs with flgld and stabiliser bar
Rack and
pinion 3.36 SAE 90 EP gea r oil 0.15 IlIre (026 pint)
i
i.
!
I (
!
:~
I:
II
procarmanuals.com

)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 -yres SllC . <;JSsu,es Illl/m' (~(Jflclll'). 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 ')~",{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 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

Chapter 10 Suspension and steering 161
fig. 10.11 Drivebelt [ldjustlllent pulley holts on 3.0 litre models -arrowed (Sec 2)
2 Routine maintenance
At the "*',vals spec ,f,ed III the Routine MainhHlance $()(;t,on in the front of til() manunl c,lIIy out the 101l0wlIl\j p,o(;cdures.
Check lyres for illflalioll, wear and conditioll 1 Check [lnd If necessary adjust the tyre pressures .
2 Check [III t yres for WC[lr and condition with referenc e to Section 21
Check power steering pump drive belt tensiof) 3 Check thm the deflection of the drivebelt m,dway ulon!) its lonyest nlll between upper pulleys is approxirn 1110tler;lle th"'''h pressure . 1 If "dl"~t"'e"l ,s necuss;uy. loosen the ,dler pulley bracket bolt~. re'posll'o" tlH~ IIIilcket then rc·t'Uhten the bolts On 30 htre llIodels the III[lck"t t"u~t he pivott:!! .1tound the end holt. whmeas on 2.8 litre ,,'odds the b';'eket mllst I", ,"oved wllh"l Ihe elonu"t<:d bolt holes
(photo).
Clwck puwer steering fluid levef (lnd hydraulic huses II pOSStble the level should be checked w,th the Buid [It nOll1lal
uper,\!mg tClIll)Cr[lture . 6 On c;lrly modcls unscrcw the wing nut nnd relnove Ihe rese,voir cover ilild uaskel. The flu,d should be up 10 Ihe MAX level mark on the
reservo". 7 On later models, wrn tht! hiler C lll.Jrk on the d'pstick.Js applicable (photo).
Fig. 10. 5 Topping·up the power steering reservoir on early models (Sec 2)
8 Whele nec.ess.1'y ~dd Ihe ~pccilled lIU1d to bring Ihe level up to the
correct ,nilrk. 9 ChC(;k the hydr[luhc hoses for comJit,on and security.
Check steerinfj ,-md suspension components 10 n,ll$O tilt) front ilno reM 01 the Cill or position over an inspeclion pn. 11 Check the SleetinlJ wck and t'e 'rods for d[lm3ge und weM. Also check the wek HJbber bellows and track rod end rubber bOOIS for spfilS
ilnd leilk[lge. 12 Chec k the front ,md reilr suspension components lor d"m.Jge [lnd wear. In particuf;lr check the front suspension tr.Jck control Mm ilrod stahiliwr r"bber mounling bushes. Usc a lever to check that there is no excessive we[lr III the Iron I slispenSlon lower IJ[ll lJoints which Me
"'\()\JIill wnh the track conlrol ilflllS . 13 Check the operat,on of the I,ont ;IIHt rear shock absorbers This is
be st ilchievcd with thO} Cilr on the \lfOlind by depressing euch corner of the ca' 1111\I1. On 'ele[lsil\ljthe C()"H~r helllU checked Ihe body should ,,~c thell s"llie IIlIl11ed,mely on ,t~ way down. II there nrc sever.J1 ()sclll;ot'ons the sho(;k absorber IS weilk nnd should be renewed.
3 Front hub _ removal. refitliny and bearing adjustillent
Apply the h[llldhr[lke then Jilek tip the front 01 the cm ilnd support
on axlt! standS Remove til(! rOildwhecl 2 Rernove the front ul;lke CJllper With ,elerence 10 Ch.Jpter 9. Whele the flex,ble br[lke host! is connecte(t dueclly to the cililper ther e IS no need 10 disconnect the hose i1S thO} caliper can be suspcnded by wire
aWily from the diSC. 3 By calelul 1 centre of the huu (phOIO).
" :<>,:,~,.
Adjusting the power Sleering pump drivebelt tension on the 2.8 litre engine
2.7 Powcr steeling filler c.Jp/d,pstlck for the 2.8 hIre engine
3.3 Removing the dUSI cap from the front
hob
i
i ,
~ !
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 II11 II) while IIngurs ~"d Ihun1l),
1 0 Rei" the nut ret;)u)Cr SO th~t the spill pUl holes ~re ~lIg"ed. Fit a
v split pin 4 Front hub be 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 4
Scoop out the grease 110m inside the huh imd wash clea". S Drive the new bearing tr 5 Working the
glease well into th e beiu ings. lully p 5
Front Suspension strut _ renl0v

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 nlll _ using locking fluid on its thre 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 crrmp the nut
II~nge into the 5101
7 F ront stabiliser bar -removal 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 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 7.3
Front Slilblliser bJr iltlilchmCIll to tr tile l 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. 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 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 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. 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 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"~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 refllovlIt l 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 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"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 11
R eM st"hiliscr har -rcmovnl ,,"d refitting
Chock tlr" from WIH'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" 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 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 10 5 ReM sprinU U ·bolts 11.3 Re i:
procarmanuals.com

,6 Chapter 10 Suspension and steering
A
l
I Lr;=::;;r""~Jj'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'''~'ll'''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 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 17 Steering ge 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 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 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 --
-,
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""~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 3 It IS now Ilecess,l'y to unSClew the housmgs from the IlnilIOUl1s. so IhJt the tr~ck rods. hOIlSUlgS , locknuts. hall se 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 1)nd lower beilJlnU {; USlIlg a serewdllver. or sinlllill tool, pnse out the pUllon oil seal 7 Clean all d'll 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