lock FORD FESTIVA 1991 Service Manual

Fig. 10: Identifying Transaxle Oil Passages
Courtesy of FORD MOTOR CO.

Fig. 11: Torque Converter Housing Components

Courtesy of FORD MOTOR CO.
COMPONENT DISASSEMBLY & REASSEMBLY
BAND SERVO
Inspection
Remove seal rings and inspect piston for damaged or worn piston. Ensure spring free length is 1.890" (48.00 mm). If less than specified,
replace spring. Install new seal rings on piston and servo retainer.
DIFFERENTIAL
Disassembly
1. Remove ring gear retaining bolts and ring gear. Using hammer and pin punch, drive out roll pin. See Fig. 12. Push out pinion gear shaft.
Remove pinion and side gears, with washers, from differential housing.
2. Using appropriate puller, remove side bearings from differential housing. DO NOT remove speedometer drive gear unless damaged.
Removal will damage speedometer drive gear.
Inspection
Check all gears for signs of excessive wear or damage. Check differential gear case for cracks or other damage. Replace as needed.
Reassembly
1. Reverse removal procedure to reassemble. Measure side gear and pinion gear backlash by inserting drive shafts into differential side
gears and supporting shafts in "V" blocks. Position dial indicator with plunger resting on teeth of pinion gear. See Fig. 13
. Measure
backlash. Repeat procedure with plunger on other pinion gear.
2. Backlash readings should be less than .004" (.10 mm). If backlash is not within specification, adjust backlash by changing thrust
washers. Thrust washers are available in .079" (2.00 mm), .083" (2.10 mm) and .087" (2.20 mm) thicknesses. Use thrust washers of t h e
same thickness on both sides whenever possible.
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Fig. 16: Identifying Oil Pump Oil Passages

Courtesy of FORD MOTOR CO.
GOVERNOR ASSEMBLY
Disassembly & Reassembly
S e c u r e go ve r n o r a sse mb l y in vise . Usin g h a mme r a n d p in p u n c h , d r ive o u t go ve r n o r sh a ft ge a r sp r in g p in . R e mo ve ge a r . R e mo ve sl eeve from
shaft. Remove oil screen clamp and screen. See Fig. 17
. Clean all parts as needed. Lubricate parts with ATF. To assemble, reverse
disassembly procedure. Replace spring pin.

Fig. 17: Exploded View Of Governor Assembly

Courtesy of GENERAL MOTORS CORP.
IDLER GEAR ASSEMBLY
Disassembly & Inspection
Attach Idler Shaft Holder (J-35286) or hex wrench to idler shaft and support assembly in vise. Remove lock nut. See Fig. 18 . Remove
bearing, spacer, idler gear, adjustment shim(s) and remaining bearing. Press bearing outer races from idler gear. Check all gear teeth for wear or
damage and bearings for breakage or unusual wear.
Reassembly
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1. Place idler shaft holder or hex wrench in vise and place idler shaft on wrench. Install outer races in idler gear. Place bearing, idler gear,
adjustment shim, spacers, bearing and nut on idler shaft and tighten nut to 94-130 ft. lbs. (127-176 N.m).
2. Measure bearing preload. Mount idler gear in vise. Using INCH lb. torque wrench, measure idler gear shaft turning torque. Turning
torque should be .26-8.0 INCH lbs. (.03-.90 N.m). If preload is not within specification, change selective shims. Selective size shims are
available from .004" (.10 mm) to .008" (.20 mm) in .04 mm increments. One .020" (.50 mm) shim is available. DO NOT use more than
7 shims. Once correct preload is obtained, retighten idler gear locknut to 94-130 ft. lbs. (128-177 N.m)

Fig. 18: Exploded View Of Idler Gear Assembly

Courtesy of FORD MOTOR CO.
LOW-REVERSE BRAKE
Inspection
Check all components for signs of damage or excessive wear. Check free length of return springs. See LOW-REVERSE BRAKE SPRING
SPECIFICATIONS . If not correct, replace spring(s).
LOW-REVERSE BRAKE SPRING SPECIFICATIONS
OIL PUMP
Disassembly
Remove pump cover retaining bolts and separate cover from pump body. Remove pump flange. See Fig. 19 . If gears are to be reused, match
mark gears to reassemble in same position. Remove drive and driven gears.
Inspection
1. Check the condition of the gear teeth and surfaces. Check seal rings for signs of cracks or breaks and replace as needed. Check condition
of pump housing sleeve and inner gear bushing. See Fig. 20
. See the OIL PUMP SPECIFICATIONS . Check sleeve outer diameter
and bushing inner diameter.
2. If sleeve diameter is less than 1.492" (37.90 mm) or bushing diameter is greater than 1.499" (38.08 mm) replace sleeve and bushing as a
set. Check pump clearances and compare with values shown in the OIL PUMP SPECIFICATIONS
.
Reassembly
Apply ATF on all parts. To assemble, reverse disassembly procedure. DO NOTtighten pump cover to oil pump housing. Oil pump reassembly
is completed during transaxle reassembly.
OIL PUMP SPECIFICATIONS
ApplicationFree Length In. (mm)
Aspire & Festiva1.091 (27.70)
Tracer1.070-1.110 (27.20-28.20)
ApplicationClearance In. (mm)
Drive & Driven Gear-To-Pump Cover.001-.003 (.025-.08)
Driven Gear-To-Crescent.006-.010 (.14-.25)
Driven Gear-To-Pump Housing.002-.003 (.04-.08)
Seal Ring Side.002-.016 (.04-.40)
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1. Record direction of rotation one-way clutch locks and turns. Remove snap ring and pull out planetary carrier from one-way clutch inner
race. See Fig. 8
. Check for worn or damaged parts. Bushing wear on one-way clutch must not exceed 5.120" (130.06 mm).
2. Check clearance between pinion gears and washers in planetary carrier. If clearance exceeds .031" (.80 mm), replace planetary carrier.
Reverse disassembly procedure to reassemble. Install one-way clutch in inner race and ensure that it will turn in one direction
(clockwise) only.
REAR CLUTCH
Disassembly
1. Remove large snap ring. Lift out retaining plate, clutch plates, and dished plate. See Fig. 21 . Using appropriate compressor, compress
rear clutch spring retainer to remove small snap ring, spring retainer, and clutch return springs.
2. Place front clutch on oil pump and rear clutch hub on top of front clutch. Apply air pressure to rear clutch oil passage to remove piston.
See Fig. 16
. Remove and discard piston seal rings.
Inspection
Inspect for wear or damage. Ensure return spring free length is 1.031-1.071" (26.20-27.20 mm).
Reassembly
1. Install seal rings on piston and install in clutch drum by applying even pressure on perimeter of piston and rotate piston slowly. Install
return springs and spring retainer. Press spring retainer. Install snap ring. Note direction of dished plate and install. Install driven and
drive plates, retainer plate and snap ring. See Fig. 21
.
2. Ensure clearance between snap ring and retainer plate is .031-.039" (.80-1.00 mm). If clearance is not within specification, select correct
retaining plate. Retaining plates are available in thicknesses .189" (4.80 mm) to .244" (6.20 mm) in .20 mm increments.
3. Check rear clutch operation by placing forward clutch on oil pump and then rear clutch. Apply compressed air (70 psi maximum) to
rear clutch oil passage and check operation. See Fig. 16
.

Fig. 21: Exploded View Of Rear Clutch

Courtesy of FORD MOTOR CO.
REAR CLUTCH HUB
Disassembly, Inspection & Reassembly
Remove snap ring and separate hub from internal gear. Check for worn or damaged snap ring or gear and replace as needed. Reverse
disassembly procedure to reassemble hub.
VALVE BODY
Disassembly
1. Remove manual control valve. Remove oil strainer retaining bolts and oil strainer. Remove upper-to-lower valve body retaining bolts.
Separate valve bodies, separator plate and sub-body. DO NOT lose check balls and springs or orifice valve and spring. See Fig. 22
.
2. Remove, clean and install each valve individually as needed. See Fig. 22
. Lubricate moving parts with ATF. Ensure all valves move
(snap) freely. If valve sticks in its bore and cannot be freed, valve body must be replaced. DO NOT attempt to hone valve bores or
polish valves.
3. Inspect the valve springs for signs of damage or deformation. Measure valve spring free length and diameter. Refer to the VALVE
NOTE:Rem ove and clean one valve at a tim e to avoid incorrect installation. If any valves, valve springs, or
valve bodies are dam aged, the entire valve body assem bly m ust be replaced.
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BODY SPRING DIMENSIONS . Reassemble components in reverse order of disassembly.

Fig. 22: Exploded View Of Valve Body Assembly

Courtesy of FORD MOTOR CO.
VALVE BODY SPRING DIMENSIONS
Reassembly
1. To reassemble, reverse disassembly procedure. Coat all parts with clean transmission fluid. DO NOT force valves into position. Ensure
orifice check valve, check ball and springs are located correctly.
2. Place separator plate on lower valve body and hold with clamps. Install upper valve body and bolt into place. Tighten upper valve body
to lower valve body. See Fig. 23
.
ApplicationFree Length In. (mm)
Throttle Back-Up1.417 (36.00)
Downshift.862 (21.90)
2-3 Shift (Aspire & Festiva)1.614 (41.00)
1-2 Shift1.260 (32.00)
Second Lock1.319 (33.50)
Pressure Regulator1.693 (43.00)
Throttle Relief.441 (11.20)
Orifice Check (Aspire & Festiva).610 (15.50)
Steel Ball (Spring)1.516 (26.80)
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case over pump cover. Measure clearance between straightedge and pump cover, or between straightedge and transaxle case. See Fig.
26 .
3. If pump cover is below edge of transaxle case, clearance between straightedge and pump cover should not exceed .004" (.10 mm). If
pump cover is above edge of transaxle case, clearance between straightedge and transaxle case should not exceed .006" (.15 mm).
4. If pump cover and/or transaxle case clearance is correct, total clutch assembly end play will be correct. Total clutch assembly end play
should be .010-.020" (.25-.50 mm). If pump cover and/or transaxle case clearance is incorrect, remove pump cover and replace pump
support thrust washer. Thrust washers are available in thicknesses from .047" (1.20 mm) to .087" (2.20 mm) in .20 mm increments.
5. Reassemble oil pump by aligning marks on oil pump gears. Place pump cover on pump housing. Install and tighten bolts to
specification. See TORQUE SPECIFICATIONS
. Install oil pump shaft in oil pump and check operation by turning shaft by hand.
Gears should move freely without binding.
6. Install front clutch thrust washer over pump support. Install oil pump to transaxle. Install oil pump bolts. Apply sealant on 2 lower
bolts and tighten bolts to specification. Refer to the TORQUE SPECIFICATIONS
.
7. Position transaxle with oil pump facing down. Turn sun shell 2 revolutions. Insert screwdriver between tabs of front clutch and sun shell
deep slots. Using a feeler gauge, measure in the shallow slots. See Fig. 26
.
8. End play should be .020-.031" (.50-.80 mm). If end play is not within specification, remove oil pump and install correct thrust washer.
Thrust washers are available in thicknesses of .051" (1.30 mm) to .106" (2.70 mm) in .20 mm increments.
9. Tighten band adjusting stop bolt to 106-133 INCH lbs. (12-15 N.m). Loosen bolt 3 turns and then tighten lock nut to 41-59 ft. lbs. (56-
80 N.m). Install valve body steel check ball and spring in case. Install valve body and oil pan. Install turbine and oil pump sh aft s. In st al l
speedometer driven gear, oil dipstick and tube.
10. Install the vacuum modulator valve in transaxle. Make sure correct length control rod is installed in the modulator. Refer to VACUUM
THROTTLE VALVE DIAPHRAGM (MODULATOR) R & I under ON-VEHICLE SERVICE. Install kickdown solenoid and
park/neutral switch. Install torque converter. With converter properly installed, distance between machined pad on torque converter and
front edge of transaxle housing should be .50" (12.7 mm).

Fig. 26: Measuring Front Drum & Total End Play

Courtesy of FORD MOTOR CO.
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Fig. 27: Identifying Needle Bearings & Thrust Washers

Courtesy of FORD MOTOR CO.
NEEDLE BEARING LOCATION
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
TRANSAXLE SPECIFICATIONS
TRANSAXLE SPECIFICATIONS
ApplicationDimension In. (mm)
Needle Bearing
"A"1.650 (41.90)
"B"1.846 (46.90)
"C"2.083 (52.90)
"D"2.752 (69.90)
Thrust Washer
"A"1.614 (41.00)
"C"2.028 (51.50)
"D"2.756 (70.00)
ApplicationFt. Lbs. (N.m)
Axle Nut116-174 (157-235)
Ball Joint Clamp Bolt40-50 (54-68)
Idler Gear Lock Nut94-130 (127-176)
Lug Nut65-87 (88-118)
Oil Pump-To-Transaxle Case11-16 (15-22)
Output Bearing/Idler Support Bolt14-19 (19-26)
Output Shaft/Stator Support Bolt8-10 (11-14)
Ring Gear51-62 (69-83)
Torque Converter-To-Drive Plate25-36 (34-49)
Transaxle Case-To-Converter Housing22-34 (29-46)
INCH Lbs. (N.m)
Go ve r n o r C o ve r B o l t s71-97 (8-11)
Oil Pan Bolts71-97 (8-11)
Oil Pump Cover97-124 (11-14)
Upper-To-Lower Valve Body(1)
Valve Body Bolts89 (10)
(1)See Fig. 19 .
ApplicationIn. (mm)
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Back To Article
T RANSMISSION SERVICING - A/T
1988-93 T RANSMISSION SERVICING Ford Motor Co. Autom atic T ransm ission
IDENTIFICATION
AUTOMATIC TRANSMISSION APPLICATIONS
LUBRICATION
SERVICE INTERVALS
Check fluid level at every engine oil change. Fluid, filter changes and band adjustments are not required under normal operation. Under severe
service operating conditions, change fluid every 30 months or 30,000 miles. Adjust band when fluid is changed.
CHECKING FLUID LEVEL
With transmission at normal operating temperature, place vehicle on level surface. Apply parking brake and run engine at idle. Run gearshift
lever through all positions, ending in Park. With engine running, fluid level should be between "F" and "L" marks. DO NOT overfill.
RECOMMENDED FLUID
Use Dexron-II ATF.
FLUID CAPACITIES
TRANSMISSION REFILL CAPACITIES
DRAINING & REFILLING
1. Remove undercover and side cover to gain access to transaxle oil pan. Remove drain plug and drain fluid. Remove oil pan and discard
gasket. Clean or replace filter screen as necessary. Tighten screen bolts to 71-97 INCH lbs. (8-11 N.m).
2. Install oil pan bolts. Tighten bolts to 44-71 INCH lbs. (5-8 N.m). On all models, install drain plug with NEW washer. Tighten plug to
29-40 ft. lbs. (39-54 N.m).
3. Install undercover and side cover. Add about 3 qts. of specified ATF through dipstick guide tube. DO NOT overfill. Run engine to
normal operating temperature and check fluid level.
ADJUSTMENTS
NEUTRAL SAFETY SWITCH
Combination neutral safety and back-up light switch is screwed into transaxle case. No adjustments are necessary.
SHIFT CONTROL CABLE
1. Disconnect negative battery cable. Remove shift console. Place shift lever in Park. Remove shift lever knob and lock nut. Remove 4 shift
quadrant attaching screws.
2. Loosen shift cable adjuster nuts until they reach end of cable threads. See Fig. 1
. Place shift lever in Park. Tighten lower adjustment
nut until it lightly touches "T" joint, then tighten upper adjustment nut to 80-97 INCH lbs. (9-11 N.m).
3. Lightly press selector push rod and make sure guide pin clearance is correct. See Fig. 2
. Check guide pin clearance when shift lever is
in Neutral and Drive. Readjust shift cable as necessary.
4. Install 4 shift quadrant attaching screws, shift lever knob, lock nut and shift console. Connect negative battery cable.
ModelTransmission
FestivaATX/3HAT
NOTE:Capacities given are approxim ate refill am ounts that apply to overhaul situation. Correct fluid level
should be determ ined by m ark on dipstick.
ApplicationQts. (L)
ATX/3HAT5.6 (5.3)
CAUT ION: DO NOT use any type of gasket sealer or RT V on oil pan gasket. DO NOT overtighten.
CAUT ION: After com pleting linkage adjustm ents, be sure neutral safety switch operates properly. With parking
brake and service brakes applied, try to start engine in each gear position. Engine m ust crank only
when gearshift lever is in Neutral and Park.
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Fig. 1: Adjusting Shift Cable

Courtesy of FORD MOTOR CO.

Fig. 2: Checking Guide Pin Clearances

Courtesy of FORD MOTOR CO.
INTERMEDIATE BAND ADJUSTMENT
1. Loosen adjuster bolt lock nut. See Fig. 3
. Tighten adjuster bolt to 9-11 ft. lbs. (12-15 N.m). Back out adjuster bolt exacty 3 turns.
2. Holding adjuster bolt, tighten lock nut to 41-59 ft. lbs. (56-80 N.m).
NOTE:Adjuster bolt threads are coated with Sealant (E1FZ-19562-A) at factory. Ensure sealer is still on bolt
after adjustm ent.
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Fig. 3: Adjusting Intermediate Band

Courtesy of FORD MOTOR CO.
KICKDOWN CONTROL ADJUSTMENT
1. Kickdown is controlled by solenoid on bottom of transaxle case. Solenoid is actuated by a kickdown switch on accelerator pedal
bracket.
2. To adjust switch, attach circuit tester to each terminal of switch. Loosen switch lock nut. Adjust switch so that there is continuity when
accelerator pedal is depressed 7/8 or more of its full travel.
SHIFT QUADRANT
1. Remove shift lever knob. Remove console attaching screws. Place shift lever in Park. Remove shift lever knob and lock nut. Remo ve
shift quadrant. Align holes in slider and shift quadrant. Install an alignment pin to hold slider in position.
2. Install quadrant and remove alignment pin. Ensure clearance between lock lever and emergency override lever is correct. See Fig. 4
.
Install lock nut and shift lever knob. Tighten lock nut to 11-15 ft. lbs. (15-20 N.m). Install console.

Fig. 4: Checking Lock Lever Clearance

Courtesy of FORD MOTOR CO.
DOWNSHIFT SWITCH
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