speedometer FORD FESTIVA 1991 User Guide

tube from evaporator core fins while removing thermostatic switch. To install, reverse removal procedure. Evacuate and recharge system.
THERMOSTATIC EXPANSION VALVE
Removal & Installation
1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove evaporator housing. See EVAPORATOR
HOUSING under REMOVAL & INSTALLATION. Remove air inlet duct. See Fig. 1 .
2. Remove insulation from sensing bulb. Disconnect thermostatic expansion valve at evaporator tube fitting and inlet tube fitting (from
receiver-drier). See Fig. 3
. Remove thermostatic expansion valve. To install, reverse removal procedure. Use new "O" rings. Evacuate
and recharge system.
A/C RELAYS
Removal & Installation
A/C relays are located in left front corner of engine compartment, near battery. Unclip relay holder from its mounting bracket. Disconnect
relay wiring. DO NOT pull on wiring connector to remove relay from holder. Remove relay from holder. To install, reverse removal procedure.
A/C-HEATER CONTROL ASSEMBLY
Removal & Installation
1. A/C control module is located above radio. Remove accessory bezel. Remove radio (if necessary) and glove box. Disconnect
recirculated/fresh air cable from door lever. See Fig. 5
. Disconnect mode select cable from door lever. See Fig. 6 .
2. Disconnect temperature control cable from door lever. See Fig. 4
. Pull control assembly away from dash, and disconnect wiring
connectors. Remove control assembly.
3. To install, reverse removal procedure. Check and adjust temperature control, recirculated/fresh air and mode cables. See
ADJUSTMENTS. Test control assembly operation.
BLOWER MOTOR
Removal & Installation
Disconnect negative battery cable. Remove A/C air outlet duct located below steering column. See Fig. 2 . Disconnect blower motor wiring.
Remove blower motor attaching screws and blower motor. Remove blower wheel attaching nut. Remove blower wheel and washer. To install,
reverse removal procedure.
BLOWER MOTOR RESISTOR
Removal & Installation
Disconnect negative battery cable. Remove air duct located below steering column. See Fig. 2 . Disconnect blower motor resistor wiring.
Remove blower resistor attaching screws and resistor. To install, reverse removal procedure.
AIR DISTRIBUTION PLENUM
Removal & Installation
1. Remove instrument panel. See INSTRUMENT PANEL under REMOVAL & INSTALLATION. Drain cooling system. Disconnect
heater hoses in engine compartment. Disconnect wiring for blower motor and blower resistor. Disengage wiring harness and antenna
lead from bracket on front of air distribution housing.
2. Loosen connector duct-to-air inlet clamp screw. Remove upper and lower mounting nuts from plenum. Disengage and remove plenum
from defroster ducts. To install, reverse removal procedure. Refill cooling system, and check for leaks.
HEATER CORE
Removal & Installation
1. Remove air distribution plenum. See AIR DISTRIBUTION PLENUM under REMOVAL & INSTALLATION. Disconnect linkage
connecting defroster doors. Remove attaching screw located near blower resistor. Turn housing around and remove attaching screw
located near blower motor opening.
2. Remove clips retaining blower housing halves. Separate blower housing halves. Remove heater core. Remove tube insert from heater
core. To install, reverse removal procedure. Test system for proper operation.
INSTRUMENT PANEL
Removal & Installation
1. Disconnect negative battery cable. Remove steering wheel, steering column covers and multifunction switch assembly. Disconnect
electrical connectors from switches on instrument panel. Remove instrument cluster hood.
2. Disconnect speedometer cable from transmission. Remove 4 instrument cluster screws. Pull instrument cluster out from instrument
panel cluster enough to disconnect wiring and speedometer cable. Remove instrument cluster.
3. Remove steering column shield. Remove shield bracket. Remove glove box. Remove fuse panel cover and 4 fuse panel screws. Pull fu se
panel out, but DO NOT remove. Remove shift lever console and mount brackets. CAUTION: DO NOT rem ove screw in front of blower resistor, or blower resistor m ounting plate will fall into air
distribution plenum . T o retrieve plate, disassem ble instrum ent panel.
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LINE PRESSURE TEST SPECIFICATIONS (ASPIRE)
LINE PRESSURE TEST SPECIFICATIONS (ALL EXCEPT ASPIRE)
LINE PRESSURE CUT-BACK TEST
1. Connect oil pressure gauges to line pressure and governor pressure ports. See Fig. 6
. Position gauges so they can be seen from driver's
seat.
2. Connect a hand-held vacuum pump to vacuum modulator. See Fig. 6
. Position vacuum pump so it can be operated from driver's seat.
With shift lever in "D", gradually increase engine RPM and observe pressure gauge readings. Record results.
3. With shift lever in "D", gradually increase engine RPM, and apply 8 in. Hg to vacuum modulator. When line pressure reading suddenly
decreases, observe the governor pressure gauge. Refer to LINE PRESSURE CUT
-BACK TEST SPECIFICATIONS .
4. If governor pressure gauge readings are not within specifications, ensure rod in vacuum modulator is installed. If a rod is installed, rod
length may be incorrect or vacuum throttle valve is sticking. See VACUUM THROTTLE VALVE DIAPHRAGM (MODULATOR)

under TESTING.
LINE PRESSURE CUT-BACK TEST SPECIFICATIONS
GOVERNOR PRESSURE TEST
1. Attach oil pressure gauge to governor pressure check port. See Fig. 6
. Position gauge so that it may be seen from driver's seat. Shift
transaxle into "D" and road test vehicle.
2. Accelerate vehicle smoothly and record governor pressure readings at 20, 35 and 55 MPH. See GOVERNOR PRESSURE
SPECIFICATIONS . If pressure gauge readings are not within specifications, check for fluid leakage in line pressure hydraulic circuit
and/or governor pressure hydraulic circuit. Also check for a faulty governor.
GOVERNOR PRESSURE SPECIFICATIONS
REMOVAL & INSTALLATION
See the appropriate TRANSMISSION REMOVAL & INSTALLATION - A/T article in this section. Refer to the following menu:
TORQUE CONVERTER
The torque converter is a sealed unit and cannot be serviced. Check for cracked or worn ring in seal area. Measure bushing in converter boss.
If I.D. is larger than 2.090" (53.08 mm) on Aspire, 1.302" (33.075 mm) on Festiva and Tracer, replace torque converter. If metal particles are
found in ATF, replace torque converter. To clean torque converter, flush with solvent, drain and flush with ATF and drain ATF.
TRANSAXLE DISASSEMBLY
1. Remove torque converter. Attach transaxle to appropriate holding fixture. Remove park/neutral switch, kickdown solenoid and vacuum
modulator with rod. Remove oil dipstick and tube. Remove speedometer driven gear retaining bolt and lift out gear assembly. Remove
oil pump drive shaft and turbine shaft.
2. Remove oil pan. Remove valve body. DO NOT lose check ball and spring. Position transaxle with oil pump facing downward. With
flat-blade screwdriver inserted in wide slot between front clutch drum and sun shell, pry down on front clutch drum. Do this seve r a l
times as you rotate assembly 2 complete revolutions.
3. Using a feeler gauge, measure front clutch drum end play. See Fig. 7
. Check clearance of small slot between front clutch drum tabs and
Applicationpsi (kg/cm2 )
At Idle
"D"46-54 (3.2-3.8)
"2 "150-166 (10.5-11.7)
"R"76-95 (5.3-6.7)
At Stall Speed
"D"141-157 (9.9-11.0)
"2 "150-166 (10.5-11.7)
"R"251-262 (17.6-18.4)
Applicationpsi (kg/cm2 )
At Idle
"D"43-57 (3.0-4.0)
"2 "114-171 (8.0-12.0)
"R"57-110 (4.0-7.0)
At Stall Speed
"D"128-156 (9.0-11.0)
"2 "114-171 (8.0-12.0)
"R"228-270 (16.0-19.0)
Vacuum Pump ReadingGovernor Pressure psi (kg/cm2 )
0 in. Hg (Atmosphere)14-23 (.98-1.6)
8 in. Hg6-14 (.42-.98)
Applicationpsi (kg/cm2 )
Aspire & Festiva
20 MPH13-21 (.9-1.5)
35 MPH25-35 (1.8-2.5)
55 MPH58-70 (4.0-4.8)
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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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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. 2: Checking Release Lever Clearance
Courtesy of FORD MOTOR CO.
CLUTCH PEDAL SPECIFICATIONS
CLUTCH PEDAL HEIGHT
1. Disconnect clutch cable from release lever at transaxle. Measure distance from upper center of pedal to firewall. See Fig. 1
. If not
within specifications, check pedal mounting for wear or damage. See CLUTCH PEDAL SPECIFICATIONS
.
2. If adjustment is required, remove instrument panel bracket and air duct located under steering column. Loosen clutch pedal switch lock
nut and rotate switch until correct clutch pedal height is obtained.
3. Install clutch cable at transaxle. Recheck pedal height. If connecting clutch cable changes pedal height, check cable for improper
routing, binding or adjustment. If connecting push rod changes pedal height, check for proper push rod adjustment. Install carpet and
insulation to complete adjustment.
REMOVAL & INSTALLATION
CLUTCH ASSEMBLY
Removal
1. Disconnect negative battery cable. Loosen clutch cable adjuster nut and disengage cable from release lever.
2. Remove starter. Disconnect back-up light switch and neutral switch. Disconnect ground cable/strap and supporting brackets. Disconnect
speedometer cable from transaxle.
3. Install Three Bar Engine Support (D88L-6000-A ) to engine hanger. See Fig. 3
. Remove top transaxle-to-engine bolts. Raise vehicle.
Remove bolt and nut retaining shift rod to input shift rail. Drain transaxle fluid. Remove all support brackets attached to transaxle.
Remove front wheels.

Fig. 3: Installing Engine Support Bar (Festiva Similar)

Courtesy of FORD MOTOR CO.
4. Remove engine splash shields. Remove front stabilizer bar. Disengage right and left side drive axle shafts from transaxle and support out
of the way. See the AXLE SHAFTS
- FRONT article in the DRIVE AXLES section.
5. Remove exhaust hanger from crossmember. Remove crossmember bolts in sequence, and remove crossmember. On Festiva, remove
crossmember mounting bracket and crossmember. Remove transaxle end plate bolts.
6. Place transmission jack under transaxle, ensuring it is secure. Remove remaining flywheel housing bolts. Lower transaxle by loosening
engine bracket bar hook bolt. Pull transaxle away from engine and lower from vehicle.
7. If reusing pressure plate, mark pressure plate-to-flywheel position for installation reference. Remove pressure plate retaining bolts
evenly. See Fig. 4
. To avoid dropping clutch assembly while removing bolts install clutch aligner. Remove pressure plate, clutch disc
and clutch aligner. Remove flywheel. Remove pilot bearing from flywheel (if replacing).
Inspection
ApplicationIn. (mm)
Pedal Height8.2-8.4 (208.2-213.2)
Free Play.35-.59 (9-15)
Release Lever-To-Pin.06-.10 (1.5-2.5)
Disengagement Height3.3 (84)
CAUT ION: DO NOT allow oil or grease to contact clutch disc face or m ating surfaces. Handle disc by edges.
DO NOT touch face.
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1. Check pressure plate surfaces for scoring, cracks or discoloration. Remove minor scratches or discoloration with fine emery cloth. Check
pressure plate diaphragm spring fingers for discoloration, scoring, broken or bent segments. Ensure all spring ends are the same height.
2. Check clutch disc lining surface for hardening or presence of oil. Check for worn clutch disc lining. Check for loose lining rivets.
Measure depth of rivet heads. Minimum allowable rivet depth is .012" (0.3 mm). Check for wear or rust on splines. Rust may be
removed with emery cloth.
3. Check flywheel surface for marks, scoring or discoloration. Minor surface repairs may be removed with fine emery cloth. Flywheel must
be machined if scoring, runout, or discoloration is excessive. Maximum flywheel runout is .008" (0.2 mm). Check for damaged or worn
ring gear teeth.
4. Check pilot bearing for wear. Check clutch release/throw out bearing for damage or wear at contact points. Rotate bearing in both
directions and check for binding or abnormal noise.
Installation
1. Replace release bearing and/or pilot bearing as necessary. Clean sealant from flywheel attaching bolt threads. Replace bolts if sealant
cannot be removed. Coat bolt threads with Stud/Bearing Mount Sealer (EOAZ-19554-B ), and install flywheel. Tighten bolts in a
diagonal sequence to specification. See TORQUE SPECIFICATIONS
at the end of this article.
2. Position clutch disc on flywheel with damper springs facing away from flywheel. Hold clutch disc in place with Clutch Aligner (T77F-
7137-A ). Position pressure plate over clutch disc. See Fig. 4
.
3. If reusing original pressure plate, align marks made during removal. Install pressure plate retaining bolts. Alternately tighten bolts to
specification. See TORQUE SPECIFICATIONS
at the end of this article. Remove clutch aligner. Place transaxle on transmission jack.
4. Lightly coat input shaft splines with Clutch Grease (C1AZ-19590-B ). Install transaxle, taking care to align input shaft through the
clutch disc spline. Align clutch housing onto engine guide bushings.
5. Install transaxle lower attaching bolts and tighten to specification. Using transaxle jack, raise transaxle to correct height and tighten
engine bracket bar hook. Install front engine mount and bracket and tighten to specification. Install starter and lower mounting b o l t s,
tighten to specification.
6. Install control rod to transaxle and tighten bolts and nuts to specification. On Festiva, install crossmember and support braces. Install
support braces. On all models, install exhaust hanger to crossmember. Remove transaxle jack.
7. Install new circlips on each half-shaft with gap at top of clip grove and slide into transaxle differential. After circlip snaps into place,
pull outward on hubs to confirm half-shafts are retained by circlip. Install front suspension components, wire harness, underbody and
fender splash shields and front tire assemblies.
8. Connect neutral and back-up light switch and ground wire. Fill transaxle with Mercon ATF transmission fluid to specification. In st al l
and adjust clutch cable or slave cylinder line bracket. Lower vehicle and remove engine support bar. Install speedometer cable into
transaxle.
9. Install battery and/or connect battery cable. Install air cleaner. Adjust pedal free play. See CLUTCH PEDAL FREE PLAY
under
ADJUSTMENTS. Recheck transaxle fluid level and road test vehicle.

Fig. 4: Exploded View Of Clutch Assembly

Courtesy of FORD MOTOR CO.
CLUTCH RELEASE BEARING & FORK
Removal
Remove transaxle. Remove release lever bolt and slide release bearing off. See Fig. 4 . Remove release lever shaft and remove release lever. CAUT ION: T ransaxle alum inum alloy construction requires precise tightening of m ounting bolts. T orque
specifications m ust be strictly adhered to. See T ORQUE SPECIFICAT IONS
.
NOTE:T he clutch release bearing is pre-lubricated and perm anently sealed. DO NOT clean release bearing in
solvent.
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Inspection
Check release bearing rotation operation for roughness, sticking and noise. Check release lever and transaxle front bearing retainer for wear or
damage. Ensure bearing slides smoothly on transaxle input shaft. Check release lever shaft for bent, worn or damaged condition. Check all
mating surfaces for wear or damage. Replace worn or defective components.
Installation
Apply light film of grease to transmission front bearing retainer lever-to-bearing surfaces and release lever contact surface. Align bolt hole in
release lever and shaft. Apply Stud/Bearing Sealant (E0AZ-19554-B ) to release lever bolt. Fill grease groove in release bearing hub and
remove any excess grease. Install release lever return spring. To complete installation, reverse removal procedure.
PILOT BEARING
Removal & Installation
Remove transaxle, pressure plate, clutch disc and flywheel. Drive pilot bearing out of flywheel using a driver that makes full contact with
bearing outer race. Reverse procedure for installation.
CLUTCH CABLE
Removal & Installation
1. Disconnect clutch cable from release lever. Remove nuts retaining clutch cable at firewall. Unhook clutch cable at clutch pedal.
2. Remove clutch cable from engine compartment side. To install, apply lithium grease to pedal cable hook and joint between release lever
and pin. Reverse removal procedure to complete installation. See Fig. 2
.
OVERHAUL
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
TRANSAXLE FLUID LEVELS
TRANSAXLE FLUID LEVELS NOTE:DO NOT rem ove pilot bearing unless necessary.
NOTE:Manufacturer does not provide overhaul inform ation for clutch m aster cylinder and clutch release
cylinder.
ApplicationFt. Lbs. (Nm)
Clutch Cable Bracket Nuts12-17 (16-23)
Clutch Pedal Push Rod Lock Nut9-13 (12-17)
Clutch Pedal Through Bolt Nut15-26 (20-35)
Crossmember
"A" Bo l t s47-66 (64-89)
"B" Bo l t21-34 (28-46)
Crossmember Brace (Front)23-34 (31-46)
Crossmember Brace69-86 (93-117)
Engine Mount Bolt (No. 2)33-48 (45-65)
Engine-To-Transaxle46-66 (63-89)
Flywheel Housing-To-Engine Bolt46-66 (63-89)
Flywheel-To-Crankshaft Bolt71-76 (96-103)
Front Wheel Lug Nut66-89 (90-120)
Lower Ball Joint Pinch Bolt32-40 (43-54)
Master Cylinder Retaining Nuts14-19 (19-26)
Pressure Plate-To-Flywheel Bolt13-20 (18-27)
Rear Engine Cover-To-Housing Bolt28-38 (38-51)
Rear Mount-To-Transmission Bolt50-70 (68-95)
Rear Transmission Mount-To-Body Bolt25-35 (34-48)
Release Fork Attaching Bolt26-30 (35-41)
Slave Cylinder Retaining Bolts12-17 (16-23)
Stabilizer Bracket-To-Body Bolt33-41 (45-56)
Starter Motor-To-Mount Bolt23-34 (31-46)
Transaxle Drain Plug29-40 (39-54)
INCH Lbs. (N.m)
Release Lever Bolt71-97 (8-11)
Speedometer Drive Gear Bolt69-106 (7.8-12)
ApplicationSpecification
Festiva2.6 Qts. (2.5L)
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
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