steering FORD FESTIVA 1991 User Guide

Fig. 1: Identifying Front Wiper/Washer Switch Terminals (Capri)

Courtesy of FORD MOTOR CO.
Festiva
Remove lower steering column cover to gain access to wiper switch electrical connector. Using an ohmmeter, ensure continuity exists between
terminals listed in table at specified switch positions. If switch does not test as specified, replace wiper/washer switch. See FRONT
WIPER/WASHER SWITCH CONTINUITY (FESTIVA) table. See Fig. 2 .
FRONT WIPER/WASHER SWITCH CONTINUITY (FESTIVA)
BLU - BLU/ORGPull washer leverYes
"Release washer leverNo
BLU - BRN/WHTIn tYes
"All other positionsNo
BLU - GRNLoYes
"HighYes
"All other positionsNo
BLU - BLU/REDHighYes
"All other positionsNo
ORG - YEL/REDRotate INT control knob(1)
(1)Ohmmeter will indicate a smoothly increasing resistance from 420-880 ohms (minimum) to 7-13 k/ohms (maximum).
TerminalPositionContinuity
BLK - BLK/WHTOffNo
"LowYes
"HighNo
BLK - BLU/REDOffNo
"LowNo
"HighYes
BLK - BLU/ORGWasher OffNo
"Washer OnYes
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Fig. 3: Identifying Rear Wiper/Washer Switch Terminals (Festiva)

Courtesy of FORD MOTOR CO.
REAR WASHER MOTOR TEST
See FRONT WASHER MOTOR TEST under TESTING.
REMOVAL & INSTALLATION
FRONT WIPER MOTOR
Removal
Disconnect negative battery cable. On Capri, gently pry linkage off ball socket at wiper motor arm. On Festiva, remove access plate then gently
pry linkage off ball socket at wiper motor arm. On all models, disconnect wiper motor electrical connector. Remove 4 mounting bolts and
rubber insulators and remove wiper motor.
Installation
Position wiper motor on firewall. Install 4 rubber insulators and mounting screws and tighten to 62-89 INCH lbs. (7-10 N.m). Reverse removal
procedure to complete installation. Check wipers for proper operation.
FRONT WIPER/WASHER SWITCH
Removal & Installation (Capri)
Remove center trim panel and access cover under steering column. Remove 2 screws and remove lower steering column shroud. Disconnect
wiper/washer switch electrical connector and pull wiring from routing clip. Firmly grasp switch and lever and remove from mounting. To
install, reverse removal procedure.
Removal & Installation (Festiva)
1. Disconnect negative battery cable. From back of steering wheel, remove 2 screws securing horn pad. Disconnect horn wire from horn
pad and remove pad. Remove steering wheel nut. Scribe reference mark on steering shaft and steering wheel hub for reassembly. Using
Steering Wheel Puller (T67L-3600-A), remove steering wheel.
2. Remove 4 screws from upper half of lower steering column cover. Remove cover. Remove upper steering column cover. Remove 5 clips
from lower half of lower steering column cover. Remove cover.
3. Release wiring harness clip and unplug 4 harness connectors from back of combination switch. From below steering column, loosen
band clamp securing switch hub to steering column jacket. Pull switch assembly from steering column.
4. To install, slide combination switch assembly onto steering column. Make sure switch assembly is seated and level against end of
column jacket. To complete installation, reverse removal procedure.
FRONT WASHER MOTOR & RESERVOIR
Removal & Installation (Capri)
Drain reservoir if necessary. Remove 2 bolts securing reservoir to inner finder. Disconnect electrical connector from washer pump mo t o r.
NOTE:Disconnect linkage from wiper m otor arm ball socket NOT by rem oving nut and wiper m otor arm . This
will elim inate the need to retim e wiper m otor and linkage. Replacem ent m otors are supplied with arm
attached. Manufacturer does not give procedure for tim ing m otor arm to wiper park position.
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Disconnect fluid lines and remove reservoir. To install, reverse removal procedure.
Removal & Installation (Festiva)
1. Disconnect negative battery cable. Remove washer reservoir filler neck attaching bolt. Remove coolant expansion reservoir. Disconnect
washer pump electrical connector. Remove left front splash shield.
2. Disconnect washer pump fluid lines and detach lines from reservoir clips. Remove reservoir attaching nuts and bolt. Detach washer
reservoir from filler neck and remove reservoir. To install, reverse removal procedure.
REAR WIPER MOTOR
Removal & Installation (Festiva)
Remove rear wiper arm and blade assembly. Remove boot from outer bushing attaching nut. Remove outer bushing attaching nut and remove
outer bushing. Remove liftgate trim panel. Disconnect wiper motor electrical connector. Remove 4 wiper motor mounting bolts and remove
motor. To install, reverse removal procedure.
REAR WIPER/WASHER SWITCH
Removal & Installation (Festiva)
Disconnect negative battery cable. Remove steering column covers. Remove screws securing instrument panel bezel to instrument panel. Pull
instrument bezel away from instrument panel. Disconnect electrical connectors from switches in bezel. Compress wiper/washer switch lock
tabs and remove switch from bezel. To install, reverse removal procedure.
REAR WASHER MOTOR & RESERVOIR
Removal & Installation (Festiva)
Open liftgate and detach reservoir cap. Remove rear quarter trim panel. Remove reservoir mounting bolts. Disconnect electrical connector
from washer pump. Disconnect fluid lines. Remove reservoir. To install, reverse removal procedure.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
WIRING DIAGRAMS
See appropriate chassis wiring diagram in the WIRING DIAGRAMS Section.
ApplicationINCH Lbs. (N.m)
Front Wiper Arm Retaining Nut89-124 (10-14)
Front Wiper Motor Mounting Bolts62-89 (7-10)
Rear Outer Bushing Retaining Nut27-44 (3-5)
Rear Wiper Arm Nut53-62 (6-7)
Rear Wiper Motor Mounting Bolts71-97 (8-11)
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00028304
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BRAKE SYST EM
1991-92 BRAKES Disc & Drum
DESCRIPTION & OPERATION
On Capri, vehicle braking is provided by front and rear disc brakes. Front and rear brakes are a full-floating, single piston design. The rear
caliper houses a self-adjusting parking brake.
On Festiva, vehicle braking is provided by front disc brakes and rear drum brakes. Rear brakes are a standard non-servo, self-en e r giz in g d e sign .
Front brakes are a full-floating, single piston design with caliper attached to steering knuckle.
BLEEDING BRAKE SYSTEM
BLEEDING PROCEDURES
Manual Bleeding
1. Exhaust vacuum from power brake unit by depressing brake pedal several times. Fill master cylinder with clean brake fluid. Install clear
vinyl bleeder hose onto first bleeder valve to be serviced. See BRAKE LINE BLEEDING SEQUENCE table. Place other end of hose in
clean transparent container.
2. Partially fill container with clean brake fluid. Open the bleeder valve 3/4 turn. Slowly depress brake pedal through its full travel. Close
bleeder valve and release pedal. Pump pedal several times to push air toward wheel cylinders. Repeat procedure until flow of brake
fluid is clear and shows no signs of air bubbles. Proceed to next bleeder valve in sequence and repeat procedure.
BRAKE LINE BLEEDING SEQUENCE
Pressure Bleeding
1. Exhaust vacuum from power brake unit by depressing brake pedal several times. Fill master cylinder with clean brake fluid. With
pressure bleeder at least 1/2 full, connect pressure bleeder to master cylinder using appropriate adaptor.
2. Install clear vinyl bleeder hose onto first bleeder valve to be serviced. See BRAKE LINE BLEEDING SEQUENCE table. Place other
end of hose in clean transparent container. Partially fill container with clean brake fluid. Open bleeder valve 1-2 turns. Allow fluid to
run until flow of fluid is clear and shows no signs of air bubbles. Proceed to next bleeder valve in sequence and repeat procedure.
Remove pressure bleeder and fill master cylinder with clean brake fluid.
ADJUSTMENTS
BRAKE PEDAL HEIGHT (FESTIVA)
1. Block wheels to prevent vehicle from rolling. Start engine and place transmission in Neutral. Fully release parking brake. Move carpet
and insulation away from firewall and brake pedal. Measure distance horizontally between upper center of brake pedal pad and firewall.
Distance should be 8.03-8.23" (204-209 mm).
2. If pedal height is incorrect, inspect pedal assembly for missing, worn or damaged bushings or for loose attaching bolts. Ensure firewall is
not distorted and pedal is not bent. If pedal height is still not within specifications, check brake pedal, booster or master cylinder for
correct and/or correctly installed parts
BRAKE PEDAL FREE PLAY (FESTIVA)
Pump brake pedal several to bleed vacuum from power brake booster. Gently depress brake pedal by hand and measure and measure play
before resistance is felt. Free play should be .16-.28" (4-7 mm). If free play is not within specifications, adjust brake pedal push rod.
BRAKE PEDAL FLOOR CLEARANCE
Capri
1. Move carpet and insulation away from floor board and brake pedal. With engine running and using Brake Pedal Effort Gauge (021-
00001), apply 132 lbs. (59.9 kg) of force to brake pedal. Measure distance from upper surface of brake pedal pad to floor board. If
distance is less than 3.27" (83 mm), inspect pedal assembly for missing, worn or damaged bushings or for loose attaching bolts.
2. Verify that floor board is not distorted and pedal is not bent. If pedal height is still not within specifications, check brake pedal, booster
or master cylinder for correct and/or correctly installed parts. Check for air in hydraulic system.
Festiva
Move carpet and insulation away from floor board and brake pedal. Using Brake Pedal Effort Gauge (021-00001) or equivalent, apply 132
lbs. (59.9 kg) of force to brake pedal. Measure distance from upper surface of brake pedal pad to floor board. If distance is less than 2.68" (68
mm), check for air in hydraulic system, faulty automatic adjusters or excessive shoe clearance.
POWER BRAKE UNIT PUSH ROD
Capri
ApplicationSequence
CapriRR, LF, LR & RF
FestivaRR, LR, RF & LF
NOTE:Check fluid level in m aster cylinder frequently during the bleeding sequence.
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Removal
Remove rotor and hub assembly from steering knuckle. Separate rotor, knuckle and hub. See FRONT BRAKE ROTOR & HUB under
REMOVAL & INSTALLATION. Press outer bearing from hub using Bearing Splitter (D84L-1123-A) and Shaft Protector (D80L-625-2).
Remove and discard outer grease seal. Pry inner wheel bearing grease seal from steering knuckle using a large screwdriver. Discard seal.
R e mo ve in n e r b e a r in g.
Bearing Preload
1. Use Spacer Selector Set (T87C-1104-B) to check and adjust preload. Install spacer selector into steering knuckle and clamp tool in vise
where shock absorber mounts, before installing hub/rotor assembly into steering knuckle. See Fig. 4
.

Fig. 4: Installing Preload Spacer Selector Set

Courtesy of FORD MOTOR CO.
2. Tighten center bolt from spacer selector set, in increments, to 36, 72, 108 and finally 145 ft. lbs. (49, 98, 147 and 196 N.m). Each time
center bolt is tightened, seat bearings by rotating hub by hand. Using an inch-pound torque wrench, measure torque required to turn
center bolt. Ensure torque reading is taken just as wrench starts to rotate.
3. Preload spacer thickness is correct if torque wrench indicates 2.2-16 INCH lbs. (.25-1.8 N.m). If measurement indicates less than 2.2
INCH lbs. (.25 N.m), a thinner spacer must be installed. If measurement indicates more than 16 INCH lbs. (1.8 N.m), a thicker spacer
must be installed.
4. Bearing spacers are available in various thicknesses. See PRELOAD SPACER AVAILABILITY table. Changing spacer thickness one
number changes bearing preload 1.8-3.5 INCH lbs. (.2-.4 N.m). Ensure correct spacer is installed and preload is within specification.
Remove preload spacer selector set.
PRELOAD SPACER AVAILABILITY
Stamped Mark On SpacerIn. (mm)
10.2474 (6.285)
20.2490 (6.325)
30.2506 (6.365)
40.2522 (6.405)
50.2537 (6.445)
60.2553 (6.485)
70.2569 (6.525)
80.2585 (6.565)
90.2600 (6.605)
100.2616 (6.645)
110.2632 (6.685)
120.2648 (6.725)
130.2663 (6.765)
140.2679 (6.805)
150.2695 (6.845)
160.2711 (6.885)
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Installation
1. Lubricate bearings with appropriate wheel bearing grease. Place inner bearing into steering knuckle. Install new inner bearing gr e a se
seal, and drive seal into place using appropriate seal installer.
2. Place original outer wheel bearing preload spacer (or spacer selected during preload inspection process) into steering knuckle bore.
Place outer wheel bearing into steering knuckle bore.
3. Liberally lubricate lip of NEW outer grease seal with appropriate lubricant. Drive seal into steering knuckle bore. Install brake rotor on
hub axle hub. Tighten bolts to 33-40 ft. lbs. (45-54 N.m). Position rotor/hub assembly into steering knuckle, and press assembly into
place using adapter from spacer selector set. To complete installation, reverse removal procedure.
REAR WHEEL BEARINGS
Removal & Installation
1. Raise and support rear axle. Remove wheel. Remove wheel bearing dust cap. On Capri, remove rear brake caliper. See REAR BRAKE
CALIPER & PADS under REMOVAL & INSTALLATION. On all models, carefully unstake rear axle lock nut using a chisel. DO NOT
damage threads on axle spindle. Remove and discard axle nut.
2. On Capri, remove rotor/hub assembly. On Festiva, remove brake drum/hub assembly. On all models, DO NOT allow outer wheel
bearing to fall out of hub. Remove inner bearing grease seal. Remove inner bearing. To install rear bearings, reverse removal procedure.
Adjust rear wheel bearings. See REAR AXLE BEARINGS under ADJUSTMENTS.
OVERHAUL

Fig. 5: Exploded View of Front Brake Assembly (Capri)

Courtesy of FORD MOTOR CO.
170.2726 (6.925)
180.2742 (6.965)
190.2758 (7.005)
200.2774 (7.045)
210.2789 (7.085)
NOTE:See Fig. 5
-12 for exploded views of brake assem blies and com ponents.
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Fig. 12: Exploded View of Master Cylinder (Festiva)

Courtesy of FORD MOTOR CO.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
DISC BRAKE SPECIFICATIONS
DISC BRAKE SPECIFICATIONS
ApplicationFt. Lbs. (N.m)
Backing Plate/Spindle Bolts (Rear)32-45 (43-61)
Brake Hose to Caliper16-22 (22-30)
Caliper Guide/Mounting Bolt29-36 (39-49)
Caliper Banjo Bolt16-21 (22-29)
Front Drive Axle Nut117-175 (159-237)
Hub-To-Rotor Bolt33-40 (45-54)
Power Booster Mounting Nuts
Capri14-19 (19-26)
Festiva12-17 (16-23)
Rear Axle Nut(1)
Rear Strut/Spindle (Capri-Rear)69-86 (93-117)
Rotor-To-Hub Bolts33-40 (44-54)
Steering Knuckle-To-Control Arm32-40 (43-54)
Steering Knuckle-To-Strut69-86 (93-117)
Steering Knuckle-To-Tie Rod21-33 (29-44)
Wheel Lug Nut65-87 (88-118)
INCH Lbs. (N.m)
Master Cylinder-To-Booster Nut89-142 (10-16)
Wheel Cylinder Mounting Bolt89-106 (10-12)
(1)See REAR AXLE BEARINGS under ADJUSTMENTS.
ApplicationIn. (mm)
Capri
Lateral Runout.004 (.1)
Parallelism.004 (.1)
Original Thickness
Front.71 (18)
Rear.39 (10)
Min imu m Refin ish Th ickn ess
Front.660 (16.762)
Rear.384 (9.762)
Discard Thickness
Front.63 (16)
Rear.35 (9)
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AXLE SHAFT S - FRONT
1988-93 Drive Axles - FWD Axle Shafts
DESCRIPTION & OPERATION
Axle shafts transfer power from transaxle to driving wheels. All axle shafts consist of a shaft with a flexible Constant Velocity (CV) joint at
each end. Inner CV joint is coupled to transaxle by splines. Outer CV joint is splined to hub assembly and secured by axle shaft nut.
Three different types of axle shaft CV joints are used: Double Offset Joint (DOJ) or Rzeppa type, Birfield Joint (BJ) and the Tripot Joint (TJ).
CV joint boots protect CV joints by maintaining proper lubrication and preventing contaminants from entering joint. Boots must be replaced
when signs of leakage or cracks are present. Inner CV joint may be disassembled and serviced. Outer CV joint boot may be replaced, but outer
Birfield CV joint must NOT be disassembled. It must be replaced as an assembly, if faulty.
To prevent torsional vibration and torque steer on turbocharged Capri vehicles, an intermediate shaft and conventional axle shaft are used on
the right side. Both shafts are of similar length and are supported by a bearing, which is attached to engine.
CV JOINT IDENTIFICATION
TROUBLE SHOOTING
REMOVAL, DISASSEMBLY, REASSEMBLY & INSTALLATION
FWD AXLE SHAFTS
Removal
1. Raise and support vehicle. Remove lower underbody splash shields. Drain transaxle fluid. Remove front wheels and loosen axle shaft
lock nut. On Capri, remove stabilizer bar-to-control arm attaching nuts, bolt, washers and bushings. On Festiva, remove stabilizer bar
attaching nuts and bracket. On all models, remove joint clamp bolt from lower control arm. Pry downward and separate steering knuckle
from ball joint, taking care not to damage ball joint dust boot.
2. On Capri turbo, remove bolts securing intermediate shaft bearing bracket to engine. On all models, slowly pry axle shaft from transaxle
using a flat-tip screwdriver or pry bar. Axle is held into transaxle by a circlip fitted to the end of the axle. Remove axle shaft from wheel
hub. If difficult to remove, use axle puller to remove axle from drive hub. Remove axle shaft from transaxle. Plug transaxle openings
with Plugs (T87C-7025-C ). Remove axle shaft assembly from vehicle. See Fig. 1
.

Fig. 1: Removing & Installing Axle Shafts

Courtesy of FORD MOTOR CO.
ApplicationJoint Type
Outer JointBirfield (BJ)
In n er Jo in t
Automatic TransaxleTripot (TJ)
Manual TransaxleRzeppa (DOJ)
NOTE:See TROUBLE SHOOTING - BASIC PROCEDURES article in GENERAL INFORMATION.
CAUTION: Dam age to CV joint will occur if a ham mer is used to separate half-shaft from wheel hub.
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Installation (All)
1. To install axle shaft, reverse removal procedure. Always install a NEW retaining circlip. Check seals at both ends of axle shaft. If
necessary, replace seals prior to installation. Lubricate transaxle seal lip with transaxle oil. See Fig. 1
.
2. After installing axle shaft into transaxle, pull axle shaft outward by hand to ensure proper engagement of retaining circlip and snap ring.
Install axle shaft into wheel hub. Align suspension alignment marks and tighten nuts.
INTERMEDIATE SHAFT
Removal
Intermediate shaft and axle shaft are removed as an assembly. See FWD AXLE SHAFTS under REMOVAL, DISASSEMBLY,
REASSEMBLY & INSTALLATION.
Disassembly
Separate intermediate shaft from axle shaft. Remove circlip from intermediate shaft and press off bearing and bracket assembly. See Fig. 4 .
Press bearing out of bracket. Inspect bracket for damage or wear and replace if necessary.
Reassembly
Press NEW bearing into bracket and install NEW seals. Install bearing and bracket assembly onto intermediate shaft. Install NEW circlip.
Assemble intermediate shaft to axle shaft.
Installation
Intermediate shaft and axle shaft are installed as an assembly. See FWD AXLE SHAFTS under REMOVAL, DISASSEMBLY,
REASSEMBLY & INSTALLATION.

Fig. 4: Exploded View Of Intermediate Shaft

Courtesy of FORD MOTOR CO.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS NOTE:Always install NEW cotter pin, washer and suspension lock nuts.
ApplicationFt. Lbs. (N.m)
Axle Nut (1) 116-173 (157-235)
Ball Joint Pinch Bolt32-40 (43-54)
Steering Knuckle-To-Strut Bolt69-86 (93-117)
Caliper Retaining Bolt29-36 (39-49)
Stabilizer Bar Bracket Nut40-50 (54-68)
Stabilizer Link Bolt9-13 (12-18)
Tie Rod End Nut21-32 (29-44)
Wheel Lug Nuts66-89 (90-120)
(1)Ensure locking flange on nut is staked into axle slot.
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00042994
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TROUBLE SHOOTING
OVERHAUL

Fig. 3: Exploded View of Mitsubishi Alternator

Courtesy of FORD MOTOR CO.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS NOTE:See T ROUBLE SHOOT ING - BASIC PROCEDURES article in the GENERAL T ROUBLE SHOOT ING
section.
NOTE:For exploded view of alternator, see Fig. 3
.
ApplicationFt. Lbs. (N.m)
Alternator Adjustment Bolt14-18 (19-25)
Alternator Mount Bolt27-38 (37-52)
Idler Pulley Attaching Nut23-34 (31-46)
Power Steering Pump Adjustment Lock Nut27-38 (37-52)
Power Steering Pump Mounting Bolt27-40 (37-54)
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00058012
Page 3 of 3 MITCHELL 1 ARTICLE - ALTERNATOR & REGULATOR 1991 ELECTRICAL Alternators & Regulators
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