suspension FORD FESTIVA 1991 User Guide

SUSPENSION TROUBLE SHOOTING
BASIC SUSPENSION TROUBLE SHOOTING CHART
article
Shroud or housing looseTighten holding screws
Lock plate retaining ring not seatedSee STEERING COLUMN
article
Loose sight shieldTighten holding screws
High Steering Shaft Effort
Co l u mn assemb l y misal ign edSee STEERING COLUMN
article
Improperly installed dust shieldAdjust or replace
Tight steering universal jointSee STEERING COLUMN
article
High Shift Effort
Column is out of alignmentSee STEERING COLUMN
article
Improperly installed dust shieldAdjust or replace
Seals or bearings not lubricatedSee STEERING COLUMNS
article
Mounting bracket screws too longReplace with new shorter
screws
Burrs on shift tubeRemove burrs or replace tube
Lower bowl bearing assembled wrongSee STEERING COLUMN
article
Shift tube bent or brokenReplace as necessary
Improper adjustment of shift leversSee STEERING COLUMN
article
Improper Trans. Shifting
Sheared shift tube jointReplace as necessary
Sheared lower shaft leverReplace as necessary
Improper shift lever adjustmentSee STEERING COLUMN
article
Improper gate plate adjustmentSee STEERING COLUMN
article
Excess Play in Column
Instrument panel bracket bolts looseTighten bolts and check
bracket
Broken weld nut on jacketSee STEERING COLUMN
article
Instrument bracket capsule shearedSee STEERING COLUMN
article
Column bracket/jacket bolts looseTighten bolts and check
bracket
Steering Locks in Gear
Release lever mechanismSee STEERING COLUMN
article
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. T he purpose of this T rouble Shooting inform ation is to provide a list
of com m on causes to problem sym ptom s. For m odel-specific T rouble Shooting, refer to SUBJECT ,
DIAGNOST IC, or T EST ING articles available in the section(s) you are accessing.
CONDITION & POSSIBLE CAUSECORRECTION
Front End Noise
Loose or worn wheelSee Wheel Bearing
Adjustment in SUSPENSION
Worn shocks or shock mountingsReplace struts or strut
mo u n t in gs
Worn struts or strut mountingsReplace struts or strut
mo u n t in gs
Loose or worn lower control armSee SUSPENSION
Loose steering gear-to-frame boltsSee STEERING
Worn control arm bushingsSee SUSPENSION
Ball joints not lubricatedLubricate ball joints & see
Ball Joint Checking in
SUSPENSION
Front Wheel Shake, Shimmy, or Vibration
Tires or wheels out of balanceCheck tire balance
Incorrect wheel alignmentSee WHEEL ALIGNMENT
Drive shaft unbalancedCheck drive shaft balance
Loose or worn wheel bearingsSee WHEEL ALIGNMENT
Loose or worn tie rod endsSee SUSPENSION
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WHEEL ALIGNMENT TROUBLE SHOOTING
BASIC WHEEL ALIGNMENT TROUBLE SHOOTING CHART
Worn upper ball jointsSee Ball Joint Checking in
SUSPENSION
Worn shock absorbersReplace shock absorbers
Worn strut bushingsReplace strut bushings
Car Pulls to One Side
Mismatched or uneven tiresCheck tire condition
Broken or sagging springsSee SUSPENSION
Loose or worn strut bushingsSee SUSPENSION
Improper wheel alignmentSee WHEEL ALIGNMENT
Improper rear axle alignmentCheck rear axle alignment
Power steering gear unbalancedSee STEERING
Front brakes draggingSee BRAKES
Abnormal Tire Wear
Unbalanced tiresCheck tire balance & rotation
Sagging or broken springsSee SUSPENSION
Incorrect front end alignmentSee WHEEL ALIGNMENT
Faulty shock absorbersReplace chock absorbers
Scuffed Tires
Toe-In incorrectSee WHEEL ALIGNMENT
Suspension arm bent or twistedSee appropriate
SUSPENSION article
Springs Bottom or Sag
Bent or broken springsSee SUSPENSION
Leaking or worn shock absorbersReplace shock absorbers
Frame misalignmentCheck frame for damage
Spring Noises
Lo o se "U" Bo l t sSee SUSPENSION
Loose or worn bushingsSee SUSPENSION
Worn or missing interlinersSee SUSPENSION
Shock Absorber Noise
Loose shock mountingsCheck & tighten mountings
Worn bushingsReplace bushings
Air in systemBleed air from system
Undercoating on shocksRemove undercoating
Car Leans or Sways on Corners
Loose stabilizer barSee SUSPENSION
Faulty shocks or mountingsReplace shocks or mountings
Broken or sagging springsSee SUSPENSION
Shock Absorbers Leaking
Worn seals or reservoir tube crimpedSee SUSPENSION
Broken Springs
Lo o se "U" b o l t sSee SUSPENSION
Inoperative shock absorbersReplace shock absorbers
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. T he purpose of this T rouble Shooting inform ation is to provide a list
of com m on causes to problem sym ptom s. For m odel-specific T rouble Shooting, refer to SUBJECT ,
DIAGNOST IC, or T EST ING articles available in the section(s) you are accessing.
CONDITION & POSSIBLE CAUSECORRECTION
Premature Tire Wear
Improper tire inflationCheck tire pressure
Front alignment out of toleranceSee ALIGNMENT SPECS in
WHEEL ALIGNMENT
section
Suspension components wornSee SUSPENSION section
Steering system components wornSee STEERING section
Improper standing heightSee WHEEL ALIGNMENT
Uneven or sagging springsSee SUSPENSION section
Bent wheelSee WHEEL ALIGNMENT
Improper torsion bar adjustmentSee SUSPENSION section
Loose or worn wheel bearingsSee WHEEL BEARING ADJ.
in SUSPENSION section
Worn or defective shockReplace shock absorbers
Tires out of balanceCheck tire balance
Pulls to One Side
Improper tire inflationCheck tire pressure
Brake draggingSee BRAKE section
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Mismatched tiresSee WHEEL ALIGNMENT
Broken or sagging springSee SUSPENSION section
Broken torsion barSee SUSPENSION section
Power steering valve not centeredSee STEERING section
Front alignment out of toleranceSee WHEEL ALIGNMENT
section
Defective wheel bearingSee WHEEL BEARINGS in
SUSPENSION section
Uneven sway bar linksSee SUSPENSION section
Frame bentCheck for frame damage
Steering system bushing wornSee STEERING section
Hard Steering
Idler arm bushing too tightSee STEERING LINKAGE in
STEERING section
Ball joint tight or seizedSee SUSPENSION section
Steering linkage too tightSee STEERING LINKAGE in
STEERING section
Power steering fluid lowAdd proper amount of fluid
Power steering drive belt looseSee STEERING section
Power steering pump defectiveSee STEERING section
Steering gear out of adjustmentSee STEERING section
Incorrect wheel alignmentSee WHEEL ALIGNMENT
Damaged steering gearSee STEERING section
Damaged suspensionSee SUSPENSION section
Bent steering knuckle or supportsSee SUSPENSION section
Vehicle "Wanders"
Strut rod or control arm bushing wornSee SUSPENSION section
Loose or worn wheel bearingsSee WHEEL BEARINGS in
SUSPENSION section
Improper tire inflationCheck tire pressure
Stabilizer bar missing or defectiveSee SUSPENSION section
Wheel alignment out of toleranceSee Adjustment in WHEEL
ALIGNMENT section
Broken springSee SUSPENSION section
Defective shock absorberReplace shock absorbers
Worn steering & suspension componentsSee SUSPENSION section
Front End Shimmy
Tire out of balance/roundCheck tire balance
Excessive wheel runoutSee WHEEL ALIGNMENT
Insufficient or improper casterSee WHEEL ALIGNMENT
section
Worn suspension or steering componentsSee SUSPENSION section
Defective shock absorbersReplace shock absorber
Wheel bearings worn or looseSee WHEEL BEARING ADJ.
in SUSPENSION section
Power steering reaction Bracket looseSee STEERING section
Steering gear box (rack) mounting looseSee STEERING section
Steering gear adjustment looseSee STEERING section
Worn spherical jointsSee SUSPENSION section
Toe-In Not Adjustable
Lower control arm bentSee SUSPENSION section
Frame bentCheck frame for damage
Camber Not Adjustable
Control arm bentSee SUSPENSION section
Frame bentCheck frame for damage
Hub & bearing not seated properlySee SUSPENSION section
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00027342
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GENERAL INFORMATION
Wheel Alignm ent T heory & Operation
* PLEASE READ THIS FIRST *
PRE-ALIGNMENT INSTRUCTIONS
GENERAL ALIGNMENT CHECKS
Before adjusting wheel alignment, check the following:
Each axle uses tires of same construction and tread style, equal in tread wear and overall diameter. Verify that radial and axial runout is
not excessive. Inflation should be at manufacturer's specifications.
Steering linkage and suspension must not have excessive play. Check for wear in tie rod ends and ball joints. Springs must not be
sagging. Control arm and strut rod bushings must not have excessive play. See Fig. 1
.

Fig. 1: Checking Steering Linkage

Vehicle must be on level floor with full fuel tank, no passenger load, spare tire in place and no load in trunk. Bounce front and rear end
of vehicle several times. Confirm vehicle is at normal riding height.
Steering wheel must be centered with wheels in straight ahead position. If required, shorten one tie rod adjusting sleeve and lengthen
opposite sleeve (equal amount of turns). See Fig. 2
.
Wheel bearings should have the correct preload and lug nuts must be tightened to manufacturer's specifications. Adjust camber, caster
and toe-in using this sequence. Follow instructions of the alignment equipment manufacturer. NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. For m odel-specific inform ation see appropriate articles where
available.
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. For m odel-specific inform ation see appropriate articles where
available.
CAUT ION: DO NOT attem pt to correct alignm ent by straightening parts. Dam aged parts MUST be replaced.
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SUSPENSION - FRONT
1991-92 SUSPENSION Front
DESCRIPTION
Front suspension system uses MacPherson strut shock assemblies. The upper ends of the strut assembly are attached to the shock towers and
the lower ends are attached to the steering knuckle. Lower control arm is attached to the chassis. Fore and aft movement is controlled by the
stabilizer bar. The stabilizer bar is connected to the lower control arm by a connecting link. See Fig. 1
or Fig. 2 .
ADJUSTMENTS & INSPECTION
WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES

Fig. 1: Front Suspension Assembly (Capri)

Courtesy of FORD MOTOR CO.

Fig. 2: Front Suspension Assembly (Festiva)

Courtesy of FORD MOTOR CO. NOTE:See SPECIFICAT IONS & PROCEDURES article in the WHEEL ALIGNMENT Section.
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WHEEL BEARINGS
Wheel bearing preload is maintained by a selective spacer in the steering knuckle, between the inner and outer hub bearings. For adjustment
procedures and inspection, see WHEEL BEARING under REMOVAL & INSTALLATION.
BALL JOINT CHECKING
Raise and support vehicle until tire is just off ground. Move wheel vertically and check for play. If play is noticed between steering knuckle
and control arm, control arm assembly should be replaced. If play is present but ball joint is okay, wheel bearings should be checked for wear
and replaced if necessary.
REMOVAL & INSTALLATION
STABILIZER BAR
Removal & Installation (Festiva)
1. Remove stabilizer mounting bracket nuts and brackets. Remove split bushings from stabilizer bar. Remove stabilizer bushing nuts at
lower control arms. Remove rear dished washers and bushings.
2. To loosen stabilizer bar, pull forward from control arms. Remove front bushings and washers. Install control arm bushing washers on
ends of stabilizer and install control arm front bushings. Insert ends of stabilizer bar into control arm bushings and install rear bushings
and washers on stabilizer bar ends.
3. Install retaining nuts finger tight. Install split bushings on stabilizer cross bar with split side forward. Position split bushings next to
White locating marks on bar. Install stabilizer mounting brackets. Tighten all bolts and nuts to specification.
STRUT ASSEMBLY & COIL SPRING
Removal
1. Raise and support front of vehicle so struts are fully extended. Remove front wheels. Remove brake line clip from strut lower mounting
bracket and remove brake line.
2. Remove 2 bolts retaining strut lower bracket to steering knuckle. Working inside engine compartment, remove 2 nuts retaining strut
mounting block in strut tower. Disengage strut lower bracket from steering knuckle and lower strut from vehicle.
Disassembly & Reassembly
1. Using spring compressor, compress spring to unload strut. Pry out mounting block cap and remove strut upper nut and lock washer.
2. Remove strut mounting block and spacer plate. Remove washer, bearing seal and bearing from strut rod. Remove spring upper seat, seat
insulator and coil spring. Remove jounce bumper and dust shield from strut. Reverse disassembly procedure to install coil spring a n d
reassemble strut.
Installation
1. Position strut, with spacer plate installed, in strut tower with White alignment mark facing outward. Install and tighten nuts on upper
mounting block studs.
2. Install steering knuckle in strut lower bracket. To complete installation, reverse removal procedure. Tighten all bolts and nuts to
specification.
HUB & KNUCKLE ASSEMBLY
Removal
1. Raise and support vehicle. Remove wheel. Straighten staked edge of drive axle lock nut flange. DO NOT damage groove or threads in
end of drive axle. Apply brakes to prevent hub assembly from turning. Remove and discard drive axle lock nut.
2. Remove clip which secures brake hose to strut bracket. Remove cotter pin and tie rod end attaching nut. Using Tie Rod End Separator
(T85M-3395A), remove tie rod end from steering knuckle.
3. Remove brake caliper attaching bolts and remove assembly from steering knuckle. Do not allow caliper to hang by brake hose. Remove
clamp bolt and nut where lower control arm ball joint connects to steering knuckle.
4. Using a pry bar, pull down on lower control arm and release ball joint from steering knuckle. Remove 2 bolts which attach steering
knuckle between flanges of MacPherson strut bracket. Slide hub/knuckle assembly off end of drive axle. If binding is present or drive
hub is rusted to half-shaft, use a hub puller to push axle from drive hub.
Installation
1. Apply a thin coat of SAE 30 weight oil to drive axle splines. Slide steering knuckle/rotor/hub assembly onto drive axle. Stop at area
where uppermost arm of steering knuckle seats into MacPherson strut bracket.
2. To complete installation, reverse removal procedure. Install NEW drive axle lock nut. Tighten all bolts and nuts to specification. Stake
axle lock nut into shaft groove.
WHEEL BEARING NOTE:Inform ation for stabilizer bar rem oval and installation on Capri is not available from m anufacturer.
NOTE:Always use a new drive axle lock nut when servicing drive hub or drive axle.
CAUT ION: DO NOT use a pointed tool to stake nut. If lock nut flange cracks, even slightly, during staking process,
it m ust be replaced.
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Removal
1. Remove hub and knuckle assembly from vehicle. See HUB & KNUCKLE ASSEMBLY under REMOVAL & INSTALLATION. Using
Knuckle Puller (T87C-1104-A), or a press and bearing puller, remove drive hub/rotor assembly from steering knuckle/dust shield
assembly.
2. Remove bearing preload spacer from hub. Spacer is preselected to provide correct bearing preload. Ensure correct spacer is installed
during reassembly. Install hub/rotor assembly in a vise. Scribe alignment marks on hub and rotor for reassembly reference.
3. Remove rotor attaching bolts and rotor. Use Bearing Splitter (D84L-1123-A), Shaft Protector (D80L-625-2) and a press, or Bearing
Puller (D80L-927-A) and Puller Attachment (D84L-1123-A) to remove outer bearing from wheel hub. Remove and discard outer and
inner grease seals. Using Bearing Puller (T77F-1102-A) and Slide Hammer (T-50T-100-A), remove races from steering knuckle. See
Fig. 3
.

Fig. 3: Front Wheel Bearing & Hub Assembly

Courtesy of FORD MOTOR CO.
Inspection
Thoroughly clean all parts in solvent. Check bearings, hub, knuckle and rotor dust shield for excessive wear or damage. If new bearing is being
installed, check bearing preload. See BEARING PRELOAD.
Bearing Preload
1. To check and adjust preload, Spacer Selector Set (T87C-1104-B) must be used. Prior to assembling hub/rotor assembly into steering
knuckle, install spacer selector into steering knuckle and clamp tool in vise. Tighten center bolt, 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 the bearings by rotating steering knuckle by hand.
2. Remove steering knuckle from vise. Reinstall steering knuckle in vise, clamping it where shock absorber mounts. Using an INCH lb.
torque wrench, measure torque required to turn center bolt. Ensure torque reading is taken just as wrench starts to rotate.
3. Spacer thickness is correct if torque wrench indicates 2.21-10.44 INCH lbs. (.25-1.8 N.m). If measurement indicates less than 2.21
INCH lbs. (.25 N.m), a thinner spacer must be installed. If measurement indicates more than 15.93 INCH lbs. (1.8 N.m), a thicker spacer
must be installed.
4. Bearing spacers are available in 21 thicknesses, in .0016" (.040 mm) increments. Spacer No. 1 is thinnest and No. 21 is thickest. See
PRELOAD SPACER AVAILABILITY table. Changing spacer thickness one increment will change bearing preload 1.7-3.5 INCH lbs.
(.2-.4 N.m). Ensure correct spacer is installed and preload is within specification. Remove spacer selector set.
PRELOAD SPACER AVAILABILITY NOTE:Rem oval of press-fitted dust shield from steering knuckle is not part of norm al bearing service. Dust
shield should not be rem oved from steering knuckle unless it is being replaced.
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)
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Installation
1. Using Bearing Cup Replacer (D79P-1202-A) and Universal Driver Handle (T80T-4000-W), install bearing races in steering knuckle.
Lubricate bearing races and bearing. Install inner bearing into steering knuckle. Lubricate seal lips and install inner bearing seal into
knuckle. Install original bearing preload spacer in steering knuckle (or spacer selected during bearing preload check). Position outer
bearing in knuckle. Install outer seal. Install hub onto rotor, using reference marks made during removal. Install rotor to hub attaching
bolts.
2. Using a press and adapter from Spacer Selector Set (T87C-1104-B), install knuckle assembly onto hub. To complete installation,
reverse removal procedure.
LOWER CONTROL ARM & BALL JOINT (FESTIVA)
Removal
Remove lower control arm pivot bolt at frame bracket. Remove ball joint clamp bolt and nut from steering knuckle assembly. Remove
stabilizer bushing retaining nut from rear of control arm. Remove rear bushing washer and bushing. Lower the control arm and pry ball joint
stud out of steering knuckle. Disconnect control arm from stabilizer end and remove.
Inspection
Check control arm and bushings for excessive wear or damage. Ensure ball joint stud moves freely but is not loose. Use Ball Joint Rotating
Adapter (T87C-5493-C) to check ball joint rotating torque. Rotating torque should be 16-27 INCH lbs. (1.8-3.1 N.m).
Installation
1. Install front bushing washer with dished side forward. Position bushing stabilizer end and engage control arm with stabilizer. Raise
control arm inner end into pivot bracket on frame. Install pivot bolt to hold it in position.
2. Engage control arm ball joint stud with clamp bore in steering knuckle. Install clamp bolt and nut. Install stabilizer rear bushing and
washer with dished side forward on stabilizer end. Tighten all bolts and nuts to specification.
LOWER CONTROL ARM (CAPRI)
Removal & Installation
Raise and support vehicle. Remove wheel and disconnect stabilizer bar from control arm, if equipped. Remove ball joint clamp bolt. Remove
control arm front mount bolt. Remove control arm rear bracket and mount bolts. Remove control arm. To install, reverse removal procedure.
BALL JOINT (CAPRI)
Removal & Installation
1. Raise and support vehicle. Remove wheel. Remove ball joint clamp bolt from steering knuckle. Use small pry bar to pull down on lower
control arm to separate it from steering knuckle. Remove 2 ball joint retaining bolts and pry ball joint off control arm. To install, reverse
removal procedure.
LOWER CONTROL ARM BUSHING
Removal & Installation (Capri)
1. Remove control arm from vehicle. See LOWER CONTROL ARM. Use Bushing Receiver Cup (T87C-5493-B1), Bushing Driver (T87C-
5493-B2) and vise to remove control arm bushing.
2. To install, press bushing into control arm using same tools used for removal. Refit control arm to chassis.
Removal & Installation (Festiva)
1. Remove control arm from vehicle. See LOWER CONTROL ARM & BALL JOINT. Use Bushing Receiver Cup (T88C-5493-E), Bushing
Pilot (T81P-5493-B2) and "C" Clamp Assembly (T74P-3044-A1) to remove control arm bushing.
2. To install, press bushing into control arm using same tools used for removal. Refit control arm to chassis.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
130.2663 (6.765)
140.2679 (6.805)
150.2695 (6.845)
160.2711 (6.885)
170.2726 (6.925)
180.2742 (6.965)
190.2758 (7.005)
200.2774 (7.045)
210.2789 (7.085)
NOTE:Insert bushing quickly and sm oothly. Bushing should only be distorted for a short tim e.
ApplicationFt. Lbs. (N.m)
Capri
Ball Joint Pinch Bolt32-40 (43-54)
Brake Rotor-To-Hub33-40 (44-54)
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Caliper Attaching Bolts29-36 (39-49)
Control Arm Bolt-To-Ball Joint69-86 (93-117)
Control Arm Bracket Bolt44-54 (59-74)
Control Arm Front Bolt69-86 (93-117)
Control Arm Rear Bolt55-69 (75-93)
Drive Axle Nut116-174 (157-236)
Shock Absorber Bolt-To-Knuckle69-72 (93-97)
Stabilizer Bracket Nuts40-50 (54-68)
Steering Knuckle-To-Strut69-86 (93-117)
Steering Knuckle-To-Tie Rod22-33 (29-44)
Strut Assembly-To-Strut Tower17-22 (23-29)
Strut Rod Nut22-27 (29-36)
Wheel Lug Nut65-88 (90-120)
Festiva
Ball Joint Pinch Bolt32-40 (43-54)
Brake Rotor-To-Hub33-40 (44-54)
Caliper Attaching Bolts29-36 (39-49)
Control Arm Bushing Nuts47-57 (64-77)
Control Arm Pivot Bolt32-40 (43-54)
Stabilizer Bar Nuts-To-Control Arm47-57 (64-77)
Stabilizer Mounting Bracket Nuts40-50 (54-68)
Steering Knuckle-To-Strut69-86 (93-117)
Steering Knuckle-To-Tie Rod22-33 (29-44)
Strut Assembly-To-Strut Tower22-27 (29-36)
Wheel Lug Nut65-88 (90-120)
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00121554
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SUSPENSION - REAR
1991-92 SUSPENSION Rear
DESCRIPTION
Rear suspension is a MacPherson strut, semi-independent system on Festiva and fully independent on Capri. On Festiva, trailing arms are
rigidly connected to each other by a torsion beam. Rubber bushings are installed at the torsion beam/trailing arm body brackets. Control arms
are not used. The rear suspension has no provision for individual wheel alignment. Rear torsion beam must be centered in chassis for proper
tracking. For alignment of torsion beam, see TORSION BEAM under REMOVAL & INSTALLATION. See Fig. 1
.

Fig. 1: Exploded View of Rear Suspension (Festiva)

Courtesy of FORD MOTOR CO.
On Capri, trailing arms and dual control arms have separate mounting points at each end. One end on each control arm is connected to rear
crossmember. The other end is connected to spindle assembly. Trailing arms are attached to strut and floorpan bracket. Rear toe-in can be
adjusted by rotating adjustment link on control arms. See Fig. 2
.
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