suspension FORD FESTIVA 1991 Owner's Manual

Fig. 2: Exploded View of Rear Suspension (Capri)

Courtesy of FORD MOTOR CO.
ADJUSTMENTS & INSPECTION
WHEEL BEARING
1. Raise and support vehicle. Ensure parking brake is fully released. Remove wheel and dust cap. Rotate brake drum and ensure there is no
brake drag. Using a small cape chisel, raise the staked portion of the lock nut. Remove and discard lock nut.
2. Install new lock nut. To seat bearings, use a torque wrench and tighten lock nut to 18-21 ft. lbs. (25-29 N.m) while rotating brake drum.
After tightening, loosen lock nut until it can be turned by hand. Measure seal drag using an INCH lb. torque wrench on a lug nut at 12
o'clock position. Measure and record amount of force required to rotate brake drum.
3. To determine preload, add amount of seal drag to specified preload of 1.3-4.3 INCH lbs. (.15-.49 N.m). As an example, if seal drag
measures 2.2 INCH Lbs. (.25 N.m), this amount must be added to required preload.
4. Tighten wheel bearing lock nut a small amount. Using an INCH lb. torque wrench on a lug nut at 12 o'clock position, measure amo u n t
of pull required to rotate brake drum. Tighten attaching nut until specified amount of preload is measured with torque wrench. Stake
lock nut with a blunt chisel. Install grease cap and wheel.
REMOVAL & INSTALLATION
WHEEL BEARING
Removal
1. Raise and support vehicle. Ensure parking brake is fully released. Remove wheel and dust cap. Using a small cape chisel, raise staked
portion of lock nut. Remove and discard lock nut. Remove brake drum, bearing and hub assembly from spindle.
2. Pry out grease seal from hub and remove inner bearing. Bearings must be marked for reassembly reference if they are to be reused. Using
Slide Hammer (T50T-100-A), Bearing Cup Puller (T77F-1102-A) or proper sized brass drift and hammer, remove inner and outer
bearing races.
Installation
NOTE:Right side lock nut has left-hand threads. Left side lock nut has right-hand threads.
NOTE:Nut m ust be replaced if lock flange splits or cracks during staking process. DO NOT stake with a sharp
edged tool.
NOTE:Right side lock nut has left-hand threads. Left side lock nut has right-hand threads.
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1. Using Installer (T77F-1217-A), Driver Handle (T80T-4000-W) or proper sized brass drift and hammer, install inner and outer bearing
races. Pack bearings and hub area with Lubricant (C1AZ-1959D-B, C, D or E).
2. Position inner bearing in bearing hub. Lubricate grease seal lips and install seal. Ensure bearings and hub have sufficient lubricant. Place
brake drum bearings and hub assembly on spindle. To prevent damage to grease seal and spindle threads, ensure hub is correctly
centered on spindle.
3. Install outer bearing, washer and new lock nut. Stake lock nut with a blunt chisel. Adjust bearing preload. See ADJUSTMENTS &
INSPECTION.
SPINDLE
Removal & Installation (Capri)
Remove wheel, caliper and brake rotor. Loosen spindle-to-strut attaching bolts. Loosen outer rear control arm common bolt and nut. Remove
spindle-to-strut mount bolts and common control arm bolt. Remove spindle from strut. To install, reverse removal procedure.
Removal & Installation (Festiva)
Remove brake drum assembly. Remove 4 spindle attaching nuts located on inboard side of torsion beam. Support backing plate with wire and
remove spindle. To install, reverse removal procedure. Tighten spindle attaching nuts to 32-45 ft. lbs. (43-61 N.m).
STRUTS
Removal & Installation (Capri)
1. Remove wheel, caliper and brake rotor. Remove trailing arm bolt and spindle-to-strut attaching bolts. Put index mark on strut rubber
mounting bracket. Remove upper strut attaching nuts from inside vehicle. Remove strut.
2. Compress strut coil spring with Spring Compressor (T18P-5310-A) or similar. Remove strut nut while spring is compressed. Remove
rubber mounting bracket, upper and lower spring seats. Slowly release coil spring and remove spring compressor. Remove coil spring,
dust boot and rebound bumpers. To install, reverse removal procedure.
Removal (Festiva)
1. Raise and support vehicle. Remove rear wheels. Using Spring Compressor (T81P-5310-A), compress spring to unload strut. Remove rear
quarter trim panel from cargo compartment.
2. Remove jam nut and flanged nut from strut rod. Remove bushing washer and upper bushing. Remove strut lower end mounting bolt
from wheel support arm. Remove strut and separate it from spring and seat insulator. Remove lower bushing and jounce bumper seat
from strut rod. Slide jounce bumper and shield off strut. See Fig. 3
. NOTE:Nut m ust be replaced if lock flange splits or cracks during staking process. DO NOT stake with a sharp-
edged tool.
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Fig. 3: Exploded View of Strut Assembly (Typical)

Courtesy of FORD MOTOR CO.
Inspection
Check jounce bumper, spring seat insulator and strut rod bushings for wear or damage. Ensure strut is not leaking.
Installation
1. Slide jounce bumper and shield onto strut rod and cylinder. Install bumper seat and lower bushing on strut rod. If upper spring seat
insulator has been replaced, install new insulator on spring upper end. Seat end of coil against step in insulator.
2. Place spring on strut. Ensure end of coil seats against step in strut spring seat. Install strut assembly into tower from wheelwell. Guide
strut rod into tower mounting hole.
3. Line up strut lower end with mounting hole in wheel support arm. Install mounting bolt to hold strut in position. Working from in sid e
cargo compartment, install rod upper end bushing, bushing washer and flanged nut. Tighten nut to 12-18 ft. lbs. (16-24 N.m). See Fig.
4 . Hold flanged nut while tightening jam nut to lock it in position.
4. Tighten strut lower mounting bolt to 40-50 ft. lbs. (54-68 N.m). Remove spring compressor. Install wheel and tire assembly.
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Fig. 4: Installing Strut Flanged Nut

Courtesy of FORD MOTOR CO.
TORSION BEAM
Removal (Festiva)
1. Raise and support vehicle so rear struts are fully extended. Remove both wheels. Remove struts and disconnect brake lines as previously
described.
2. Disconnect parking brake cable clevises at brake backing plates. Remove parking brake equalizer and cables from torsion beam. Remove
4 nuts from back of each brake assembly to release backing plates and wheel spindle supports.
3. Remove torsion beam pivot bolts from body brackets. See Fig. 5
. Do not loosen or remove torsion beam body brackets if they are not
to be replaced. Remove torsion beam.

Fig. 5: Removing Torsion Beam Pivot Bolt

Courtesy of FORD MOTOR CO.
Installation
1. If removed, install torsion beam pivot brackets. Do not tighten mounting bolts at this time. If a new torsion beam is to be installed,
install new pivot bushings in beam arms. See TORSION BEAM BUSHINGS.
2. Install bushing flange washers and position beam arms in body brackets. Align pivot bolt holes and install bolts. Do not tighten nuts at
this time. Install brake backing plates and wheel spindle support assemblies. Tighten nuts to 32-45 ft. lbs. (43-61 N.m).
3. Install parking brake equalizer assembly on torsion beam. Install cable clevises to brake levers with clevis pins and cotter pins. Clip right
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and left brake lines in place. Install rear suspension struts and wheels. Block wheels and lower vehicle to load suspension to normal ride
height. Tighten torsion beam pivot bolts at body brackets to 69-87 ft. lbs. (93-118 N.m).
4. Check rear suspension alignment. Place an alignment mark at the center of the underbody, at a point of equal distance from the right and
left body bracket inboard mounting bolts. From this alignment mark, measure distance to centers of right and left strut lower mounting
bolts.
5. Both measurements must be within .20" (5 mm) of being the same. If not, shift torsion beam body brackets from side-to-side to center
suspension. Once centered, tighten upper body bracket mounting bolts to 40-50 ft. lbs. (54-68 N.m) and lower bolt to 69-87 ft. lbs. (93-
118 N.m). Bleed brakes.
TORSION BEAM BUSHINGS
Removal
1. Raise and support vehicle to fully extended rear struts. Remove wheels. Remove retaining clip at right brake line routing bracket and
disconnect brake line. Remove clip from left brake line and disconnect at body crossmember.
2. Remove torsion beam pivot bolt bolts and nuts at right and left body brackets. Swing torsion beam trailing arm downward to clear body
brackets.
3. Using piece of wood, block beam in disengaged position. Using Bushing Remover/Replacer (D80L-1002-L), remove bushings from
inboard side of torsion beam arm. See Fig. 6
.

Fig. 6: Removing Torsion Beam Bushing

Courtesy of FORD MOTOR CO.
Installation
1. Place bushings on outboard sides of torsion beam arms with marks "F" and "R" aligned parallel to arm axis. To ease installation,
lubricate bushings with soapy water. Press in bushings using bushing remover/installer.
2. Remove wood block holding torsion beam out of body pivot brackets. Place bushing flange washers on outboard faces of bushings.
Raise torsion beam arms into brackets until pivot bolt holes align.
3. Install pivot bolts through brackets from inboard side but do not tighten nuts at this time. Connect brake lines at routing brackets.
Reinstall brake line retaining clips. Reinstall wheels. Lower vehicle and block wheels. Jounce vehicle until suspension is fully loaded in
its normal riding position. Tighten torsion beam pivot bolt nuts to 69-87 ft. lbs. (93-118 N.m). Bleed brakes.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
NOTE:Bushings have "F" (front) and "R" (rear) stam ped on bushing face. Ensure these m arks are right side
up when "F" is toward front of vehicle.
ApplicationFt. Lbs. (N.m)
Capri
Control Arm Bolt-To-Spindle45-55 (61-75)
Inner Control Arm Bolts69-86 (93-117)
Rear Hub Lock Nut18-21 (25-29)
Rear Stabilizer Bracket32-39 (43-55)
Spindle-To-Strut Bolts69-86 (93-117)
Strut Rod Upper Flanged Nut40-50 (54-68)
Strut-To-Strut Tower17-22 (23-29)
Wheel Bearing Lock Nut18-21 (25-29)
Wheel Lug Nuts67-88 (90-120)
Festiva
Brake Backing Plate Spindle Support Bolts32-45 (43-61)
Lower Body Bracket Mounting Bolts69-87 (93-118)
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Rear Hub Lock Nut18-21 (25-29)
Spindle Attaching Nuts31-45 (43-61)
Strut Lower Mounting Bolt40-50 (54-68)
Strut Rod Upper Flanged Nut12-18 (16-25)
Torsion Beam Pivot Bolts69-87 (93-118)
Upper Body Bracket Mounting Bolts40-50 (54-68)
Wheel Lug Nuts67-88 (90-120)
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00121555
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Back To Article
1983-95 WHEEL ALIGNMENT
Pre-Alignm ent Inspection Procedures
PRE-ALIGNMENT CHECKS
Before making wheel alignment adjustment, perform the following checks:
1. Tires should be equal in size and runout must not be excessive. Tires and wheels should be in balance, and inflated to manufacturer's
specifications.
2. Wheel bearings must be properly adjusted. Steering linkage and suspension must not have excessive looseness. Check for wear in tie rod
ends and ball joints.
3. Steering gear box must not have excessive play. Check and adjust to manufacturer's specifications.
4. Vehicle must be at curb height with full fuel load and spare tire in vehicle. No extra load should be on vehicle.
5. Vehicle must be level with floor and with suspension settled. Jounce front and rear of vehicle several times and allow it to settle to
normal curb height.
6. If steering wheel is not centered with front wheels in straight-ahead position, correct by shortening one tie rod adjusting sleeve and
lengthening opposite sleeve equal amounts.
7. Ensure wheel lug nuts are tightened to torque specifications.
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00060347
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RIDING HEIGHT ADJUSTMENT
1991-92 WHEEL ALIGNMENT Ford Motor Co. - Riding Height Adjustm ent
RIDING HEIGHT ADJUSTMENT
1. Examine vehicle and ensure front or rear end is not higher or lower than normal. Ensure vehicle is level from side to side. Remove any
unusual heavy items before checking suspension.
2. If loading is normal but vehicle is not level, check for spring damage, spring set, or non-standard replacement springs. Repair or replace
as necessary. If in doubt, compare with a new vehicle (if possible).
3. Measure height of fender cutout rim above wheel center at all 4 wheels. Compare left and right side measurements at both front and
rear. See Fig. 1
. On Festiva, side-to-side variation should not exceed 0.4" (10 mm). These measurements should not be made from
floor, but from center of wheel only, as unequal tire wear could cause a variance.

Fig. 1: Measuring Riding Height

Courtesy of FORD MOTOR CO. NOTE:Before adjusting alignm ent, check riding height. Riding height m ust be checked with vehicle on level
floor and tires properly inflated. Bounce vehicle several tim es and allow suspension to settle.
NOTE:Specifications for Capri suspension height are not available.
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00061366
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WHEEL ALIGNMENT SPECIFICAT IONS & PROCEDURES
1991-92 WHEEL ALIGNMENT Ford Motor Co. - Specifications & Procedures
ADJUSTMENTS
CASTER
Caster is permanently set at factory and is not adjustable. Caster should be checked however as a possible cause of suspension complaint.
CAMBER
To adjust camber on Festiva, see Fig. 1
. Camber adjustment on Capri is similar. Instead of 2 strut mount studs, Capri has 4 studs.

Fig. 1: Adjusting Front Camber

Courtesy of FORD MOTOR CO.
FRONT TOE-IN NOTE:Before adjusting alignm ent, check riding height. Riding height m ust be checked with vehicle on level
floor and tires properly inflated. Bounce vehicle several tim es and allow suspension to settle.
NOTE:See Fig. 2 for toe-in adjustm ent procedures.
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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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