wheel alignment FORD FESTIVA 1991 Owner's Manual

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ST EERING SYST EM - MANUAL
1991 ST EERING Ford Motor Co. - Steering - Manual Rack & Pinion
DESCRIPTION
Rack and pinion type steering is mounted on rubber insulators to the chassis bulkhead. Adjustment is provided for pinion gear preload. Pinion
shaft is coupled to steering shaft. Tie rods connect end of rack to steering knuckles.

Fig. 1: Exploded View of Manual Steering Gear Assembly

Courtesy of FORD MOTOR CO.
TROUBLE SHOOTING
Refer to TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL TROUBLE SHOOTING section.
ADJUSTMENTS
Necessary adjustments are made during reassembly procedure. See OVERHAUL .
REMOVAL & INSTALLATION
STEERING GEAR
Removal
1. Raise and support vehicle. Remove front wheels. Remove vehicle battery. Remove cotter pins and castle nuts from tie rod ends. Using
tie rod puller, separate tie rod ends from steering knuckles. Remove the catalytic converter.
2. Remove plastic splash shield from right side lower inner fender panel. Mark the lower steering column "U" joint for reassembly
reference and disconnect steering column and intermediate shaft. Remove steering gear bracket bolts. Lower steering gear until steering
shaft is clear of column boot.
3. Slide steering gear to the right, through the inner fender tie rod opening until the left tie rod clears the left fender opening. Lower left
side of steering gear until it can be removed from the left side. Ensure rack boots are not pinched or damaged during removal.
Installation
To install, reverse removal procedure. Check and adjust toe-in. See WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in
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the WHEEL ALIGNMENT section.
OVERHAUL
STEERING GEAR
Disassembly
1. With steering gear removed from vehicle, place steering gear in a soft-jawed vise. Mark threaded portion of tie rod for reassembly.
Remove tie rod ends. Remove tie rod boots. Remove lock pins from both ends of rack. See Fig. 1
.
2. Remove tie rod ball socket from end of rack. Remove both tie rods. Remove lock nut from yoke plug. Remove yoke plug, spring and
yoke support. Use a small screwdriver to remove pinion oil seal from pinion shaft. Remove pinion bearing snap ring.
3. Remove pinion and bearing assembly. If necessary use Valve Body Puller (T78P-3504-B) to remove pinion and bearing assembly.
Remove rack from pinion side of housing. If lower pinion bearing needs replacing, use Blind Hole Bearing Puller (D80L-100-L) and
Slide Hammer (T50T-100-A) to remove.
4. Press bushing lock tabs into the 3 slots located at end of rack housing. Use Blind Hole Bearing Puller (D80L-100-L), to remove rack
support bushing from right end of rack housing.
Inspection
1. Check rubber boots, ball bearings and tooth surface of rack for wear or damage. Using a dial indicator and "V" blocks, check rack for
straightness. Maximum allowable runout is 0.012" (0.3 mm). If rack support bushings are worn, use a screwdriver to release the tab lock
on the side opposite the pinion. Use blind hole Bearing Puller (D80L-100R) with slide hammer to remove bushing.
2. Check tie rod ball joints for smooth operation. Replace parts as necessary. Check sliding surface of rack support and gear housing for
cracks or damage. Check rack bushing for excessive wear. Replace entire gear housing assembly if any of these parts are worn or
damaged.
Reassembly
1. Apply lithium grease to ball bearing, roller bearing, inside of gear housing, lip of oil seal, sliding surface and back of rack support,
sliding surface of rack bushing, rack pinion teeth and ball joints. Install rack support bushing into right end of rack housing. Ensure lock
tabs engage with slots in housing.
2. If previously removed, install a new lower pinion bearing using a bushing installer or a piece of wooden dowel stock. Carefully insert
non-toothed side of rack into left end of rack housing, with rack teeth facing pinion bore. Position rack in housing so rack protrudes
2.4" (62 mm) from the left side of housing. Install pinion and upper bearing assembly so that when bearing is seated, notch (for "U" joint
clamp bolt) in pinion splines forms a 35-55 degree angle with the centerline of the housing. See Fig. 2
.

Fig. 2: Removing & Installing Rack Components

Courtesy of FORD MOTOR CO.
3. Install snap ring and spacer, with beveled side of snap ring facing upward (toward oil seal). Install oil seal spacer with tab side down,
locating tab in snap ring gap. Protect pinion shaft splines with tape. Coat tape with a thin coat of grease and install new seal. Using a soft
hammer, tap lightly on seal until it is flush with end surface of housing. Remove protective tape.
4. Mount rack in a soft-jawed vise and install new lock tabs and tie rods. Tighten tie rod with a "crows foot" wrench to 44-58 ft. lbs. (59-
78 N.m). Use a center punch to stake lock tabs washer in 2 places. Slide tie rod boot over tie rod and position on rack. Secure with
mechanic's tie wire. Install other boot and other boot clamps.
5. Center rack so that tie rods are equally extended. Grease rack support yoke. Install rack support yoke, spacer and spring in housing.
Apply sealer to adjusting cover (yoke plug) threads and install in housing. Install adjusting bolt and lock nut.
6. Tighten adjusting cover to 80-97 INCH lbs. (9-11 N.m). Slowly cycle rack back and forth 5 times through 90 percent of its full stroke.
Center rack so tie rods are equally extended. Loosen adjusting cover and retighten to 22-30 INCH lbs. (2.5-3.4 N.m). Using a spring pull
scale, measure force needed to turn pinion 180 degrees from center rack position.
7. Adjust pinion to position where most force was needed to turn it. Tighten adjusting cover to 48 INCH lbs. (5.4 N.m), then back off 5-10
degrees. Hold adjusting bolt with a wrench and tighten the lock nut with a "crows foot" to 29-36 ft. lbs. (39-49 N.m). 8) To comp l et e
reassembly, reverse disassembly procedure. Install tie rod ends and jam nuts. Ensure index marks align. See Fig. 1
. CAUT ION: If rack is taken out of wrong side, dam age m ay result to rack bushing.
NOTE:If fit between housing and bearing is too tight, strike outer ring of bearing lightly while checking
m esh of rack and pinion.
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WHEEL ALIGNMENT
After performing appropriate service procedures, refer to WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in the WHEEL
ALIGNMENT section.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
ApplicationFt. Lbs. (N.m)
Pinion Adjusting Screw Lock Nut29-36 (39-49)
Mounting Bracket Bolt23-34 (31-46)
Tie Rod End Castle Nut26-30 (35-40)
Tie Rod-to-Rack Ball Joint43-58 (58-79)
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00054859
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Fig. 7: Power Steering Pump Mounting & Pressure Hose (Festiva)
Courtesy of FORD MOTOR CO.

Fig. 8: Exploded View of Power Steering Pump (Festiva)

Courtesy of FORD MOTOR CO.
2. Remove return line and "O" ring. Remove pulley nut and washer. Remove pulley using Pulley Remover (OTC-1024). Remove keyway,
front bracket bolts and washers. Remove front bracket, rear bracket bolts and washers and rear bracket. Remove rear body bolts and
washers. Remove rear body. Remove shaft retaining ring. Remove shaft and rotor.
3. Remove vanes, "O" ring, and center body. Remove "O" ring and cam ring. Remove seal using Collet (D80L-100-Q) and Slide Hammer
( T5 0 T- 1 0 0 - A) . R e mo ve va l ve fit t in g. R e mo ve 4 "O" r in gs fr o m va l ve fit t in g. R e mo ve c o n t r o l va l ve , sp r in g, p r e ssu r e swit c h fit t ing a n d
spring. Remove "O" ring from pressure switch fitting. Remove spring seat. Remove plunger.
Reassembly (Festiva)
1. Coat pump vanes, rotor and control valve with ATF. Install new "O" ring on pressure switch fitting. Install plunger, spring seat, spring
and pressure switch fitting. Install new "O" rings on valve fitting. Install spring, control valve and valve fitting. Coat lip of new seal with
grease and install seal using suitable installer.
2. Install cam ring, new "O"ring, center body, new "O" ring and rotor. Ensure rounded edge of vanes face toward center of rotor. In st al l
vanes, shaft and retaining ring. Position rear body and install washers and bolts. Position rear bracket and install washers and bolts.
Position front bracket and install washers and bolts.
3. Position key in keyway and install pulley. Install pulley washer and nut. Tighten nut to 22-29 ft. lbs. (29-39 N.m). Install new "O" ring
at return line port. Position high pressure line and install support bracket and cap screw. Install high pressure line attaching washer and
nut. Tighten to 29-36 ft. lbs. (39-49 N.m).
4. Ensure pump rotates freely. If not, disassemble and repair as necessary. Install pump on vehicle. Bleed air from hydraulic system before
starting engine. See HYDRAULIC FLUID BLEEDING
under LUBRICATION.
WHEEL ALIGNMENT
After performing appropriate service procedures, refer to WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in the
WHEEL ALIGNMENT section.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
ApplicationFt. Lbs. (N.m)
Pinion Cover Lock Nut29-36 (40-50)
Pinion Shaft Nut29-36 (39-49)
Power Steering Pump Bracket27-38 (37-52)
Power Steering Lock Nut32-45 (43-61)
Tie Rod-To-Rack44-58 (60-80)
Tie Rod-To-Steering Knuckle26-29 (35-40)
Valve Body Cover Lock Nut29-36 (40-50)
Wheel Lug Nut67-88 (90-120)
INCH Lbs.
Pinion Bearing Cover39-47 (4.5-5.5)
ApplicationFt. Lbs. (N.m)
Intermediate Shaft Clamp Bolt13-20 (18-26)
Pinion Adjusting Plug Lock Nut36-43 (49-59)
Pressure Hose Fitting29-36 (39-49)
Power Steering Pump Lock Nut27-38 (37-52)
Power Steering Pump Mounting Bolt27-40 (36-54)
Steer Gear Mount Bolts23-34 (32-47)
Tie Rod-To-Steering Knuckle22-33 (30-45)
Page 8 of 9 MITCHELL 1 ARTICLE - STEERING SYSTEM - POWER 1991-92 STEERING Ford Motor Co. - Steering - Power Rack & Pi
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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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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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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)
Page 6 of 7 MITCHELL 1 ARTICLE - SUSPENSION - REAR 1991-92 SUSPENSION Rear
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JACKING & HOISTING
1991-92 WHEEL ALIGNMENT Ford Motor Co. - Jacking & Hoisting
JACKING & HOISTING
FRAME & UNDERBODY
The following illustrations indicate areas (parts) of the underbody and frame which may be used to raise and support the vehicle, using either
floor jack or hoist. These points are indicated by shaded areas on the frame. See Fig. 1
.

Fig. 1: Jacking & Hoisting Points Courtesy of Ford Motor Co.

OUTERBODY
Those points designated on the outline of the body were specifically designed to facilitate the use of the vehicle's own jack. These jacking
points are indicated by circular dots on the outline of the body. See Fig. 1 . If floor jack or hoist is employed, extreme care should be
exercised to avoid damaging the outer body shell. NOTE:T he JACKING & HOIST ING illustrations are not intended to represent the exact structure of each
vehicle's fram e, underbody or body outline. T hey are presented only to give the m echanic som e point
of reference.
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00061372
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