ect FORD FESTIVA 1991 Service Manual

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T RANSMISSION SERVICING - A/T
1988-93 T RANSMISSION SERVICING Ford Motor Co. Autom atic T ransm ission
IDENTIFICATION
AUTOMATIC TRANSMISSION APPLICATIONS
LUBRICATION
SERVICE INTERVALS
Check fluid level at every engine oil change. Fluid, filter changes and band adjustments are not required under normal operation. Under severe
service operating conditions, change fluid every 30 months or 30,000 miles. Adjust band when fluid is changed.
CHECKING FLUID LEVEL
With transmission at normal operating temperature, place vehicle on level surface. Apply parking brake and run engine at idle. Run gearshift
lever through all positions, ending in Park. With engine running, fluid level should be between "F" and "L" marks. DO NOT overfill.
RECOMMENDED FLUID
Use Dexron-II ATF.
FLUID CAPACITIES
TRANSMISSION REFILL CAPACITIES
DRAINING & REFILLING
1. Remove undercover and side cover to gain access to transaxle oil pan. Remove drain plug and drain fluid. Remove oil pan and discard
gasket. Clean or replace filter screen as necessary. Tighten screen bolts to 71-97 INCH lbs. (8-11 N.m).
2. Install oil pan bolts. Tighten bolts to 44-71 INCH lbs. (5-8 N.m). On all models, install drain plug with NEW washer. Tighten plug to
29-40 ft. lbs. (39-54 N.m).
3. Install undercover and side cover. Add about 3 qts. of specified ATF through dipstick guide tube. DO NOT overfill. Run engine to
normal operating temperature and check fluid level.
ADJUSTMENTS
NEUTRAL SAFETY SWITCH
Combination neutral safety and back-up light switch is screwed into transaxle case. No adjustments are necessary.
SHIFT CONTROL CABLE
1. Disconnect negative battery cable. Remove shift console. Place shift lever in Park. Remove shift lever knob and lock nut. Remove 4 shift
quadrant attaching screws.
2. Loosen shift cable adjuster nuts until they reach end of cable threads. See Fig. 1
. Place shift lever in Park. Tighten lower adjustment
nut until it lightly touches "T" joint, then tighten upper adjustment nut to 80-97 INCH lbs. (9-11 N.m).
3. Lightly press selector push rod and make sure guide pin clearance is correct. See Fig. 2
. Check guide pin clearance when shift lever is
in Neutral and Drive. Readjust shift cable as necessary.
4. Install 4 shift quadrant attaching screws, shift lever knob, lock nut and shift console. Connect negative battery cable.
ModelTransmission
FestivaATX/3HAT
NOTE:Capacities given are approxim ate refill am ounts that apply to overhaul situation. Correct fluid level
should be determ ined by m ark on dipstick.
ApplicationQts. (L)
ATX/3HAT5.6 (5.3)
CAUT ION: DO NOT use any type of gasket sealer or RT V on oil pan gasket. DO NOT overtighten.
CAUT ION: After com pleting linkage adjustm ents, be sure neutral safety switch operates properly. With parking
brake and service brakes applied, try to start engine in each gear position. Engine m ust crank only
when gearshift lever is in Neutral and Park.
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Fig. 3: Adjusting Intermediate Band

Courtesy of FORD MOTOR CO.
KICKDOWN CONTROL ADJUSTMENT
1. Kickdown is controlled by solenoid on bottom of transaxle case. Solenoid is actuated by a kickdown switch on accelerator pedal
bracket.
2. To adjust switch, attach circuit tester to each terminal of switch. Loosen switch lock nut. Adjust switch so that there is continuity when
accelerator pedal is depressed 7/8 or more of its full travel.
SHIFT QUADRANT
1. Remove shift lever knob. Remove console attaching screws. Place shift lever in Park. Remove shift lever knob and lock nut. Remo ve
shift quadrant. Align holes in slider and shift quadrant. Install an alignment pin to hold slider in position.
2. Install quadrant and remove alignment pin. Ensure clearance between lock lever and emergency override lever is correct. See Fig. 4
.
Install lock nut and shift lever knob. Tighten lock nut to 11-15 ft. lbs. (15-20 N.m). Install console.

Fig. 4: Checking Lock Lever Clearance

Courtesy of FORD MOTOR CO.
DOWNSHIFT SWITCH
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1. Inspect wiring and components for shorts, corrosion, overheating, loose connections, or any other damage. Check 10-amp METER fu se.
Disconnect downshift solenoid.
2. With key off, voltage measured at Black/Blue wire should be zero volts. With key on and accelerator pedal fully depressed, voltage
should be greater than 10 volts. If Black/Blue wire is okay, remove downshift solenoid.
3. Apply battery voltage to downshift solenoid connector and ground case. Control rod should move freely when solenoid case is
grounded. If control rod does not move freely, replace downshift solenoid.
VACUUM DIAPHRAGM ROD
If transaxle shift points are incorrect, check for a defective vacuum diaphragm and replace if necessary. If diaphragm is operating correctly,
check length of diaprhagm rod using Vacuum Diaphragm Rod Gauge (T87C-77000-A). Measure dimension "N." See Fig. 5
. Select proper
length diaphragm rod. See VACUUM DIAPHRAGM ROD SELECTION
table.
VACUUM DIAPHRAGM ROD SELECTION

Fig. 5: Adjusting Vacuum Diaphragm Rod Length

Courtesy of MAZDA MOTORS CORP.
Dimension "N" In. (mm)Rod Length In. (mm)
Below 1.000 (25.4)1.16 (29.5)
1.000-1.020 (25.4-25.9)1.18 (30.0)
1.020-1.039 (25.9-26.4)1.20 (30.5)
1.039-1.059 (26.4-26.9)1.22 (31.0)
Over 1.059 (26.9)1.24 (31.5)
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00124558
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CLUTCH
1988-93 Clutch
DESCRIPTION
The clutch is single-disc type, using a diaphragm spring to engage pressure plate. Clutch operation is controlled by a mechanical release
system consisting of clutch pedal, cable, release lever and release bearing.
ADJUSTMENTS
CLUTCH PEDAL FREE PLAY
1. Measure clutch pedal movement from parked position to first indication of clutch application. See Fig. 1
. Free play must be within
specifications. See CLUTCH PEDAL SPECIFICATIONS
.

Fig. 1: Adjusting Clutch Pedal

Courtesy of FORD MOTOR CO.
2. If free play is not within specification, rotate clutch cable adjustment nut at release lever to obtain correct pedal free play. See Fig. 2
.
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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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