height FORD FESTIVA 1991 Service Manual

Back To Article
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.
Page 1 of 12 MITCHELL 1 ARTICLE - BRAKE SYSTEM 1991-92 BRAKES Disc & Drum
3/10/2009 http://www.eautorepair.net/app/PrintItems.asp?S0=2097152&S1=0&SG=%7B7DD6473C%2DB5BB%2D4F20%2D9D70%2D
...

Fig. 2: Moving Quadrant on Drum Brake Adjuster (Festiva)

Courtesy of FORD MOTOR CO.
FRONT AXLE BEARINGS
Front bearing preload is adjusted during bearing replacement by changing preload spacer. See FRONT WHEEL BEARINGS under
REMOVAL & INSTALLATION.
REAR AXLE BEARINGS
With bearings installed, tighten NEW lock nut to 18-22 ft. lbs. (24-30 N.m) while rotating wheel. Slightly loosen lock nut so it can be turned
by hand. Install a lug nut into axle hub. Attach an inch-pound torque wrench to lug nut at 12 o'clock position. Measure bearing preload.
Tighten lock nut until bearing preload, including seal drag, is 3.5-6.2 INCH lbs. (.4-.7 N.m). Stake NEW lock nut into notch on spindle.
TESTING
POWER BRAKE UNIT
Functional Test
1. Check master cylinder fluid level and hydraulic system for leaks. Place transaxle in Neutral or Park, turn ignition off and apply parking
brake. Pump brake pedal several times to eliminate vacuum from system, and hold pedal in depressed position.
2. Start and idle engine. If vacuum system is functioning properly, pedal moves downward under constant foot pressure. If no pedal motion
is felt, vacuum booster is not functioning properly. Go to next step.
3. Run engine for at least one minute and turn ignition off. Depress brake pedal several times. Booster is okay if pedal stroke is long at first
and becomes shorter with each stroke. If stroke does not shorten, check for a damaged, restricted or improperly connected check va l ve
vacuum hose. Repair and recheck. Go to next step.
4. Restart engine. Depress and hold pedal down. Turn ignition off and wait 30 seconds. Booster is okay if pedal height remains unchanged.
If pedal height changes, check for a damaged, restricted or improperly connected check valve or vacuum hose. Go to next step.
5. Connect a pressure gauge to master cylinder output line. Connect a vacuum gauge to booster and a pedal depression force gauge to
brake pedal. Bleed air from pressure gauge. Start engine. When vacuum gauge reads 19.7 in. Hg, turn ignition off. Watch vacuum ga u ge
for 15 seconds. Booster is okay if vacuum gauge reads 18.7-19.7 in. Hg. If vacuum gauge reads less than 18.7 in. Hg, proceed to next
step.
6. Restart engine. Apply and hold 44 lbs. (196 N) force to brake pedal. When vacuum gauge reading reaches 19.7 in. Hg, turn ignition off.
Watch vacuum gauge for 15 seconds. Booster is okay if vacuum gauge reads 18.7-19.7 in. Hg. If vacuum gauge reads less than 18.7 in.
Hg, proceed to next step.
7. With engine stopped and vacuum gauge at zero, check pressure gauge. Apply 44 lbs. (196 N) force to brake pedal and check pressure
gauge. Booster is okay if pressure gauge reads 256 psi (18 kg/cm
2 ).
8. Remove pedal force and start engine. When vacuum gauge reaches 19.7 in. Hg, apply 44 lbs. (196 N) force to pedal. Booster is okay if
pressure gauge read 768 psi (54 kg/cm
2 ).
Diagnosis
If booster does not function properly, see Fig. 3 .
NOTE:Axle lock nut on right side has left-hand threads. Always install NEW lock nut when rem oved.
NOTE:Inspect all vacuum hoses for holes, collapsed areas and secure connections. Ensure all unused
vacuum ports are capped.
Page 3 of 12 MITCHELL 1 ARTICLE - BRAKE SYSTEM 1991-92 BRAKES Disc & Drum
3/10/2009 http://www.eautorepair.net/app/PrintItems.asp?S0=2097152&S1=0&SG=%7B7DD6473C%2DB5BB%2D4F20%2D9D70%2D
...

Autolamp Control RelayHeadlight Systems; Daytime Running Lights
Automatic Shutdown (ASD) RelayEngine Performance; Generators & Regulators
Autostick SwitchEngine Performance
Auxiliary Battery RelayGenerators & Regulators
Back-Up LightsBack-Up Lights; Exterior Lights
Barometric (BARO) Pressure SensorEngine Performance
BatteryPower Distribution
Battery Temperature SensorEngine Performance
Body Control ModuleBody Control Computer; Anti-Theft System; Daytime Running
Lights; Engine Performance; Headlight Systems; Warning Systems
Boost Control SolenoidEngine Performance
Boost SensorEngine Performance
Brake Fluid Level SwitchAnalog Instrument Panels
Brake On/Off (BOO) SwitchCruise Control Systems; Engine Performance; Shift Interlock
Systems
Buzzer ModuleWarning Systems
Camshaft Position (CMP) SensorEngine Performance
Central Control ModuleAnti-Theft System
ClockspringAir Bag Restraint System; Cruise Control Systems; Steering
Column Switches
Clutch Pedal Position SwitchStarters
Clutch Start SwitchStarters
Combination MeterAnalog Instrument Panels
Constant Control Relay Module (CCRM)Engine Performance; Electric Cooling Fans
Convenience CenterPower Distribution; Illumination/Interior Lights
Convertible Top MotorPower Convertible Top
Convertible Top SwitchPower Convertible Top
Crankshaft Position (CKP) SensorEngine Performance
Cruise Control ModuleCruise Control Systems
Cruise Control SwitchCruise Control Systems
Condenser Fan Relay(s)Electric Cooling Fans
Data Link Connector (DLC)Engine Performance
Da yt ime R u n n in g Ligh t s M o d u l eDaytime Running Lights; Exterior Lights
Defogger RelayRear Window Defogger
Diagnostic Energy Reserve Module (DERM)Air Bag Restraint System
Discriminating Sensor (Air Bag)Air Bag Restraint System
DistributorEngine Performance
Door Lock ActuatorsPower Door Locks; Remote Keyless Entry
Door Lock Relay(s)Power Door Locks
Electrochromic MirrorPower Mirrors
Electronic Level Control (ELC) Height SensorElectronic Suspension
Electronic Level Control (ELC) ModuleElectronic Suspension
Engine Coolant Temperature (ECT) Sending UnitAnalog Instrument Panels
Engine Coolant Temperature (ECT) SensorEngine Performance
Engine Control ModuleEngine Performance; Generators & Regulators; Starters
ETACS ECUWarning Systems; Power Windows; Remote Keyless Entry
Evaporative (EVAP) Emissions CanisterEngine Performance
EVAP Canister Purge SolenoidEngine Performance
EVAP Canister Vent SolenoidEngine Performance
Exhaust Gas Recirculation (EGR) ValveEngine Performance
Fuel Tank Vacuum SensorEngine Performance
F o g Ligh t sHeadlight Systems; Daytime Running Lights
F o g Ligh t R e l a yHeadlight Systems; Daytime Running Lights
Fuel Door Release SolenoidPower Fuel Door Release
Fuel Gauge Sending UnitAnalog Instrument Panels
Fuel InjectorsEngine Performance
Fuel PumpEngine Performance
Fuel Pump RelayEngine Performance; Power Distribution
Fuse/Relay BlockPower Distribution
Fusible LinksPower Distribution; Generators & Regulators; Starters
GeneratorGenerators & Regulators; Engine Performance; Power Distribution
Generic Electronic Module (GEM)Body Control Modules; Electronic Suspension
Glow Plug RelayEngine Performance
Glow PlugsEngine Performance
GroundsGround Distribution
Headlight Door ModuleHeadlight Doors
Headlight RelayHeadlight Systems; Daytime Running Lights
HeadlightsHeadlight Systems; Daytime Running Lights
Heated Oxygen Sensor(s) (HO2S)Engine Performance
Heated Windshield Control ModuleHeated Windshields
Page 4 of 6 MITCHELL 1 ARTICLE - GENERAL INFORMATION Using Mitchell1's Wiring Diagrams
3/10/2009 http://www.eautorepair.net/app/PrintItems.asp?S0=2097152&S1=0&SG=%7B959286D2%2D3A85%2D4BFC%2D9C5C%2D
...

Height SensorElectronic Suspension
HornsSteering Column Switches
Horn RelaySteering Column Switches
Idle Air Control (IAC) Motor/ValveEngine Performance
Ignition Coil(s)Engine Performance
Ignition Key Lock CylinderAnti-Theft System
Ignition ModuleEngine Performance
Ignition SwitchPower Distribution; Engine Performance; Generators &
Regulators; Starters
Illuminated Entry ModuleIllumination/Interior Lights
Illumination LightsIllumination/Interior Lights
Impact SensorAir Bag Restraint System
Inertia Fuel Shutoff SwitchEngine Performance
In h ib it Rel ayStarters
Instrument ClusterAnalog Instrument Panels
Intake Air Temperature (IAT) SensorEngine Performance
Interior LightsIllumination/Interior Lights
In t erl o ck Swit chStarters
Junction BlockPower Distribution
Keyless Entry ReceiverRemote Keyless Entry
Key Reminder SwitchStarters
Knock SensorEngine Performance
Lamp Control ModuleExterior Lights
License Plate LampExterior Lights
Lighting Control ModuleLighting Control Modules; Anti-Theft System; Daytime Running
Lights; Headlight Systems
Lower RelayPower Convertible Top
Malfunction Indicator Light (MIL)Engine Performance; Instrument Panels
Manifold Absolute Pressure (MAP) SensorEngine Performance
Mass Airflow (MAF) SensorEngine Performance
Mega FuseGenerators & Regulators
Memory Seat/Mirror ModuleMemory Systems
M ir r o r De fo gge rRear Window Defogger
Moon Roof MotorPower Moon Roof
Moon Roof RelayPower Moon Roof
Multi-Function Control ModuleWarning Systems
Neutral Safety SwitchStarters
Oil Level SwitchEngine Performance
Oil Pressure Switch/Sending UnitAnalog Instrument Panels; Engine Performance
Overhead ConsoleOverhead Console
Oxygen Sensor(s) (O2S)Engine Performance
Parking Brake SwitchAnalog Instrument Panels
Park LightsExterior Lights
Park/Neutral Position SwitchStarters; Engine Performance; Anti-Theft System; Body Control
Module
Perimeter Lighting Control RelayExterior Lights
Power AmplifierPower Antennas
Power Antenna ModulePower Antennas
Power Antenna MotorPower Antennas
Power Distribution CenterPower Distribution; Generators & Regulators; Starters
Power Door Lock MotorsPower Door Locks
Power Mirror MotorsPower Mirrors; Memory Systems
Power Sliding Door ControllerPower Sliding Side Door
Power Seat MotorsPower Seats; Memory Systems
Power Steering Pressure SwitchEngine Performance
Power Top MotorPower Convertible Top
Power Top Relay(s)Power Convertible Top
Powertrain Control ModuleEngine Performance; Analog Instrument Panels; Cruise Control
Systems; Data Link Connectors; Generators & Regulators; Starters
Power Window MotorsPower Windows
Power Window Relay(s)Power Windows
Radiator Fan Motor(s)Electric Cooling Fans
Radiator Fan Relay(s)Engine Performance; Electric Cooling Fans;
Rainsense ModuleWiper/Washer Systems
Raise RelayPower Convertible Top
Remote Anti-Theft Personality (RAP) ModuleAnti-Theft System; Starters; Warning Systems
Seat Belt PretensionersAir Bag Restraint System
Seat Belt Retractor SolenoidPassive Restraints
Seat Belt SwitchAir Bag Restraint System; Passive Restraints
Shift Interlock SolenoidShift Interlock Systems
Page 5 of 6 MITCHELL 1 ARTICLE - GENERAL INFORMATION Using Mitchell1's Wiring Diagrams
3/10/2009 http://www.eautorepair.net/app/PrintItems.asp?S0=2097152&S1=0&SG=%7B959286D2%2D3A85%2D4BFC%2D9C5C%2D
...

front oil seal. Carefully slide camshaft out front of cylinder head. DO NOT d a ma ge b e a r in g b o r e s.
Inspection (1.3L)
1. Check cylinder head for warpage. See INSPECTION under CYLINDER HEAD under REMOVAL & INSTALLATION. Measure
camshaft lobes across their maximum dimensions. Inspect for scoring and wear. Replace camshaft if not within specification. See, in this
article, CAMSHAFT LOBE SPECIFICATIONS
table.
2. Measure camshaft bearing journals and cylinder head bores. See Fig. 6
and Fig. 7 . Subtract camshaft bearing journal O.D. from
cylinder head bore I.D. to obtain oil clearance. If clearance is not within specification, replace head and/or camshaft. See, in this article,
CAMSHAFT SPECIFICATIONS
table under ENGINE SPECIFICATIONS tables.
Installation (1.3L)
1. Oil camshaft and insert carefully. Install thrust plate. Install camshaft front oil seal. Install rocker arm shaft assemblies to original
location. Ensure oil holes in rocker arm shaft face downward.
2. While tightening rocker arm shaft, slide shaft springs away from retaining bolt to prevent pinching spring. Tighten rocker arm shaft bolts
in sequence and to specification. See Fig. 5
. See TORQUE SPECIFICATIONS table at end of article. To complete installation,
reverse removal procedure. Tighten all bolts and nuts to specification.
CAMSHAFT LOBE SPECIFICATIONS

Fig. 5: Rocker Arm Shaft Tightening Sequence (1.3L)

Courtesy of FORD MOTOR CO.
Removal (1.6L)
1. Disconnect battery ground terminal. Disconnect air by-pass hoses, and remove intake air tube. Disconnect throttle cable, and remove
ret ain in g b racket s. Remo ve cam co ver. Remo ve t imin g b el t .
2. Hold camshaft with wrench while removing pulley retaining bolt. Remove camshaft pulley(s). Remove seal plate. Remove camshaft seal
using Seal Remover (T78P-3504-N). If removing intake cam, remove distributor.
3. Note numerical and directional markings on camshaft bearing caps for installation. Remove bearing cap retaining bolts alternately and
gradually to prevent overstressing camshaft. Remove camshaft.
Inspection (1.6L)
1. Check cylinder head for warpage (if removed). See INSPECTION in CYLINDER HEAD . Measure camshaft lobes across their
maximum dimensions. Inspect for scoring and wear. Replace camshaft if not within specification. See CAMSHAFT LOBE
SPECIFICATIONS table. NOTE:For additional cam shaft specifications, see, in this article, CAMSHAFT SPECIFICAT IONS
table
under ENGINE SPECIFICATIONS at end of this article.
NOTE:Cam shaft bearings are NOT replaceable. If not within specification, replace cylinder head and/or
cam shaft.
ApplicationStandard Height: In. (mm)W ear Limit: In. (mm)
1.3L1.4332-1.4371 (36.403-36.503)1.4273 (36.253)
1.6L1.6098 (40.888)1.5944 (40.498)
NOTE:For additional cam shaft specifications, see CAMSHAFT SPECIFICAT IONS table under ENGINE
SPECIFICAT IONS at end of this article.
NOTE:Cam shaft bearings are NOT replaceable. If not within specification, replace cylinder head and/or
Page 8 of 19 MITCHELL 1 ARTICLE - ENGINE OVERHAUL 1991-92 FORD MOTOR CO. ENGINES 1.3L & 1.6L 4-Cylinder
3/10/2009 http://www.eautorepair.net/app/PrintItems.asp?S0=2097152&S1=0&SG=%7B959286D2%2D3A85%2D4BFC%2D9C5C%2D
...

Fig. 8: Identifying Oil Pan Sealing Points

Courtesy of FORD MOTOR CO.
OVERHAUL
VALVE SPRINGS
Measure valve springs squareness and free length. Replace spring if either measurement is out of specification. See, at end of article, VALVES
& VALVE SPRINGS table in ENGINE SPECIFICATIONS.
VALVE STEM INSTALLED HEIGHT
Measure protruding length of each valve stem. See VALVE STEM INSTALLED HEIGHT table. If length is at service limit, use valve spring
shims to bring measurement within range of acceptable limit. If length is greater than service limit, replace valve seat or cylinder head.
VALVE STEM INSTALLED HEIGHT
VALVE GUIDES
Remove cylinder head, camshaft(s) and valves. Check valve stem-to-guide oil clearance. If clearance exceeds specification, replace valve
guides and/or valves. See CYLINDER HEAD
table under ENGINE SPECIFICATIONS at end of this article.
ROCKER ARM SHAFT ASSEMBLY (1.3L)
Remove valve cover. Keep components in order of removal to ensure reassembly to original position. Remove rocker arm shaft retaining bolts
and rocker arm shaft assembly. To install, reverse removal procedure.
VALVE LASH ADJUSTERS (1.3L)
Warm engine to normal operating temperature. Remove valve cover. Inspect hydraulic lash adjuster operation by pushing each rocker arm
down by hand. If rocker arm moves downward, replace hydraulic lash adjuster. Adjustment on valve lash adjusters is NOT possible or
necessary.
CAM SHAFT(S) (1.6L)
Remove cam cover. Remove camshaft(s). Keep components in order of removal to ensure reassembly to original position. To install, reverse
removal procedure.
VALVE LASH ADJUSTERS (1.6L)
Inspect friction surfaces for wear and damage. Hold bucket body (each adjuster) and press between thumb and forefinger. If plunge r mo ve s,
ApplicationIn. (mm)
1.3L
New1.520-1.539 (38.6-39.1)
Acceptable Limit1.539-1.579 (39.2-40.1)
Service Limit1.579 (40.1)
1.6L
New1.713-1.732
Acceptable Limit1.7732-1.772 (44-45)
Service Limit1.772 (45)
NOTE:For additional valve specifications, see, at end of this article, VALVES & VALVE SPRINGS
table under
ENGINE SPECIFICAT IONS.
Page 12 of 19 MITCHELL 1 ARTICLE - ENGINE OVERHAUL 1991-92 FORD MOTOR CO. ENGINES 1.3L & 1.6L 4-Cylinder
3/10/2009 http://www.eautorepair.net/app/PrintItems.asp?S0=2097152&S1=0&SG=%7B959286D2%2D3A85%2D4BFC%2D9C5C%2D
...

1.3L
No. 1 & 31.7102-1.7109 (43.440-
43.456)
No. 21.7091-1.7100 (43.410-
43.435)
1.6L (All Journals)1.0213-1.0222 (25.940-
25.965)
Journal Runout.002 (.05)
Lobe Height
1.3L(2) 1.4332-1.4371 (36.403-
36.503)
1.6L(3) 1.6098 (40.888)
Oil Clearance
1.3L
No. 1 & 3 Journals(4) .0014-.0033 (.035-.085)
No. 2 Journal(4) .0026-.0045 (.065-.115)
1.6L (All Journals)(4) .0014-.0033 (.035-.085)
(1)End play limit is .008" (.20 mm).
(2)Wear limit is 1.4272" (36.253 mm)
(3)Wear limit is 1.5940" (40.489)
(4)Maximum clearance is .0059" (.150 mm)
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00048707
Page 19 of 19 MITCHELL 1 ARTICLE - ENGINE OVERHAUL 1991-92 FORD MOTOR CO. ENGINES 1.3L & 1.6L 4-Cylinder
3/10/2009 http://www.eautorepair.net/app/PrintItems.asp?S0=2097152&S1=0&SG=%7B959286D2%2D3A85%2D4BFC%2D9C5C%2D
...

Federal
FI
Fuel Injection
FICU
Fuel Injection Control Unit
FIPL
Fuel Injector Pump Lever
FPR-VSV
Fuel Pressure Regulator Vacuum Switching Valve
Ft. Lbs.
Foot Pounds
FWD
Front Wheel Drive
"G"
g
gr a ms
Gals.
ga l l o n s
GND or GRND
Ground
"H"
HAC
High Altitude Compensation
HC
Hydrocarbons
H/D
Heavy Duty
HO2S
Heated Exhaust Gas Oxygen Sensor
Hg
Mercury
Hgt.
Height
HLDT
Headlight
HO
High Output
HO2S
Heated Oxygen Sensor
HP
Page 7 of 15 MITCHELL 1 ARTICLE - GENERAL INFORMATION Commonly Used Abbreviations
3/10/2009 http://www.eautorepair.net/app/PrintItems.asp?S0=2097152&S1=0&SG=%7B9B990D68%2D660A%2D45E9%2D8F46%2DE
...

DRIVE AXLE (RWD) TROUBLE SHOOTING
FWD AXLE SHAFTS & CV JOINTS TROUBLE SHOOTING
BASIC FWD AXLE SHAFTS & CV JOINTS TROUBLE SHOOTING CHART
STEERING & SUSPENSION
MANUAL STEERING GEAR TROUBLE SHOOTING
BASIC MANUAL STEERING GEAR TROUBLE SHOOTING CHART
CONDITION & POSSIBLE CAUSECORRECTION
Knocking or Clunking
Differential Side Gear ClearanceCheck Clearance
Worn Pinion ShaftReplace Pinion Shaft
Axle Shaft End PlayCheck End Play
Missing Gear TeethCheck Differential/Replace
Gear
Wrong Axle BacklashCheck Backlash
Misaligned DrivelineRealign Driveline
Clinking During Engagement
Side Gear ClearanceCheck Clearance
Ring and Pinion BacklashCheck Backlash
Worn/Loose Pinion ShaftReplace Shaft/Bearing
Bad "U" JointReplace "U" Joint
Sticking Slip YokeLube Slip Yoke
Broken Rear Axle MountReplace Mount
Loose Drive Shaft FlangeCheck Flange
Click/Chatter On Turns
Differential Side Gear ClearanceCheck Clearance
Wrong Turn On Plates (1)Replace Clutch Plates
Wrong Differential Lubricant (1)Change Lubricant
Knock Or Click
Flat Spot on Rear Wheel BearingReplace Wheel Bearing
Low Vibration At All Speeds
Faulty Wheel BearingReplace Wheel Bearing
Faulty "U" JointReplace "U" Joint
Faulty Drive ShaftBalance Drive Shaft
Faulty Companion FlangeReplace Flange
Faulty Slip Yoke FlangeReplace Flange
(1)Limited slip differential only.
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.
CONDITIONPOSSIBLE CAUSE
Grease LeaksCV boot torn or cracked
Clicking Noise on CorneringDamaged outer CV
Clunk Noise on AccelerationDamaged inner CV
Vibration or Shudder on AccelerationSticking, damaged or worn CV Misalignment or spring height
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
Rattle or Chucking Noise in Rack and Pinion
Rack and pinion mounting bracket looseTighten all mounting bolts
Lack of/or incorrect lubricantCorrect as necessary
Steering gear mounting bolts looseTighten all mounting bolts
Excessive Play
Front wheel bearing improperly adjustedSee FRONT SUSPENSION
article
Loose or worn steering linkageSee STEERING LINKAGE
article
Loose or worn steering gear shiftSee MANUAL STEERING
GEAR article
Steering arm loose on gear shaftSee MANUAL STEERING
GEAR article
Steering gear housing bolts looseTighten all mounting bolts
Page 29 of 36 MITCHELL 1 ARTICLE - GENERAL INFORMATION Trouble Shooting - Basic Procedures
3/10/2009 http://www.eautorepair.net/app/PrintItems.asp?S0=2097152&S1=0&SG=%7B9B990D68%2D660A%2D45E9%2D8F46%2DE
...

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
Page 35 of 36 MITCHELL 1 ARTICLE - GENERAL INFORMATION Trouble Shooting - Basic Procedures
3/10/2009 http://www.eautorepair.net/app/PrintItems.asp?S0=2097152&S1=0&SG=%7B9B990D68%2D660A%2D45E9%2D8F46%2DE
...