tire size FORD FESTIVA 1991 Service Manual

If temperature gauge always reads hot, check these items:
Check for temperature gauge wire shorted to ground.
Check for defective temperature sender.
Check for defective temperature gauge.
Check for defective instrument panel voltage regulator (Festiva).
Temperature Gauge Inaccurate
If temperature gauge is inaccurate, check these items:
Check for faulty (loose or corroded) wire connections.
Check for defective temperature sender.
Check for defective instrument panel voltage regulator (Festiva).
SPEEDOMETER
Speedometer Does Not Operate
If speedometer does not operate, check these items:
Check for broken speedometer drive cable.
Check for broken drive gear in transmission.
Check for defective speedometer head.
Speedometer Needle Bounces
If speedometer needle bounces, check these items:
Check for binding speedometer drive cable.
Check for missing teeth on drive gear in transmission.
Check for defective speedometer head.
Speedometer Does Not Indicate Correct Vehicle Speed
If speedometer does not indicate correct vehicle speed, check these items:
Check for incorrect size tires.
Check for improper tire inflation.
Check for defective speedometer head.
TACHOMETER (CAPRI)
Tachometer Does Not Work, But All Other Gauges Work Properly
-If tachometer does not work, but all other gauges function properly, check these items:
Check for defective tachometer.
Check for open Yellow/Black tachometer signal wire from ignition coil to instrument panel.
Check for faulty Black ground wire to instrument panel.
Tachometer & All Gauges Do Not Function
If tachometer and all other gauges do not function properly, check these items:
Check for blown 10-amp METER fuse in fuse panel.
Check for open in Black/Yellow wire to fuse panel to instrument panel and Black/White wire from ignition switch to fuse panel
Tachometer Reading Low
If tachometer reading is lower than normal, check these items:
Check for defective tachometer.
Check for faulty Black ground wire at instrument panel.
TURBO BOOST GAUGE (CAPRI)
Turbo Boost Gauge Always Reads Low
If turbo boost gauge always reads low, check these items:
Check boost gauge for open or damaged wires.
Check for defective boost sensing unit.
Check for defective boost gauge.
Check for blown 10-amp METER fuse in fuse panel.
Check for loose or corroded connections.
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2. Remove main bearing cap bolts. Remove cap and lower bearing insert. Use bearing remover or fabricated cotter key to remove upper
bearing insert. Insert bearing remover in journal lubrication hole. Rotate crankshaft in normal direction of operation only. Repeat
procedure for remaining main bearings.
3. Check bearings for abnormal wear. Check crankshaft for grooves, scratches and pitting. Using Plastigage method, check clearance of
main bearing-to-crankshaft. Always keep at least 2 bearings and caps tight during clearance check. See, at end of article,
CRANKSHAFT MAIN & CONNECTING ROD BEARINGS
table under ENGINE SPECIFICATIONS.
4. Lubricate and install new bearings in cap and block. Match bearing tangs with notch in cap and block. Position cap in its proper
location and position. Install cap bolts and tighten to specification. See TORQUE SPECIFICATIONS
table at end of article. Repeat
procedure for remaining main bearings.
CRANKSHAFT END PLAY
Check crankshaft end play with dial indicator. End play should be .0031-.0111" (.08-.282 mm). Service limit is .012" (.30 mm). If end play is
not within specification, replace thrust bearings as necessary.
CYLINDER BLOCK
1. Using straightedge and feeler gauge, check entire cylinder head surface of cylinder block. Ensure warpage does not exceed .006" (.15
mm). If warpage exceeds specification, cylinder block surface can be machined a maximum of .008" (.20 mm).
2. Replace cylinder block if it needs to be machined more than .008" (.20 mm). Check cylinder bore for wear, out-of-round, taper and
piston fit. See CYLINDER BORE SPECIFICATIONS
table. Oversize pistons are available in .010" and .020" (.25 mm and .50 mm).
CYLINDER BORE SPECIFICATIONS
LUBRICATION
ENGINE OILING SYSTEM
Oiling system is force-feed type and uses a full-flow oil filter. Oil is retrieved from oil pan by oil pump pick-up tube and distributed to oil
filter. Oil is then filtered and routed throughout engine.
Crankcase Capacity
1.3 L crankcase capacity is 3.2 qts. (3.0 L) without filter change and 3.6 qts. (3.4 L) with filter change. For 1.6 L vehicles, capacity is 3.2 qts
(3.2 L) without filter and 3.72 qts. (3.5 L) with filter.
Normal Oil Pressure (Hot)
Normal oil pressure is 50-64 psi (3.5-4.5 kg/cm2 ) at 3000 RPM.
Pressure Regulator Valve
Pressure regulator valve is located in oil pump body and is nonadjustable.
OIL PUMP
Removal
Remove oil pan, pick-up tube and screen, timing belt and crankshaft sprocket. Remove front engine cover bolts and remove front cover.
R e mo ve b o l t s r e t a in in g p u mp c o ve r t o b a c k sid e o f fr o n t c o ve r h o u sin g.
2) Remove pump cover and inner and outer gears. Pry out front seal from front cover. Remove cotter pin. Remove pressure regulator retainer,
spring and valve.
OIL PUMP SPECIFICATIONS or replacem ent.
ApplicationIn. (mm)
Cylinder Diameter
Standard Bore
1.3L2.7953-2.7960 (71.000-71.019)
1.6L3.0709-3.0716 (78.000-78.019)
Maximu m Bo re
1.3L2.8020 (71.17)
1.6L3.0905-3.0913 (78.500-78.519)
Maximu m Ou t -Of-Ro u n d & Tap er.0007 (.019)
Piston-To-Bore Clearance.006 (.15)
ApplicationIn. (mm)
Inner Gear-To-Outer Gear
1.3L.008 (.20)
1.6L.0008-.0063 (.02-.16)
Outer Gear-To-Housing
1.3L.009 (.22)
1.6L.0035-.0071 (.09-.18)
End Play
1.3L.006 (.14)
Page 14 of 19 MITCHELL 1 ARTICLE - ENGINE OVERHAUL 1991-92 FORD MOTOR CO. ENGINES 1.3L & 1.6L 4-Cylinder
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BRAKES
BRAKE SYSTEM TROUBLE SHOOTING
BRAKE SYSTEM TROUBLE SHOOTING CHART
CONDITIONPOSSIBLE CAUSE
Insufficient, Erratic, or No HeatLow Coolant Level
.....Incorrect thermostat.
.....Restricted coolant flow through core.
.....Heater hoses plugged.
.....Misadjusted control cable.
.....Sticking heater control valve.
.....Vacuum hose leaking.
.....Vacuum hose blocked.
.....Vacuum motors inoperative.
.....Blocked air inlet.
.....Inoperative heater blower motor.
.....Oil residue on heater core fins.
.....Dirt on heater core fins.
Too Much HeatImproperly adjusted cables.
.....Sticking heater control valve.
.....No vacuum to heater control valve.
.....Temperature door stuck open.
Air Flow Changes During AccelerationVacuum system leak.
.....Bad check valve or reservoir.
Air From Defroster At All TimesVacuum system leak.
.....Improperly adjusted control cables.
.....Inoperative vacuum motor.
Blower Does Not Operate CorrectlyBlown fuse.
.....Blower motor windings open.
.....Resistors burned out.
.....Motor ground connection loose.
.....Wiring harness connections loose.
.....Blower motor switch inoperative.
.....Blower relay inoperative.
.....Fan binding or foreign object in housing.
.....Fan blades broken or bent.
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
Brakes Pull Left or Right
Incorrect tire pressureInflate tires to proper pressure
Front end out of alignmentSee WHEEL ALIGNMENT
Mismatched tiresCheck tires sizes
Restricted brake lines or hosesCheck hose routing
Loose or malfunctioning caliperSee DISC BRAKES or
BRAKE SYSTEM
Bent shoe or oily liningsSee DRUM BRAKES or
BRAKE SYSTEM
Malfunctioning rear brakesSee DRUM, DISC BRAKES
or BRAKE SYSTEM
Loose suspension partsSee SUSPENSION
Noises Without Brakes Applied
Front linings worn outReplace linings
Dust or oil on drums or rotorsSee DRUM, DISC BRAKES
or BRAKE SYSTEM
Noises With Brakes Applied
Insulator on outboard shoe damagedSee DISC BRAKES or
BRAKE SYSTEM
Incorrect pads or liningsReplace pads or linings
Brake Rough, Chatters or Pulsates
Excessive lateral runoutCheck rotor runout
Parallelism not to specificationsReface or replace rotor
Wheel bearings not adjustedSee SUSPENSION
Rear drums out-of-roundReface or replace drums
Disc pad reversed, steel against rotorRemove and reinstall pad
Excessive Pedal Effort
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POWER STEERING TROUBLE SHOOTING
BASIC POWER STEERING TROUBLE SHOOTING CHART
Steering gear adjustment too looseSee MANUAL STEERING
GEAR article
Steering arms loose on knucklesTighten and check steering
linkage
Rack and pinion mounting looseTighten all mounting bolts
Rack and pinion out of adjustmentSee adjustment in STEERING
article
Tie rod end looseTighten and check steering
linkage
Excessive Pitman shaft-to-ball nut lashRepair as necessary
Poor Returnability
Lack of lubricant in ball joint or linkageLubricate and service systems
Binding in linkage or ball jointsSee STEERING LINKAGE
and SUSPENSION article
Improper front end alignmentSee WHEEL ALIGNMENT
article
Improper tire pressureInflate to proper pressure
Tie rod bindingInflate to proper pressure
Shaft seal rubbing shaftSee STEERING COLUMN
article
Excessive Vertical Motion
Improper tire pressureInflate to proper pressure
Tires, wheels or rotors out of balanceBalance tires then check
wheels and rotors
Worn or faulty shock absorbersCheck and replace if necessary
Loose tie rod ends or steeringTighten or replace if necessary
Loose or worn wheel bearingsSee SUSPENSION article
Steering Pulls to One Side
Improper tire pressureInflate to proper pressure
Front tires are different sizesRotate or replace if necessary
Wheel bearings not adjusted properlySee FRONT SUSPENSION
article
Bent or broken suspension componentsSee FRONT SUSPENSION
article
Improper wheel alignmentSee WHEEL ALIGNMENT
article
Brakes draggingSee BRAKES article
Instability
Low or uneven tire pressureInflate to proper pressure
Loose or worn wheel bearingsSee FRONT SUSPENSION
article
Loose or worn idler arm bushingSee FRONT SUSPENSION
article
Loose or worn strut bushingsSee FRONT SUSPENSION
article
Incorrect front wheel alignmentSee WHEEL ALIGNMENT
article
Steering gear not centeredSee MANUAL STEERING
GEARS article
Springs or shockCheck and replace if necessary
Improper cross shaftSee MANUAL STEERING
GEARS 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
Rattle or Chucking Noise
Pressure hoses touching engine partsAdjust to proper clearance
Loose Pitman shaftAdjust or replace if necessary
Tie rods ends or Pitman arm looseTighten and check system
Rack and pinion mounts looseTighten all mounting bolts
Free play in worm gearSee POWER STEERING
GEAR article
Loose sector shaft or thrust bearing adjustmentSee POWER STEERING
GEAR
Free play in pot couplingSee STEERING COLUMN
article
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GENERAL INFORMATION
Manual Transmission Trouble Shooting
* PLEASE READ THIS FIRST *
INTRODUCTION
There are many times when the transmission is incorrectly blamed for shifting problems or noises that are actually caused by other reasons.
Shift difficulties are frequently caused by conditions outside of the transmission or transaxle. Typical conditions include: shift linkage, shift
cables, alignment of engine to transmission, worn engine mounts or clutch problems. Drive train noises may come from many sources such as
tires, road surfaces, wheel bearings, differentials, engine or exhaust system. Repairing or overhauling transmission will not cure these
problems.
No manufacturer makes a perfectly quiet transmission. Gear rollover noise is present in most constant mesh transmissions and will tend to
disappear when the clutch is disengaged or transmission is placed in gear. If clutch is properly adjusted, clutch release bearing noise will
disappear when release bearing is moved enough to slide release bearing away from pressure plate.
Trouble shooting can be helped by driving vehicle on a smooth level road to help eliminate tire and body noise. Note whether noise occurs on
acceleration, coasting, deceleration or steady driving conditions. Some problems may only occur when transmission is either hot or cold. Gear
lubricant that is too thick can cause hard shifting on cold mornings before engine is warm and vehicle has been driven.
MANUAL TRANSMISSION/TRANSAXLE TROUBLE SHOOTING 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.
ConditionPossible Cause
Noisy In Forward GearsLow Gear Oil Level, Loose Bellhousing Bolts, Worn Bearings Or
Gears
Clunk On Deceleration (FWD Only)Loose Engine Mounts, Worn Inboard CV Joints, Worn Differential
Pinion Shaft, Oversized Side Gear Hub Counterbore in Case
Gear Clash When Shifting Forward GearsClutch Out Of Alignment, Shift Linkage Damaged Or Out Of
Adjustment, Gears Or Synchronizers Damaged, Low Gear Oil
Level
Transmission Noisy When Moving (RWD Only); Quiet In Neutral
With Clutch EngagedWorn Rear Output Shaft Bearing
Gear RattleWorn Bearings, Worn Gear Oil, Low Gear Oil, Worn Gears
Steady Ticking At Idle (Increases With RPM)Broken Tooth On A Gear
Gear Clash When Shifting Forward GearsWorn Or Broken Synchronizers, Faulty Clutch
Loud Whine In ReverseNormal Condition (1)
Noise When Stepping On ClutchFaulty Release Bearing, Worn Pilot Bearing
Ticking Or Screeching As Clutch Is EngagedFaulty Release Bearing, Uneven Pressure Plate Fingers
Click Or Snap When Clutch Is EngagedWorn Clutch Fork, Worn Pivot Ball, Worn Or Broken Front
Bearing Retainer
Transmission Shifts HardClutch Not Releasing, Incorrect Gear Oil, Shift Mechanism
Binding, Clutch Installed Backward
Will Not Shift Into One Gear, Shifts Into All OthersBent Shift Fork, Worn Detent Balls
Locked Into Gear, Cannot ShiftClutch Adjustment, Worn Detent Balls
Transmission Jumps Out Of GearPilot Bearing Worn, Bent Shift Fork, Worn Gear Teeth Or Face,
Excessive Gear Train End Play, Worn Synchronizers, Missing
Detent Ball Spring, Shift Mechanism Worn Or Out Of Adjustment,
Engine Or Transmission Mount Bolts Loose, Transmission Not
Aligned
Shift Lever RattleWorn Detents Or Shift Lever, Worn Shift Fork, Worn
Synchronizer Sleeves
Shift Lever Hops Under AccelerationWorn Engine Or Transmission Mounts
(1)Most units use spur cut gears in Reverse and are naturally noisy.
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Article GUID: A00010942
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compressor label before adding refrigerant oil to A/C compressor/system. See Fig. 2 . The following R-134a refrigerant oils are currently
available.
Lexus
PAG Refrigerant Oil (ND-OIL 8) with 10P/10PA swashplate (piston) compressor. Synthetic Refrigerant Oil (ND-OIL 9) with through-va n e
(rotary vane) compressor.
Mercedes-Benz
PAG Refrigerant Oil (001 989 08 03).
Nissan
PAG Refrigerant Oil (KLH00-PAGR0) with rotary vane compressor. PAG Refrigerant Oil (KLH00-PAGS0) with piston (swashplate)
compressor.
Saab
PAG Refrigerant Oil (40 74 787).
SERVICE EQUIPMENT
Because R-134a is not interchangeable with R-12, separate sets of hoses, manifold gauge set and recovery/recycling equipment are required to
service vehicles. This is necessary to avoid cross-contaminating and damaging system.
All equipment used to service systems using R-134a must meet SAE standard J1991. The service hoses on the manifold gauge set must have
manual (turn wheel) or automatic back-flow valves at the service port connector ends. This will prevent refrigerant from being released into
the atmosphere.
For identification purposes, R-134a service hoses must have a Black stripe along its length and be clearly labeled SAE J2196/R-134a. The low
pressure test hose is Blue with a Black stripe. The high pressure test hose is Red with a Black stripe, and the center test hose is Yellow with a
Black stripe.
R-134a manifold gauge sets can be identified by one or all of the following.
Labeled FOR USE WITH R-134a on set
Labeled HFC-134 or R-134a on gauge face
Light Blue color on gauge face
In addition, pressure/temperature scales on R-134a gauge sets are different from R-12 manifold gauge sets.
SYSTEM SERVICE VALVES
SCHRADER-TYPE VALVES
Schrader valve is similar in construction and operation to a tire valve. When a test gauge hose with built-in valve core depressor is attached,
Schrader stem is pushed inward to the open position and allows system pressure to reach gauge.
If test hose does not have a built-in core depressor, an adapter must be used. Never attach hose or adapter to Schrader valve unless it is first
connected to manifold gauge set.
Refrigerant R-12 Schrader-type valve cores have TV5 thread size. Refrigerant R-134a Schrader-type valve cores use M6 (Metric) threads. R-
134a valve cores can be easily identified by use of "O" rings and external spring. See Fig. 1
.
SERVICE VALVE LOCATIONS
SERVICE VALVE LOCATIONS NOTE:Synthetic/PAG oils absorb m oisture very rapidly, 2.3-5.6% by weight, as com pared to a m ineral oil
absorption rate of .005% by weight.
NOTE:Refrigerant R-12 service hoses will ONLY be labeled SAE J2196.
NOTE:Although sim ilar in construction and operation to a tire valve, NEVER replace a Schrader-type valve
with a tire valve.
VehicleHighLow
Audi(14) (15)
Acura(2) (3)
BMW(4) (5)
Chrysler, Eagle & Mitsubishi
Colt, Mirage & Summit(10) (11)
Colt Vista & Summit Wagon(10) (11)
Diamante(1) (1)
Eclipse & Expo(10) (11)
Galant(10) (11)
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MAINTENANCE INFORMATION
1988-93 MAINT ENANCE Ford Motor Co. Maintenance Inform ation
MODEL IDENTIFICATION
VIN LOCATION
The Vehicle Identification Number (VIN) is located on the left side of the dash panel at the base of the windshield. The VIN chart explains the
code characters.
VIN CODE ID EXPLANATION
Numbers preceding the explanations in the legend below refer to the sequence of characters as listed on VIN identification label. See VIN
example below.

Fig. 1: VIN Code ID Explanation

MAINTENANCE SERVICE INFORMATION
SEVERE & NORMAL SERVICE DEFINITIONS
Service is recommended at mileage intervals based on vehicle operation. Service schedules are based on the following primary operating
conditions:
Severe Service
Short Trips (About 10 Miles) In Freezing Temperatures
Towing Or Heavily Loaded
Severe Dust Conditions
Hot Weather, Stop-And-Go Driving
Extensive Idling Conditions (Taxi Or Delivery Type Service)
Normal Service
NOTE:For scheduled m aintenance intervals and the related fluid capacities, fluid specifications and labor
tim es for m ajor service intervals, see SCHEDULED SERVICES article in this section. Warranty
inform ation and specifications for fluid capacities, lubrication specifications, wheel and tire size, and
battery type are covered in this article.
NOTE:Use the Severe Service schedule if the vehicle to be serviced is operated under ANY (one or m ore) of
these conditions:
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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.
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Article GUID: A00060347
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See STALL SPEED SPECIFICATIONS .
Testing Procedures
1. With engine at normal operating temperature, tachometer installed and parking and service brakes applied, perform transaxle stall test in
"D", "2", "1" and "R" ranges at full throttle and note maximum RPM obtained. Correct stall speed should occur at specified RPM. See
the STALL SPEED SPECIFICATIONS
.
STALL SPEED SPECIFICATIONS
2. If stall speed is too high in all shift ranges, the following components may be faulty:
Worn Oil Pump.
Oil leakage from oil pump, valve body or transaxle case.
Sticking pressure regulator valve.
3. If stall speed is too high in "D", "2" and "1", the following component may be faulty:
Slipping rear clutch.
4. If stall speed is too high in "D", the following component may be faulty:
Slipping one-way clutch.
5. If stall speed is too high in "2", the following components may be faulty:
Slipping intermediate band.
6. If stall speed is too high in "R", the following components may be faulty:
Slipping Low/Reverse Clutch.
Slipping Front Clutch.
7. If stall speed is too low in all shift ranges, the following components may be faulty:
Slipping torque converter one-way clutch.
ROAD TEST
1. Before road test, ensure that fluid level, fluid condition and control linkage adjustments are okay. During test, transaxle should upshift
or downshift at about same speed as specified. See appropriate SHIFT SPEED SPECIFICATIONS
.
2. All shifts may vary slightly due to production tolerances or tire size. The quality of the shifts are more important. All shifts should be
smooth, responsive and with no slippage or engine flare. Slippage or engine flare in any gear usually indicates clutch or band problems.
3. The slipping clutch or band in a particular gear can usually be identified by noting transaxle operation in other selector positions and
comparing internal units which are applied in these positions. See CLUTCH & BAND APPLICATION
.
SHIFT SPEED SPECIFICATIONS
VEHICLE SHIFT SPEED SPECIFICATIONS (ASPIRE & FESTIVA)
VEHICLE SHIFT SPEED SPECIFICATIONS (TRACER)
ApplicationEngine RPM
Aspire2300-2500
Festiva & Tracer2300-2500
Operating Condition (1) Shift Speed MPH (km/h)
Half Throttle (50%)
1-29-17 (15-28)
2-316-34 (26-55)
Full Throttle (WOT) (2)
1-228-33 (44-53)
2-355-63 (88-101)
3-253-48 (86-78)
2-124-22 (39-35)
Coasting (2-1)9-6 (14-9)
(1)Transmission is in "D" range.
(2)To determine deceleration shift speeds, release throttle once transaxle has shifted into 3rd gear. Manually downshift shift lever
into next lower gear and record speed at which downshift occurs. Continue downshifting and recording vehicle speed until
transaxle has downshifted into low gear.
Operating Condition (1) Shift Speed MPH
Half Throttle (50%)
1-2 - Carbureted10-19
1-2 - EFI12-21
2-3 - Carbureted17-37
2-3 - EFI37-48
Full Throttle (WOT)
1-230-36
2-360-68
3-253-58
2-124-26
Fully Closed Throttle
Fro m "D" Ran ge (3 -1 )6-9
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