Ford Festiva. Manual — part 110

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. Remove

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

1. Inspect wiring and components for shorts, corrosion, overheating, loose connections, or any other damage. Check 10-amp METER fuse.

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)

Copyright 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

.

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

Application

In. (mm)

Pedal Height

8.2-8.4 (208.2-213.2)

Free Play

.35-.59 (9-15)

Release Lever-To-Pin

.06-.10 (1.5-2.5)

Disengagement Height

3.3 (84)

CAUTION:

DO NOT allow oil or grease to contact clutch disc face or mating surfaces. Handle disc by edges.
DO NOT touch face.