Ford Festiva. Manual — part 10

Fig. 12: Exploded View of Master Cylinder (Festiva)

Courtesy of FORD MOTOR CO.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

DISC BRAKE SPECIFICATIONS

DISC BRAKE SPECIFICATIONS

Application

Ft. Lbs. (N.m)

Backing Plate/Spindle Bolts (Rear)

32-45 (43-61)

Brake Hose to Caliper

16-22 (22-30)

Caliper Guide/Mounting Bolt

29-36 (39-49)

Caliper Banjo Bolt

16-21 (22-29)

Front Drive Axle Nut

117-175 (159-237)

Hub-To-Rotor Bolt

33-40 (45-54)

Power Booster Mounting Nuts

Capri

14-19 (19-26)

Festiva

12-17 (16-23)

Rear Axle Nut

(1)

Rear Strut/Spindle (Capri-Rear)

69-86 (93-117)

Rotor-To-Hub Bolts

33-40 (44-54)

Steering Knuckle-To-Control Arm

32-40 (43-54)

Steering Knuckle-To-Strut

69-86 (93-117)

Steering Knuckle-To-Tie Rod

21-33 (29-44)

Wheel Lug Nut

65-87 (88-118)

INCH Lbs. (N.m)

Master Cylinder-To-Booster Nut

89-142 (10-16)

Wheel Cylinder Mounting Bolt

89-106 (10-12)

(1)

See REAR AXLE BEARINGS under ADJUSTMENTS.

Application

In. (mm)

Capri

Lateral Runout

.004 (.1)

Parallelism

.004 (.1)

Original Thickness

Front

.71 (18)

Rear

.39 (10)

Minimum Refinish Thickness

Front

.660 (16.762)

Rear

.384 (9.762)

Discard Thickness

Front

.63 (16)

Rear

.35 (9)

DRUM BRAKE SPECIFICATIONS

DRUM BRAKE SPECIFICATIONS

Minimum Brake Pad Thickness

.12 (3)

Master Cylinder Diameter

.811 (20.6)

Festiva

Lateral Runout

.004 (.1)

Parallelism

.004 (.1)

Original Thickness

.5 (13)

Minimum Refinish Thickness

.46 (11.762)

Discard Thickness

.43 (11)

Minimum Brake Pad Thickness

.12 (3)

Minimum Brake Pad Thickness (1992)

.16 (4)

Application

In. (mm)

Drum Diameter

Original

6.69 (170)

Maximum Refinish Diameter

6.75 (171.5)

Minimum Lining Thickness

.04 (1.0)

Copyright 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.

Article GUID: A00044014

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AXLE SHAFTS - FRONT

1988-93 Drive Axles - FWD Axle Shafts

DESCRIPTION & OPERATION

Axle shafts transfer power from transaxle to driving wheels. All axle shafts consist of a shaft with a flexible Constant Velocity (CV) joint at
each end. Inner CV joint is coupled to transaxle by splines. Outer CV joint is splined to hub assembly and secured by axle shaft nut.

Three different types of axle shaft CV joints are used: Double Offset Joint (DOJ) or Rzeppa type, Birfield Joint (BJ) and the Tripot Joint (TJ).

CV joint boots protect CV joints by maintaining proper lubrication and preventing contaminants from entering joint. Boots must be replaced
when signs of leakage or cracks are present. Inner CV joint may be disassembled and serviced. Outer CV joint boot may be replaced, but outer
Birfield CV joint must NOT be disassembled. It must be replaced as an assembly, if faulty.

To prevent torsional vibration and torque steer on turbocharged Capri vehicles, an intermediate shaft and conventional axle shaft are used on
the right side. Both shafts are of similar length and are supported by a bearing, which is attached to engine.

CV JOINT IDENTIFICATION

TROUBLE SHOOTING

REMOVAL, DISASSEMBLY, REASSEMBLY & INSTALLATION

FWD AXLE SHAFTS

Removal

1. Raise and support vehicle. Remove lower underbody splash shields. Drain transaxle fluid. Remove front wheels and loosen axle shaft

lock nut. On Capri, remove stabilizer bar-to-control arm attaching nuts, bolt, washers and bushings. On Festiva, remove stabilizer bar
attaching nuts and bracket. On all models, remove joint clamp bolt from lower control arm. Pry downward and separate steering knuckle
from ball joint, taking care not to damage ball joint dust boot.

2. On Capri turbo, remove bolts securing intermediate shaft bearing bracket to engine. On all models, slowly pry axle shaft from transaxle

using a flat-tip screwdriver or pry bar. Axle is held into transaxle by a circlip fitted to the end of the axle. Remove axle shaft from wheel
hub. If difficult to remove, use axle puller to remove axle from drive hub. Remove axle shaft from transaxle. Plug transaxle openings
with Plugs (T87C-7025-C ). Remove axle shaft assembly from vehicle. See

Fig. 1

.

Fig. 1: Removing & Installing Axle Shafts

Courtesy of FORD MOTOR CO.

Application

Joint Type

Outer Joint

Birfield (BJ)

Inner Joint

Automatic Transaxle

Tripot (TJ)

Manual Transaxle

Rzeppa (DOJ)

NOTE:

See TROUBLE SHOOTING - BASIC PROCEDURES article in GENERAL INFORMATION.

CAUTION:

Damage to CV joint will occur if a hammer is used to separate half-shaft from wheel hub.

Fig. 2: Exploded View Of Axle Shafts & CV Joints

Courtesy of FORD MOTOR CO.

Fig. 3: Measuring & Identifying Axle Shafts & CV Boots

Courtesy of FORD MOTOR CO.

Disassembly (Rzeppa/DOJ Type)

1. Label and remove CV joint boot. Mark alignment of axle shaft to outer race of CV joint. Remove circlip and outer bearing race housing.

Mark alignment of inner race to shaft. Remove inner snap ring. Remove cage assembly. See

Fig. 2

.

2. Pry ball bearings from bearing cage. Mark alignment of bearing cage to inner race. Rotate inner race about 30 degrees and remove from

cage assembly. If necessary, remove remaining boot.

Reassembly (Rzeppa/DOJ Type)

1. Apply Grease (E43Z-19590-A ) to all areas of CV joint during reassembly. Reverse disassembly procedure for reassembly, noting

alignment marks made during disassembly. Ensure chamfer on bearing cage faces snap ring. Lubricate outer race housing with 1.4-2.1
ounces (40-60 g) of grease.

2. Install right side dynamic damper at a distance of 18.99-19.27" (482.5-489.5 mm) from outboard end of axle shaft. Installed length of

CV boot should be 3.5" (90 mm). See

Fig. 3

.

Disassembly (Tripot Type)

Remove boot clamp and boot. Paint an alignment mark of axle shaft to outer race of CV joint. Remove circlip and outer bearing race housing.
Mark alignment of inner race to shaft. Remove snap ring and remove tripot assembly using a soft brass drift and hammer. See

Fig. 2

.

Reassembly (Tripot Type)

Apply Grease (E43Z-19590-A ) to all areas of CV joint during reassembly. Reverse removal procedure, noting alignment marks made during
disassembly. Ensure chamfer on bearing cage faces snap ring. Lubricate outer race housing with 3.5 ounces (100 g) of grease. Installed length
of CV boot should be 3.5" (90 mm).

NOTE:

Check old grease for contamination by rubbing between two fingers. Any gritty feeling indicates
contaminated CV joint. If joint is contaminated disassemble, clean, and inspect thoroughly.