Ford Festiva. Instruction — part 111
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 bolts,
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. Install
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.
CAUTION:
Transaxle aluminum alloy construction requires precise tightening of mounting bolts. Torque
specifications must be strictly adhered to. See
TORQUE SPECIFICATIONS
.
NOTE:
The clutch release bearing is pre-lubricated and permanently sealed. DO NOT clean release bearing in
solvent.
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 remove pilot bearing unless necessary.
NOTE:
Manufacturer does not provide overhaul information for clutch master cylinder and clutch release
cylinder.
Application
Ft. Lbs. (Nm)
Clutch Cable Bracket Nuts
12-17 (16-23)
Clutch Pedal Push Rod Lock Nut
9-13 (12-17)
Clutch Pedal Through Bolt Nut
15-26 (20-35)
Crossmember
"A" Bolts
47-66 (64-89)
"B" Bolt
21-34 (28-46)
Crossmember Brace (Front)
23-34 (31-46)
Crossmember Brace
69-86 (93-117)
Engine Mount Bolt (No. 2)
33-48 (45-65)
Engine-To-Transaxle
46-66 (63-89)
Flywheel Housing-To-Engine Bolt
46-66 (63-89)
Flywheel-To-Crankshaft Bolt
71-76 (96-103)
Front Wheel Lug Nut
66-89 (90-120)
Lower Ball Joint Pinch Bolt
32-40 (43-54)
Master Cylinder Retaining Nuts
14-19 (19-26)
Pressure Plate-To-Flywheel Bolt
13-20 (18-27)
Rear Engine Cover-To-Housing Bolt
28-38 (38-51)
Rear Mount-To-Transmission Bolt
50-70 (68-95)
Rear Transmission Mount-To-Body Bolt
25-35 (34-48)
Release Fork Attaching Bolt
26-30 (35-41)
Slave Cylinder Retaining Bolts
12-17 (16-23)
Stabilizer Bracket-To-Body Bolt
33-41 (45-56)
Starter Motor-To-Mount Bolt
23-34 (31-46)
Transaxle Drain Plug
29-40 (39-54)
INCH Lbs. (N.m)
Release Lever Bolt
71-97 (8-11)
Speedometer Drive Gear Bolt
69-106 (7.8-12)
Application
Specification
Festiva
2.6 Qts. (2.5L)
Copyright 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00043399
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OIL CIRCUIT DIAGRAMS
ATX/KF-400
Fig. 1: Park - "P" Range
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