1974 FORD CAPRI light

1
134 Chapte r 8 Rea r axl e
FiO. 8.5 Discorlllccti!l9 the rcar sI"biliser Iwr (Sec 3)
7 U~"'!I u"ps (FlU 8 5) I)UU rile s1.1h,l,s(lI b.ll 10 lilt:! lCol. while unstocwIIlIJ the mOlllllnlU I)oIIS from the Ie;)' ;l~II!. flcl110vc the C!JIllI'S 8 W,lh the rC:II Ildc sUlt,lbly SUIlI>o.ICd. lIIlSCICW rhe nulS hom the hallom 01 the U-bolts i1rld reOlOlle rhe lowel S I)llrlU p l;lrcs .. ",t! 1115 .. 1<11015. 9 Wllh rhe help of an asslSlilnt. hft the rem a~lc over the "~ 13 I O.:.lt!"! the ul~"''''o.s 1m!! lowe. SP""1J pl~ws all the sp rin!jS thclI "1 Ihn 1)·llo\1s. W!IClhc. wilh Il/!W sld/.locklll\) lIutS T'!Jhlf:l1 thc IHII S l"o!Jlnsslvuly 10 Ihe spo{;lf ,/!(IIOIQUC. III 1')<;,lIe Ihc CI;1I1IP~ 011 liIe Slilhd,scr bilr "'0\I1111\1 tubhers tlrCII pull 1 hili IlltO poslllon WIllI thl) grips l1~ 10 the S IICclllI .. '(l toIlIUI) . • ,. j , Ihe" I/.ac ket s. In se'l Ihe nloum"lU bolts and tlghlel1 the nUI S. H i Ilelll Ihe lIexll/le b.,lko hose and lIuhten the nuts. 17 Rel1lovc the hoso cl,lrn p or polythene sh eet then blcL,{/ Ihe hr t 8 nelll t he h 1 AxleshMt -removal ilnd refilting
Chock Ihe front wheels then jack up the re,lr of the c~r ilnd support with onle stilnds. Remove the .ear wheel 2 Ilelea se the hilndb.nke and .emove Ihe brake drum.
3 USIng a socket through the special holes in the drive lI.::tnge. unsc'ew the bollS secu.ing the b.::tckp late and bearing ,el.::tinor to tho a~le cilSln g (pholo). 11 Withdraw tho a~leshnft. together with the bearing. " it is tight due 10 tho oulor Ir 1 0 the dtive lIange. or ,1Iternil1ively sc rew two long baits th.ough Ihe jng al diametlicaUy opposite pOInts (FIg. 8 .7) and lighten them I,·...rply a liule Illhium based glease both 1 0 the casing and bear ing outer !rack . F
ig. 8
.6 RelHoving t h o Mdeshalt .e l'l ining hoits (Soc 4)
If
I
/1
II
I
\,
Fig 8 .7 U sing long bolls to ""ithdra"" tho a~leshaft (Sec 4)
cd
procarmanuals.com

) Chapter 9 Braking syste m 143
2
Fig. 9.1 DU

) Chapter 9 Braking system 145
/ll.Iid reservoir tille , cap \0 help roduce any fluid loss. 4 Where a rigi d brake line is connec ted \0 the calipe r, comple tely unscrOw the union nUl . Where Iho flex ible hose is connected directly \0 Ihe caliper. loosen only .he union (lnd unscrew Ihc caliper f.om Ihe
hose later. S Prise back the laus on the locking plale and unscrew Ihe mouming boilS (photo). The cJliper may now be wit hdrawn ove r th o disc and where neCessary unscrew ed from Ihc flex ible hose, 6 Refilling is a revCfsal of fernOv;!I, but lit a new locking plate and
l ighten the mouming bol ts \0 the specified torque. Bend the Inbs \0 Io<:k I he boils. On comple tion bleed the hydwulic system wit h
reference \ 0 Sec tion 15.
5 Front brake caliper -ovorlulU l
1 With the c~liper removed . cle~n away all external dlr1. 2 Where applicable, prise out the dust cover cirClips dust covers from the external ~onular groove. : lIr"ct the pistons: keeping them idenhlied side lor s.de. If nt .... "ss"ry. use low [lir P"CSSlU(! frOill a foot pump to lorc e the pistons
IrOIl' lho bores. 4 nove tho dust covers Irom the pistons or bores as apphc hydrau lic Uuid . Inspect the piSlons and bores for signs 01 weilr . score markS. or damage and il evident. new par ts should be obtained !Cady for lilting. or a new ca lipe r obtained. 7 R eassem ble tho components using a reversal of th n disnwn tling procedure. but before inserting the pis tons dip them in clen n hydrnulic fluid to assist entry through the seals. On comple tion press the pistons fully into the bores.
45 Front brake caliper mounting bolts (arrowed)
6 Front brake discs -in spection. re rnovnl and refitting
Apply the hilndlxake then jn ck up the hom of the car and support on :1xle st:1flds. Remove the Iront roadwheels . 2 Rotate the disc by hand and examine il lor deep scoring, grooving or cf1lcks. light scoring is normal, but if excessive the disc must be
renewed.
3 SCrJpe RUEO '.(RlW
--
1-""£0""""" ~Plf'l ~-____ ttIP
BI"'~( ".",~"" PI~I()'
4IOUf llltlGOOLI tCCKltlG PLATE
R( 1 Altl{R RltlG
BRAKE (VLIHOER PISTO'l
(l001
Fig. 9.3 EKp loded view of the front brake calipe( on fater models (Sec 5)
RING
., .,
,
procarmanuals.com

) Chapter 10 Susp e nsion an d steerin g 167
• ____ I,,, .. r,,,.,
.. , ..
"""""
/
..... . '''M'
""'''''' . ..... >'< '.' AU ... , ..... • Ut ~" ... '''toI •• " .. (', @
........ ' ........ -~~ ' • • ~Mr
.,,·,"'·'·,v"""" ".$"'" ''''.''''.",,~. ~
."', ~
F ig. 10. 13 Ellplodcd view o f the IlHII HHl I steering gear (Soc 13)
No 7.7. d"lI) ''''''''':1\:1 )( !) nit" (035 Inch) deep "1);"""" IOG,t'''!J huit) III Iho h OllsOIl\j 18 FI t IWW wl""""11 pUI S :11.<1 pt!cn ove, the SUlloumhng meW!. 10 1(.:1;"" them 19 Llghtlv IJ'C,lSC the ,nSlde of the bellows. where they "",II corlt,lC the '''lck .o d s II1SI,111 one bellows. cnsunnu that " locales on the "ack rod groove. then 1, a new 1010111''''9 Ch, ) 20 Add Ihe SI)Cclhcd (IU;II' I'ly 01 SI(,e""u gear OIl. ope •• n ing the rack over liS limue 01 Havel '0 ,15SIS ' thO lubliCilnt in "owrng. Do not OVllrl,1l 21 FII the othOI bullows. then CilllY 0111 the lollowing ildluslmenl prOCedulOs Ideally Ih ls Will IC(IUIIO thc use 01 a diill gilllge ilnd mountlOg block. a 5udace tahlc. il torquc yiluge and iI splrned adilplor. It IS lelt Ihat most peo,)le Will bo ahlo 10 SUitably improvise. using Olhcr equipment. hul II IllIs Cilllnot he done and thO equlpmOnt "sled is lIot ilVillla ble. Ihe 101/ s hould be unllu$tcd 10 your locill Ford Dealer .
22 Wllh the ~Ieelmg Ueilr mountud III iI so h·Jawcd yice. remoye the r,:u:k ~I'ppur coy", pl!!Ie. shim p,1ck. {lilskor. mid sprIng . Also "Jmoye the I"n'on bOilflll\J coyer plalC. sh im pac k and gaskot. It i1ny oil is lost dUIIIl!) thc adJustfllenl procedures thO steering gea r must be rl!'
plc'''~hcd hclore IllIIng to Iho cm.
P,niOIl bec1ring preload 23 PlilCC the shun p,l c k alld covcr pl1lle 011 Ihe bearinU. lighten the 'JOlts. then s lacken Ihcm 50 .hal Ihe covel platc louches the shim The \' pilck Illll~t (;omj}lIs e ill hlil st three sh ims. one 01 which musl bc Q m,n (0 093 In). tlus bern!) ullllledlalely agaIns t the COYcr plate. 24 Measure Ihl! COV'" pl,lle .to·housllIg gilp. and if outside I he ranUe 02810033 fllill (0 all 10 a 013 In) reduce 'he shim pack th ic kness {If
Ihe UilP is '00 li1rud. or Illcrei lse II ("the gap IS 100 slllilll) unlll Ihls gill) IS Ob'ilillcd Remembe r Ihat lhc 2 35 111m (0 093 III) shim Illustrcmillll
Immcdiately "UilIllSt Ihe cover pl;)'e 25 When the COIICCt \1.11) IS ohl!!lIlcd. rernoye Ihc coy!;'. pl"le. IlIs!.111 thc gasket ilild r efit ,ho coyer ,)IJ tc. Am)ly locklllg lIuid 10 Ihe coyer hOi' th.eilds. lit Ihem ;)"d lighlen,o a 10 11 N m (6 \0 albf It).
Rack sl/iJpcr .1djus(mell( 26 HilYlllg set thO pOlllon bearing preloJd. measure 'he heIght 01 the stopper il!J.OYC the IIIillll body 0 1 the rJck. as ,he rilck is moyed Irom lock \0 lock by turnIng 'he pillion NOIe thc height reilding obtained. 27 Pr CPilre ;l shim pack w hiCh. Including the thickness 01 the 'ilck sloppe r beJring {JilslIet. is 0.05 to 0 15 mill (0.002 10 0 .006 in) thicker than ,he dimcnSlo n lIoted In piuagrilph 26. 2a FII Ihe spring. gas ke t. shim pilck and coyel plate to 'h e ra ck housing (gaske l ncareSt housing) Apply locking lIuid 10 the coyer bolt thrcads. III them illld 10rque tigh.e n to 8 10 11 Nm (6 to 8 Ibl h). 29 Measur e thc ,orque rC(tullcd \0 lurn Ihe p inion throughout i,s mnge of I!.lY cl. ThiS should bc 1 t 3 10 2.03 Nm (0.83 to 1.50 Ibl It); if oulside th,s ,ange. Iilul,y componcnts. lack ollubriCilnt etc. should be
suspected.
1 4
Track rocl end balljo int -renew al
Jack up thc loon. Of thO Cil r and SUf)pOrt on Jx le stands Apply the halldbrilke ;)nd re!llove Ihe applopriil'C Iiont roadwhcel. 2 Slacken Ihe baliJo in l locknut 011 the track rod by iI quarter 01 a turn. 3 Extra ct the spl, t p,n Jnd unscrew thc nul securrng the !Jilc k .od ond
, .. • • ..
::
procarmanuals.com

)8 Ch apter 10 Suspensio n and steering
\0 the SI(lcring Mill (photo) 4 USlIlg" 1)[lIi)onH SCpilriltor tool (photo). reh:o,lS(l the ['ilek rod end from the Slc(!rino ""m 5 Unscrew the h,"'IOlilt hom the [' 8 T'Uh!C1l th e h 15 Power steering -hlccdinU
The power ~1P.elln\J SysHllll WIll only need blc",rhnfj Ifl the even! of . .., hell1\J Il1tl<)(hu:ed ",to the system. cu whcn: IH llI:S h;IV() IW(}1l dlscoI1l1cc«:d or whel() J Ifl.lk"(Je has occlUfed To hleed the system ···ocp.ed ;'s (1<,~<:"I)Cd III 1(11) followlllU l),l';)\J,,1I)hs
I Open llH~ hO'Hl()1 ,111<1 cl\p.(:k the Il",d h:v el "llhe Il'Sl'IVi'" Top·llp.t llucess;IIY IIS"'!J (Il<) spe.:II,ed lype of 11(11<1 3 11 11."d IS added. allow two "'''HlWS. th"l1 lUll 11m I;I\U"W at apPI{)xIIllntnly 1500 rp'" Slowly \illll lhe st'!""Il(! wheel 1,0m lo,:k to lock. wlllisl r:l\.,,;klllH and WPP"'!I up Ih e Ihlld unlll th" l"v,,1 ",m;II11S
Stf),li1y ;1<\<1 no molC hubhl"s ilPP":U I II tlw I"S,,,V,,II
" elc ;,", and refn Ihe r"servoll cap ami close II,,, 1>0"",,1
16 Power steering gear rellloval and refittinu
The p'ocedure IS Sllml", to thilt descrd)<)d III Sc(:t lon 12 10' th" m,10u,,1 steeling gC,lf NOlO. how"ver. lhm tile 111011111(1)(1 1)I)Its (jo cOllipletely tl1(ouyh lhe front e,ossmflmhe,. "nd the II.),,, nil IS a,e
I()(;ked wllh sphl pillS. Add,llon"lly lhe lIuld IIIH)S rnu~;t Iw lhsc.onnec · l"d. and atln' ,uI,Um!J the system ~hollid he loppud III' ,lnd Illed wllh lui"",,,!:,, 10 $"(;tl{>n 15 (photos)
17 Power steerillU pump remov;ll "lid rcfil1 ill\J
Loo~"n tl", «II.." Iwlley 1",lck,,1 b"lts. ,el..,ase Ih" d"ve!Jclt lellSlon. Ihcn ,emOVe II", dllvelu:lt I,,)m the P"'''I' pulley Oil 3 0 101", IIIO O ,sc<)nll,,(;1 Ihe IIlIal hnes hom the pump ~nd <1,,111 Ihe IIUI(III)to" sultahl" (;Olliall'", The pIIISS(lIe I",e h,15 .1 sell)w"d (1111011. hul the lehlln Ime 1 5 ,1 ,ulJhCl hose connecl'on (pll()I"~) " Ulliloit (111) powe,· steuIIIIU punlp. (o\Jelhu, WIth thn IllOUnllllU
h,;lc.k(,t ~nd st;)y. wlw,e ;1j)1'11 <:;,I)I". ,!Ill! ","'ove f'DIII Ihe CII!) "le (photos). The "",d..,1 C;'rl lh"" 1m (lnl)nlt"d flOm Ihe pUlllp of nccess;"y, 5 RellltlllU IS .1 ,ev,,'~al 01 I..,moval. "ul l"'Il~lon Ihe lhlvehelt ~Ild "Iced Ihe sy~IC'" wllh lek'e'll:tJ to Sec;1I0ns 2 ,!Ild 15
"V',~, , .,' , -t .~/ ,.
~
' ---... . . ' .. ' , "
A-i·J<'~ r~ _ I' .' If! h \l:: fITI \~, . '''''
~
•• :. ' 10)",', / )
. .. 'I.· L../,
'": .. ':;' ., .... ---,.
. .. .
18 S teerinU wheel removnl nnd rIllittinu
1 Dlsconneci the lodlielY nCU~lIve le,,(1, 2 PIISC Ih" mOllf hUIll Ihe celn,,) o f Ihe stcclln(j whc,,1 (photos)
15.1 A Powef SICCIIIl(j (je,, ' showUlU pinlOrl and lowe, coupl",U ~h,,11 un,vcfsnl lo;nl 161 B Power steering ue", mountUlg bolt (,,"owed) 1 G 1 C "nd nul (""owed)
.' ---------------------------------procarmanuals.com

Chapter 10 Suspension and steering 171
19 4C Removinu the top steering column Shroud 19 G lunitlon SWitch ,1nd wirlllU (A). also COllll'lII upper mOlUllnl!J holt (0) 19.7 Removing the steering column uppcr mounlul(J holt (arrowed)
'5 Secure Ihe SIt:(;(1I1(1 lock 10 Ihe colulIlIl ,lIal ~heil' the h eads I,om ,he m:w holt~ 11) U~e the stecrin\J lock to locate the shaft in Ihe column. then III Ihe )ct,on mdlGltor OICIlJalinn GUll alld Stecrmn wheel. CtlCC~ that Ihe ruadwheels afC st,lIln the 5trai\jht·ahead P05,110l1. 17 Install the Stce!Ul(J column orommet Oil the lowm en(t. 18 LOCille the column assembly ami sr:c",e It wrth the Iwo mOllrlllng bolts. 19 The ((,milliuler of the rellllUI\J proccrl",e ,~ th" reverSI! of lhe removill procedure,
20 F ront wheel alignment and steering ilngles
Accurate front whcel alignment IS essential lor good stoer"'g and lyre WOiJr. Scion) cons,dering the steering angle. check Ihat Ihe tyres
are correctly inflated. tllnt the front wheel s arc nOI IJlJckled. the hub hea"nns arc not worn o r mcorrectly adjusted und thilt the sleflr"'g IlIlkaUfl is in IJood order. wllhout slackness or we,ll at thu Jo,nls
2 WIH;f; 1 "I'!JIununt co"s'st~ 01 loUl I"ctors, C;"lliJcr_ IS the ""Ule "t wilich the front whet:ls ,lie sci from Ihe
verllcal when v'ewud 100'" the IrOnt 01 the c"r 1'0sIt,ve camber 's Ihe .. mount (111 de\J'ee~) th"t til() whucls ,ue toited outwards at the lOp 100'"
thu vert,c;,1
Castor. ,~tho i"'~Jlu between the SIl,erlIlU ,,~,s OIrld.1 v..,'I,e.11 lone len viewud IrOIll p,lch ~,dfl 01 the C,lI 1'0~;llIve castor 's when the ~tcermu ",x,s 'S ",cloned rUiHw,,,ds ill the top jStcerinu ilxis inclin,,{ion 's lhe illl\Jle. when VIewed frOI11 the .It 01 the Cilr. bel ween the verltcal and "n 1Il'''U>I1.1ry hne drawn betwCl)n the upper ilnd lower suspensIon strut p,vots, Toe-i n IS the ilmoUl,t by wh,ch tlte dl5li"'Ce helween the frOrlt
IIlsuJu ed\Je~ 01 the rOildwhecls ('He,lsu1ed m huh heiuht) ,s less thiln lhe d'sWrlCI) ",e 5 PI"ce the Cilr on level ground WIth the wheels 111 the sualghl·uheild pos' lion,
6
Oht"in or m"ke ne:w components have heen I'lted. set the ro"dwheels ,n the stral\jht·ilheil(f p05otrOn and also cent",lrse the steering wheel. AdJ"st the len\Jths of the track rods hy lllll1ing tltem so th,,! the track rod end IJ,litJoinl studs w,11 drop eils,ly onlO the eyes of the steer inu ilrlllS Measllfe the dislilllces between the centres of the hilllfOllllS illld the grooves on Ihe inner ends of the track rods and ildjust. ,r neceSSilry. so Ihiltthey me equ,ll Thl~ is all lII,t,,,1 sellinlJ only and prec,se ildillstmellt mu~t he carried oul as descrrhed earheL
21 Wheels and lyres -uonNal care and milintenl1nce
Wheels ilild tyre~ shOuld give no reill problems in usc provided thm ,1 close eye IS kept on Ihe", with re\janlto excessive weilr or dilmilge To llns end. the following pOllltS should he noted Ensure thm lyre pressures ",e checked re\Jularly ami ma,ntallled correctly. Checklllg should be c,Hried out woth the tyres cold alld nOI IIlHlledialely alter the vehicle hilS heen "I usc. II the pressures are checked w'th the tyres hOI. iln ap(l,Hently hi\jh readmlJ w,1l be ohw'lled OWlnH to heilt expJnsron. Under n<) Cllcumst"Iucs.
eSpecii\lIy 111 the s,dewalls Remove any na,ls or stones ell\bedded 111 the tread hefore they penetr"te lhe tyre 10 cnuse dcfliltlon If remov,,1 {)i dilll1i1ged by ·kerbing· wh,lst par king. and simililrly stee l wheels may hecome denIed or buckled, Renewnl of the wheel rs very ohenthe only course of rellled'ill ilct,on poss,ble, The balance 01 each wheel Jnd tyre ilssembly should be mainta,ned to ilvoid excess,ve weilr, not only 10 the tyres but illso to the s teering and suspension components. Wheel imbillilnce 's normilily S'\ln, f,ed by v,i)rilllOn through the veillcle·s bodyshell. illthouUh III many c~ses it IS piullcularly nOliceahle Ihrouoh the steenng whuel. Conversely. it ~hould bc noted thilt weilr o r dilnlaUc 111 suspellS IOll or steer ing components may '.:ause e~ceSSlve tyre wear. Out·of·round or out-of· t!Ue lyres, damaged wheels and wheel !leafing weilf/ nlilladJustntent also lilll into th ,.
:.
procarmanuals.com