1991 FORD FESTIVA wheel

Removal & Installation (Capri)
Disconnect negative battery cable. With steering wheel removed, remove screws from lower column cover and remove lower cover. Remove
steering column upper retaining bolts. Steering column will rest on instrument panel bracket. Release wiring harness clip and unplug
connectors. Remove 2 switch retaining screws and remove switch from steering column. To install, reverse removal procedure.
Removal & Installation (Festiva)
Disconnect negative battery cable. With steering wheel removed, remove screws from lower column cover and remove both upper and lower
cover. Release wiring harness clip and unplug connectors. Loosen band clamp securing switch hub to steering column jacket. Remove swit c h
from steering column. To install, reverse removal procedure.
IGNITION SWITCH & LOCK
Removal & Installation (Capri Ignition Switch)
1. Disconnect negative battery cable. With steering wheel removed, remove upper and lower column covers. Remove center access panel
and trim panel under steering wheel. Remove left side defroster connector tube.
2. Remove steering column upper attaching bolts. Lower steering column onto instrument panel brace. Remove ignition tumbler. With
ignition key inserted, rotate tumbler while pushing release pin with .125" (3.17 mm) drift. Pull tumbler out of ignition lock housing.
3. Remove column lock shield. Disconnect switch harness connector. Remove single retaining screw. Remove ignition switch. See Fig. 2
.
Reverse removal procedures to complete installation.
Removal & Installation (Festiva Ignition Switch)
1. Disconnect negative battery cable. With steering wheel removed, remove screws from lower column cover and remove both upper and
lower covers. Remove steering column shield and shield bracket. Remove air discharge tube.
2. Remove steering column attaching nuts and lower the steering column support bracket. Remove single retaining screw from top side of
ignition switch. Remove ignition switch wiring harness and ignition switch. See Fig. 2
.

Fig. 2: Ignition Switch & Lock Mechanism

Courtesy of FORD MOTOR CO.
Removal & Installation (Festiva Ignition Lock)
1. Remove combination switch, see COMBINATION SW ITCH earlier. Remove ignition switch. Remove shift lock cable attaching bolt
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and disconnect cable from lock housing. Using slim-nose locking pliers, grip and remove round headed shear screws securing column
lock housing and cap to column jacket. See Fig. 2
.
2. Remove lock housing. To install lock housing, position lock cylinder and cap on column jacket. Using new screws, tighten only enough
to hold lock housing in position. Use ignition key to ensure lock works correctly without binding. Adjust switch if necessary. Tighten
shear screws until heads break off. Install ignition switch in cylinder. Reverse removal procedures to complete installation.
STEERING COLUMN
Removal & Installation (Capri)
1. Place wheels in a straight-ahead position. Remove ignition key and lock steering wheel. Disconnect negative battery cable and air bag
back-up power supply. Back-up power supply is a Blue rectangular unit located behind glove box, attached to instrument panel.
2. Remove air bag module from steering wheel. Remove steering column access cover and trim panel. Remove defroster duct connecting
hose. Remove steering column lower shroud. Loosen lower steering c o l u mn r e t a in in g n u t s. R e mo ve st e e r in g c o l u mn u p p e r r e t a in in g
nuts.
3. Remove ignition lock shield and ignition switch mount screw. Disconnect all necessary electrical connectors. Mark and remove steering
shaft universal joint bolt. Remove steering column from instrument panel. To install, reverse removal procedure. Once steering column
is completely installed, check all switches and functions for proper operation.
Removal (Festiva)
1. Disconnect battery ground cable. Place wheels in a straight-ahead position. Remove steering wheel, upper and lower column covers,
combination switch, ignition switch and harness connectors.
2. Remove steering column shield and air duct from below steering column. Remove 2 steering column upper mounting bracket-to-
instrument panel crossmember nuts.
3. Lower upper end of column as necessary to gain access to intermediate shaft upper "U" joint. Mark steering shaft and upper "U" jo in t fo r
reassembly reference.
4. Remove "U" joint attaching bolt. Loosen 2 steering column hinge bracket-to-clutch/brake pedal support nuts. Remove steering column
with upper "U" joint by pulling toward passenger compartment.
Installation (Festiva)
1. Align marks made during removal and install column with intermediate shaft upper "U" joint over intermediate shaft. Install, but do not
tighten, "U" joint clamp bolt.
2. Install and tighten hinge bracket nuts. Install shim clips on column upper bracket flanges (if removed). Position upper end of steering
column to instrument panel mounting studs.
3. Install upper bracket retaining nuts. Turn steering wheel lock-to-lock several times to align "U" joint splines. Tighten "U" joint clamp
bolt.
4. Install air duct and instrument panel brace. Install harness connectors, ignition switch, combination switch, upper and lower column
covers and steering wheel.
OVERHAUL
STEERING COLUMN
Disassembly & Reassembly (Capri)
1. Remove steering column. See STEERING COLUMN under REMOVAL & INSTALLATION. Position steering column in soft-jawed
vise. Using Steering Wheel Remover (T67L-3600-A), remove steering wheel. Put 2 strips of tape on air bag clockspring, to avoid
rotation.
2. Remove 3 clockspring retaining screws and remove clockspring. With ignition key installed, rotate tumbler to Run position while
pushing tumbler release pin with .125" (3.17 mm) drift. Remove tumbler and upper column shroud. Remove key warning switch.
3. Remove bearing plate. Remove and discard snap ring located at front end of steering column. Remove multifunction switch. Remove
column lock and upper bearing using a suitable bearing puller. To reassemble, reverse disassembly procedure.
Disassembly (Festiva)
Disassembly of steering column assembly is not recommended by manufacturer. If any components are found defective, replace steering
column assembly.
Inspection (Festiva)
1. Measure steering shaft for signs of collapse. Steering shaft length should be between 23.86-23.94" (606-608 mm). If measurement is not
within specification, replace steering column assembly.
2. Check for steering shaft side play. Any detectable side play can adversely affect steering control. If side play in excess of .03" (.75 mm)
is present, bearings are badly worn. Replace steering column assembly.
Reassembly (Festiva)
NOTE:If steering rack and interm ediate shaft are also rem oved, "U" joints and interm ediate shaft m ust be
m arked for reassem bly reference. Both ends of shaft are identical.
CAUT ION: If steering shaft shear pins break during housing or bearing rem oval, the com plete shaft and colum n
m ust be replaced. T o determ ine if pins have sheared, m easure steering shaft from top end of shaft to
center of U-
joint bearing. If length is less than 24.23" (615.7 m m ) or greater than 24.66" (617.7 m m ), pins
have sheared.
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To reassemble, reverse disassembly procedure.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
ApplicationFt. Lbs. (N.m)
Ignition Lock Housing Bolt12-21 (16-28)
Steering Column Attaching Bolt17-23 (23-31)
Steering Column Attaching Nut14-18 (19-25)
Steering Column Bracket Nut & Bolt14-18 (19-25)
Steering Wheel Nut23-33 (31-45)
INCH Lbs. (N.m)
Air Bag Module35-53 (4-6)
Ignition Switch Screw53-71 (6-8)
ApplicationFt. Lbs. (N.m)
Steering Column Attaching Bolt23-34 (31-46)
Steering Wheel Nut29-36 (39-49)
INCH Lbs. (N.m)
Ignition Switch Screw53-71 (6-8)
Shift Lock Cable Bolt35-53 (4-6)
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00054857
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Back To Article
SUSPENSION - FRONT
1991-92 SUSPENSION Front
DESCRIPTION
Front suspension system uses MacPherson strut shock assemblies. The upper ends of the strut assembly are attached to the shock towers and
the lower ends are attached to the steering knuckle. Lower control arm is attached to the chassis. Fore and aft movement is controlled by the
stabilizer bar. The stabilizer bar is connected to the lower control arm by a connecting link. See Fig. 1
or Fig. 2 .
ADJUSTMENTS & INSPECTION
WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES

Fig. 1: Front Suspension Assembly (Capri)

Courtesy of FORD MOTOR CO.

Fig. 2: Front Suspension Assembly (Festiva)

Courtesy of FORD MOTOR CO. NOTE:See SPECIFICAT IONS & PROCEDURES article in the WHEEL ALIGNMENT Section.
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WHEEL BEARINGS
Wheel bearing preload is maintained by a selective spacer in the steering knuckle, between the inner and outer hub bearings. For adjustment
procedures and inspection, see WHEEL BEARING under REMOVAL & INSTALLATION.
BALL JOINT CHECKING
Raise and support vehicle until tire is just off ground. Move wheel vertically and check for play. If play is noticed between steering knuckle
and control arm, control arm assembly should be replaced. If play is present but ball joint is okay, wheel bearings should be checked for wear
and replaced if necessary.
REMOVAL & INSTALLATION
STABILIZER BAR
Removal & Installation (Festiva)
1. Remove stabilizer mounting bracket nuts and brackets. Remove split bushings from stabilizer bar. Remove stabilizer bushing nuts at
lower control arms. Remove rear dished washers and bushings.
2. To loosen stabilizer bar, pull forward from control arms. Remove front bushings and washers. Install control arm bushing washers on
ends of stabilizer and install control arm front bushings. Insert ends of stabilizer bar into control arm bushings and install rear bushings
and washers on stabilizer bar ends.
3. Install retaining nuts finger tight. Install split bushings on stabilizer cross bar with split side forward. Position split bushings next to
White locating marks on bar. Install stabilizer mounting brackets. Tighten all bolts and nuts to specification.
STRUT ASSEMBLY & COIL SPRING
Removal
1. Raise and support front of vehicle so struts are fully extended. Remove front wheels. Remove brake line clip from strut lower mounting
bracket and remove brake line.
2. Remove 2 bolts retaining strut lower bracket to steering knuckle. Working inside engine compartment, remove 2 nuts retaining strut
mounting block in strut tower. Disengage strut lower bracket from steering knuckle and lower strut from vehicle.
Disassembly & Reassembly
1. Using spring compressor, compress spring to unload strut. Pry out mounting block cap and remove strut upper nut and lock washer.
2. Remove strut mounting block and spacer plate. Remove washer, bearing seal and bearing from strut rod. Remove spring upper seat, seat
insulator and coil spring. Remove jounce bumper and dust shield from strut. Reverse disassembly procedure to install coil spring a n d
reassemble strut.
Installation
1. Position strut, with spacer plate installed, in strut tower with White alignment mark facing outward. Install and tighten nuts on upper
mounting block studs.
2. Install steering knuckle in strut lower bracket. To complete installation, reverse removal procedure. Tighten all bolts and nuts to
specification.
HUB & KNUCKLE ASSEMBLY
Removal
1. Raise and support vehicle. Remove wheel. Straighten staked edge of drive axle lock nut flange. DO NOT damage groove or threads in
end of drive axle. Apply brakes to prevent hub assembly from turning. Remove and discard drive axle lock nut.
2. Remove clip which secures brake hose to strut bracket. Remove cotter pin and tie rod end attaching nut. Using Tie Rod End Separator
(T85M-3395A), remove tie rod end from steering knuckle.
3. Remove brake caliper attaching bolts and remove assembly from steering knuckle. Do not allow caliper to hang by brake hose. Remove
clamp bolt and nut where lower control arm ball joint connects to steering knuckle.
4. Using a pry bar, pull down on lower control arm and release ball joint from steering knuckle. Remove 2 bolts which attach steering
knuckle between flanges of MacPherson strut bracket. Slide hub/knuckle assembly off end of drive axle. If binding is present or drive
hub is rusted to half-shaft, use a hub puller to push axle from drive hub.
Installation
1. Apply a thin coat of SAE 30 weight oil to drive axle splines. Slide steering knuckle/rotor/hub assembly onto drive axle. Stop at area
where uppermost arm of steering knuckle seats into MacPherson strut bracket.
2. To complete installation, reverse removal procedure. Install NEW drive axle lock nut. Tighten all bolts and nuts to specification. Stake
axle lock nut into shaft groove.
WHEEL BEARING NOTE:Inform ation for stabilizer bar rem oval and installation on Capri is not available from m anufacturer.
NOTE:Always use a new drive axle lock nut when servicing drive hub or drive axle.
CAUT ION: DO NOT use a pointed tool to stake nut. If lock nut flange cracks, even slightly, during staking process,
it m ust be replaced.
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Removal
1. Remove hub and knuckle assembly from vehicle. See HUB & KNUCKLE ASSEMBLY under REMOVAL & INSTALLATION. Using
Knuckle Puller (T87C-1104-A), or a press and bearing puller, remove drive hub/rotor assembly from steering knuckle/dust shield
assembly.
2. Remove bearing preload spacer from hub. Spacer is preselected to provide correct bearing preload. Ensure correct spacer is installed
during reassembly. Install hub/rotor assembly in a vise. Scribe alignment marks on hub and rotor for reassembly reference.
3. Remove rotor attaching bolts and rotor. Use Bearing Splitter (D84L-1123-A), Shaft Protector (D80L-625-2) and a press, or Bearing
Puller (D80L-927-A) and Puller Attachment (D84L-1123-A) to remove outer bearing from wheel hub. Remove and discard outer and
inner grease seals. Using Bearing Puller (T77F-1102-A) and Slide Hammer (T-50T-100-A), remove races from steering knuckle. See
Fig. 3
.

Fig. 3: Front Wheel Bearing & Hub Assembly

Courtesy of FORD MOTOR CO.
Inspection
Thoroughly clean all parts in solvent. Check bearings, hub, knuckle and rotor dust shield for excessive wear or damage. If new bearing is being
installed, check bearing preload. See BEARING PRELOAD.
Bearing Preload
1. To check and adjust preload, Spacer Selector Set (T87C-1104-B) must be used. Prior to assembling hub/rotor assembly into steering
knuckle, install spacer selector into steering knuckle and clamp tool in vise. Tighten center bolt, in increments, to 36, 72, 108 and
finally 145 ft. lbs. (49, 98, 147 and 196 N.m). Each time center bolt is tightened, seat the bearings by rotating steering knuckle by hand.
2. Remove steering knuckle from vise. Reinstall steering knuckle in vise, clamping it where shock absorber mounts. Using an INCH lb.
torque wrench, measure torque required to turn center bolt. Ensure torque reading is taken just as wrench starts to rotate.
3. Spacer thickness is correct if torque wrench indicates 2.21-10.44 INCH lbs. (.25-1.8 N.m). If measurement indicates less than 2.21
INCH lbs. (.25 N.m), a thinner spacer must be installed. If measurement indicates more than 15.93 INCH lbs. (1.8 N.m), a thicker spacer
must be installed.
4. Bearing spacers are available in 21 thicknesses, in .0016" (.040 mm) increments. Spacer No. 1 is thinnest and No. 21 is thickest. See
PRELOAD SPACER AVAILABILITY table. Changing spacer thickness one increment will change bearing preload 1.7-3.5 INCH lbs.
(.2-.4 N.m). Ensure correct spacer is installed and preload is within specification. Remove spacer selector set.
PRELOAD SPACER AVAILABILITY NOTE:Rem oval of press-fitted dust shield from steering knuckle is not part of norm al bearing service. Dust
shield should not be rem oved from steering knuckle unless it is being replaced.
Stamped Mark On SpacerIn. (mm)
10.2474 (6.285)
20.2490 (6.325)
30.2506 (6.365)
40.2522 (6.405)
50.2537 (6.445)
60.2553 (6.485)
70.2569 (6.525)
80.2585 (6.565)
90.2600 (6.605)
100.2616 (6.645)
110.2632 (6.685)
120.2648 (6.725)
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Installation
1. Using Bearing Cup Replacer (D79P-1202-A) and Universal Driver Handle (T80T-4000-W), install bearing races in steering knuckle.
Lubricate bearing races and bearing. Install inner bearing into steering knuckle. Lubricate seal lips and install inner bearing seal into
knuckle. Install original bearing preload spacer in steering knuckle (or spacer selected during bearing preload check). Position outer
bearing in knuckle. Install outer seal. Install hub onto rotor, using reference marks made during removal. Install rotor to hub attaching
bolts.
2. Using a press and adapter from Spacer Selector Set (T87C-1104-B), install knuckle assembly onto hub. To complete installation,
reverse removal procedure.
LOWER CONTROL ARM & BALL JOINT (FESTIVA)
Removal
Remove lower control arm pivot bolt at frame bracket. Remove ball joint clamp bolt and nut from steering knuckle assembly. Remove
stabilizer bushing retaining nut from rear of control arm. Remove rear bushing washer and bushing. Lower the control arm and pry ball joint
stud out of steering knuckle. Disconnect control arm from stabilizer end and remove.
Inspection
Check control arm and bushings for excessive wear or damage. Ensure ball joint stud moves freely but is not loose. Use Ball Joint Rotating
Adapter (T87C-5493-C) to check ball joint rotating torque. Rotating torque should be 16-27 INCH lbs. (1.8-3.1 N.m).
Installation
1. Install front bushing washer with dished side forward. Position bushing stabilizer end and engage control arm with stabilizer. Raise
control arm inner end into pivot bracket on frame. Install pivot bolt to hold it in position.
2. Engage control arm ball joint stud with clamp bore in steering knuckle. Install clamp bolt and nut. Install stabilizer rear bushing and
washer with dished side forward on stabilizer end. Tighten all bolts and nuts to specification.
LOWER CONTROL ARM (CAPRI)
Removal & Installation
Raise and support vehicle. Remove wheel and disconnect stabilizer bar from control arm, if equipped. Remove ball joint clamp bolt. Remove
control arm front mount bolt. Remove control arm rear bracket and mount bolts. Remove control arm. To install, reverse removal procedure.
BALL JOINT (CAPRI)
Removal & Installation
1. Raise and support vehicle. Remove wheel. Remove ball joint clamp bolt from steering knuckle. Use small pry bar to pull down on lower
control arm to separate it from steering knuckle. Remove 2 ball joint retaining bolts and pry ball joint off control arm. To install, reverse
removal procedure.
LOWER CONTROL ARM BUSHING
Removal & Installation (Capri)
1. Remove control arm from vehicle. See LOWER CONTROL ARM. Use Bushing Receiver Cup (T87C-5493-B1), Bushing Driver (T87C-
5493-B2) and vise to remove control arm bushing.
2. To install, press bushing into control arm using same tools used for removal. Refit control arm to chassis.
Removal & Installation (Festiva)
1. Remove control arm from vehicle. See LOWER CONTROL ARM & BALL JOINT. Use Bushing Receiver Cup (T88C-5493-E), Bushing
Pilot (T81P-5493-B2) and "C" Clamp Assembly (T74P-3044-A1) to remove control arm bushing.
2. To install, press bushing into control arm using same tools used for removal. Refit control arm to chassis.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
130.2663 (6.765)
140.2679 (6.805)
150.2695 (6.845)
160.2711 (6.885)
170.2726 (6.925)
180.2742 (6.965)
190.2758 (7.005)
200.2774 (7.045)
210.2789 (7.085)
NOTE:Insert bushing quickly and sm oothly. Bushing should only be distorted for a short tim e.
ApplicationFt. Lbs. (N.m)
Capri
Ball Joint Pinch Bolt32-40 (43-54)
Brake Rotor-To-Hub33-40 (44-54)
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Caliper Attaching Bolts29-36 (39-49)
Control Arm Bolt-To-Ball Joint69-86 (93-117)
Control Arm Bracket Bolt44-54 (59-74)
Control Arm Front Bolt69-86 (93-117)
Control Arm Rear Bolt55-69 (75-93)
Drive Axle Nut116-174 (157-236)
Shock Absorber Bolt-To-Knuckle69-72 (93-97)
Stabilizer Bracket Nuts40-50 (54-68)
Steering Knuckle-To-Strut69-86 (93-117)
Steering Knuckle-To-Tie Rod22-33 (29-44)
Strut Assembly-To-Strut Tower17-22 (23-29)
Strut Rod Nut22-27 (29-36)
Wheel Lug Nut65-88 (90-120)
Festiva
Ball Joint Pinch Bolt32-40 (43-54)
Brake Rotor-To-Hub33-40 (44-54)
Caliper Attaching Bolts29-36 (39-49)
Control Arm Bushing Nuts47-57 (64-77)
Control Arm Pivot Bolt32-40 (43-54)
Stabilizer Bar Nuts-To-Control Arm47-57 (64-77)
Stabilizer Mounting Bracket Nuts40-50 (54-68)
Steering Knuckle-To-Strut69-86 (93-117)
Steering Knuckle-To-Tie Rod22-33 (29-44)
Strut Assembly-To-Strut Tower22-27 (29-36)
Wheel Lug Nut65-88 (90-120)
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00121554
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