1991 FORD FESTIVA lock

and left brake lines in place. Install rear suspension struts and wheels. Block wheels and lower vehicle to load suspension to normal ride
height. Tighten torsion beam pivot bolts at body brackets to 69-87 ft. lbs. (93-118 N.m).
4. Check rear suspension alignment. Place an alignment mark at the center of the underbody, at a point of equal distance from the right and
left body bracket inboard mounting bolts. From this alignment mark, measure distance to centers of right and left strut lower mounting
bolts.
5. Both measurements must be within .20" (5 mm) of being the same. If not, shift torsion beam body brackets from side-to-side to center
suspension. Once centered, tighten upper body bracket mounting bolts to 40-50 ft. lbs. (54-68 N.m) and lower bolt to 69-87 ft. lbs. (93-
118 N.m). Bleed brakes.
TORSION BEAM BUSHINGS
Removal
1. Raise and support vehicle to fully extended rear struts. Remove wheels. Remove retaining clip at right brake line routing bracket and
disconnect brake line. Remove clip from left brake line and disconnect at body crossmember.
2. Remove torsion beam pivot bolt bolts and nuts at right and left body brackets. Swing torsion beam trailing arm downward to clear body
brackets.
3. Using piece of wood, block beam in disengaged position. Using Bushing Remover/Replacer (D80L-1002-L), remove bushings from
inboard side of torsion beam arm. See Fig. 6
.

Fig. 6: Removing Torsion Beam Bushing

Courtesy of FORD MOTOR CO.
Installation
1. Place bushings on outboard sides of torsion beam arms with marks "F" and "R" aligned parallel to arm axis. To ease installation,
lubricate bushings with soapy water. Press in bushings using bushing remover/installer.
2. Remove wood block holding torsion beam out of body pivot brackets. Place bushing flange washers on outboard faces of bushings.
Raise torsion beam arms into brackets until pivot bolt holes align.
3. Install pivot bolts through brackets from inboard side but do not tighten nuts at this time. Connect brake lines at routing brackets.
Reinstall brake line retaining clips. Reinstall wheels. Lower vehicle and block wheels. Jounce vehicle until suspension is fully loaded in
its normal riding position. Tighten torsion beam pivot bolt nuts to 69-87 ft. lbs. (93-118 N.m). Bleed brakes.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
NOTE:Bushings have "F" (front) and "R" (rear) stam ped on bushing face. Ensure these m arks are right side
up when "F" is toward front of vehicle.
ApplicationFt. Lbs. (N.m)
Capri
Control Arm Bolt-To-Spindle45-55 (61-75)
Inner Control Arm Bolts69-86 (93-117)
Rear Hub Lock Nut18-21 (25-29)
Rear Stabilizer Bracket32-39 (43-55)
Spindle-To-Strut Bolts69-86 (93-117)
Strut Rod Upper Flanged Nut40-50 (54-68)
Strut-To-Strut Tower17-22 (23-29)
Wheel Bearing Lock Nut18-21 (25-29)
Wheel Lug Nuts67-88 (90-120)
Festiva
Brake Backing Plate Spindle Support Bolts32-45 (43-61)
Lower Body Bracket Mounting Bolts69-87 (93-118)
Page 6 of 7 MITCHELL 1 ARTICLE - SUSPENSION - REAR 1991-92 SUSPENSION Rear
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Rear Hub Lock Nut18-21 (25-29)
Spindle Attaching Nuts31-45 (43-61)
Strut Lower Mounting Bolt40-50 (54-68)
Strut Rod Upper Flanged Nut12-18 (16-25)
Torsion Beam Pivot Bolts69-87 (93-118)
Upper Body Bracket Mounting Bolts40-50 (54-68)
Wheel Lug Nuts67-88 (90-120)
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00121555
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Fig. 2: Adjusting Front Toe
-In
Courtesy of FORD MOTOR CO.
REAR TOE-IN
Festiva
Capri
Rear toe should be adjusted before setting front alignment angles. To adjust rear toe, loosen lock nuts and rotate adjustment link on rear
control arms.
ALIGNMENT SPECIFICATIONS
WHEEL ALIGNMENT SPECIFICATIONS (CAPRI)
WHEEL ALIGNMENT SPECIFICATIONS (FESTIVA)
TORQUE SPECIFICATIONS
NOTE:On Festiva, rear toe is not adjustable.
ApplicationPreferredRange
Camber (1)
Front.8.05 To 1.55
Rear-.03-.78 To .72
Caster (1) 1.6.85 To 2.35
Toe-In (1)
Front.30 To .6
Rear.30 To .6
Toe-In (2)
Front.15 (4)0 To .3 (0 To 7.5)
Rear.15 (4)0 To .3 (0 To 7.5)
Steering Axis Inclination (SAI) (1) 12.36N/A
(1)- Measurement in degrees.
(2)- Measurement in inches (mm).
ApplicationPreferredRange
Camber (1) .67-.25 To 1.58
Caster (1) 1.58.33 To 1.83
Toe-In (1) .28.04 To .52
Toe-In (2) .14 (3.5).02 To .26 (.5 To 6.5)
Steering Axis Inclination (SAI) (1) 14.18N/A
(1)- Measurement in degrees.
(2)- Measurement in inches (mm).
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Fig. 2: Compressing Band Apply Servo

Courtesy of FORD MOTOR CO.
DIFFERENTIAL OIL SEALS R & I
Removal
1. Raise and support vehicle. Drain transaxle fluid. Carefully raise staked portion of axle nut. Apply brakes and loosen, but DO NOT
remove, axle nut. Remove lower control arm ball joint clamp bolt. Pry downward on lower control arm to separate control arm from
knuckle.
2. Insert pry bar between transaxle case and axle flange. Carefully apply force to pry bar until axle circlip is disengaged. Slide knuckle
assembly off axle shaft, and remove axle from vehicle. Quickly install appropriate plug in transaxle. Using appropriate puller, remove
seal.
Installation
1. Apply lubrication to new seal. Using appropriate driver, install seal. Install new circlip on transaxle end of axle. Remove transaxle plug,
and carefully install axle into transaxle. Ensure circlip snaps into retaining groove.
2. Install axle into hub. Install NEW axle nut. Tighten bolts to specifications. See TORQUE SPECIFICATIONS
. Stake NEW axle nut
with blunt nose chisel. To complete installation, reverse removal procedure. Fill transaxle fluid to correct level.
OIL COOLER FLUSHING
Contaminates MUST be removed from oil cooler before transmission is put back into service. Replace cooler supply tubes if leaking.
Thoroughly flush oil cooler and lines if a major service or transaxle removal has occurred. It is recommended that a mechanically agitated
cleaner, such as Rotunda (014-00028), be used.
VACUUM THROTTLE VALVE DIAPHRAGM (MODULATOR) R & I
Removal
1. Drain transaxle fluid. Disconnect vacuum hose from modulator. Unscrew modulator from transaxle. Remove control rod. With beveled
side out, insert Vacuum Diaphragm Rod Gauge (T87C-77000-A) into mounting hole until gauge bottoms out.
2. Place gauge rod through opening of gauge until rod bottoms out against vacuum throttle valve. Tighten lock knob on gauge and remove
tool. Using depth gauge, measure distance from flat surface of gauge to end of rod. See Fig. 3
. Select proper length throttle valve rod.
See THROTTLE VALVE ROD DIMENSION CHART
.
THROTTLE VALVE ROD DIMENSION CHART
Installation
Install selected throttle valve rod. Coat threads of modulator with appropriate sealant. To install, reverse removal procedures.
NOTE:If replacing m odulator, it is necessary to replace throttle control valve rod.
Measurement In. (mm)Applicable Rod Length In. (mm)
1.0 (25.4)1.16 (29.5)
1.0-1.02 (25.4-25.9)1.18 (30.0)
1.02-1.04 (25.9-26.4)1.20 (30.5)
1.04-1.06 (25.9-26.4)1.22 (31.0)
1.06-1.08 (26.9-27.4)1.24 (31.5)
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Leak in vacuum circuit. Oil pressure incorrect. Manual valve faulty. Band servo faulty. Contaminated fluid. Front clutch faulty. Brake band
out of adjustment or damaged. Leak in hydraulic system.
Transaxle Slips In 1st Gear
Incorrect fluid level. Shift linkage faulty, out of adjustment or incorrectly installed. Incorrect oil pressure. Manual control valve faulty.
Contaminated fluid. Incorrect idle speed. Faulty kickdown solenoid, switch or wiring.
No 1-2 Shift
Shift linkage defective, out of adjustment or incorrectly installed. Leak in vacuum circuit. Faulty kickdown solenoid, switch or wiring.
Contaminated fluid. Manual control valve faulty. Governor valve faulty. Band servo faulty. Brake band out of adjustment. Leak in hydraulic
system. Rear clutch faulty.
No 2-3 Shift
Shift linkage defective, out of adjustment or incorrectly installed. Leak in vacuum circuit. Faulty kickdown solenoid, switch or wiring.
Contaminated fluid. Manual control valve, governor valve or band servo faulty. Leak in hydraulic system. Front clutch faulty.
No Lock-Up
Faulty torque converter, wiring or solenoid.
1-3 Shift; Skips 2nd
Contaminated fluid. Brake band out of adjustment or damaged. Leak in hydraulic system.
No 3-2 Downshift
Leak in vacuum circuit. Manual control valve, governor valve or band servo faulty. Contaminated fluid. Faulty front clutch. Brake band out of
adjustment of damaged. Leak in hydraulic system.
No 2-1 or 3-1 Downshift
Leak in vacuum circuit. Manual control valve, governor valve or band servo faulty. Contaminated fluid. Brake band out of adjustmen t o r
damaged. One-way clutch faulty.
Slippage When Accelerating In 3rd Gear Above Kickdown Speed
Shift linkage damaged, out of adjustment or installed incorrectly. Leak in vacuum circuit. Oil pressure incorrect. Manual control valve or
governor valve faulty. Contaminated fluid. Front clutch faulty. Leak in hydraulic system.
No Kickdown At Normal Speeds In 3rd Gear
Leak in vacuum circuit. Kickdown solenoid, switch or wiring faulty. Manual control valve or governor valve faulty. Contaminated fluid. Brake
band out of adjustment or damaged. Leak in hydraulic system.
1-2 & 2-3 Shift Points Too High
ATF contaminated or level incorrect. Vacuum modulator faulty or leak in vacuum circuit. Line pressures incorrect. Manual valve out of
adjustment. Governor valve faulty. Hydraulic circuit leaking.
3-2 & 2-1 Shift Points Too High
Shift linkage damaged, out of adjustment or incorrectly installed. Kickdown solenoid, switch or wiring faulty. Leak in vacuum circuit.
Incorrect oil pressure. Manual control valve or governor valve faulty. Leak in hydraulic system.
1-2 Or 2-3 Shifts With Shift Lever In "1" Position
Shift linkage damaged, out of adjustment or installed incorrectly. Manual control valve faulty. Leak in hydraulic system.
2-1 or 2-3 Shifts With Shift Lever In "2" Position
Shift linkage damaged, out of adjustment or installed incorrectly. Incorrect oil pressure. Manual control valve faulty.
Vehicle Moves In "P" Or Parking Gear Remains Engaged When
Shifted Out Of "P" Position
Shift linkage damaged, out of adjustment or incorrectly installed. Parking linkage out of adjustment or damaged.
Transaxle Noisy In "P" Or "N" Position
Incorrect fluid level. Incorrect oil pressure. Faulty rear clutch, oil pump, one-way clutch or planetary gear.
Transaxle Noisy In "D", "1", "2" or "R"
Oil pressure incorrect. Rear clutch, oil pump, one-way clutch or planetary gears faulty.
Transmission Overheats
ATF level incorrect. Engine stall speed and/or line pressure incorrect. Faulty band servo, front clutch, rear clutch, brake band, low-reverse
brake, oil pump, torque converter or planetary gear. Leak in hydraulic circuit.
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sun shell slots. Record measurement for reassembly reference. End play should be .020-.031" (.5-8 mm).

Fig. 7: Measuring Front Drum End Play

Courtesy of FORD MOTOR CO.
4. Remove oil pump. If oil pump is difficult to remove, tighten band adjusting stop bolt 106-133 INCH lbs. (12-15 N.m) and then remove
oil pump. Remove brake band adjustment stop bolt, lock nut, band strut and band. See Fig. 8
. Store band partially closed with a piece
of wire.
5. Remove front clutch assembly. Remove rear clutch needle bearing and rear clutch drum. Remove front ring gear. Remove needle bearing
and rear clutch hub assembly. Remove thrust bearing and sun gear spacer from front planetary gear. Remove planetary gear carrier.

Fig. 8: Exploded View Of Transaxle Housing & Primary Components

Courtesy of FORD MOTOR CO.
6. Remove the sun gear, spacer and connecting sun shell. See Fig. 8
. Using "C" clamp and socket, compress servo piston with and remove
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Fig. 10: Identifying Transaxle Oil Passages
Courtesy of FORD MOTOR CO.

Fig. 11: Torque Converter Housing Components

Courtesy of FORD MOTOR CO.
COMPONENT DISASSEMBLY & REASSEMBLY
BAND SERVO
Inspection
Remove seal rings and inspect piston for damaged or worn piston. Ensure spring free length is 1.890" (48.00 mm). If less than specified,
replace spring. Install new seal rings on piston and servo retainer.
DIFFERENTIAL
Disassembly
1. Remove ring gear retaining bolts and ring gear. Using hammer and pin punch, drive out roll pin. See Fig. 12. Push out pinion gear shaft.
Remove pinion and side gears, with washers, from differential housing.
2. Using appropriate puller, remove side bearings from differential housing. DO NOT remove speedometer drive gear unless damaged.
Removal will damage speedometer drive gear.
Inspection
Check all gears for signs of excessive wear or damage. Check differential gear case for cracks or other damage. Replace as needed.
Reassembly
1. Reverse removal procedure to reassemble. Measure side gear and pinion gear backlash by inserting drive shafts into differential side
gears and supporting shafts in "V" blocks. Position dial indicator with plunger resting on teeth of pinion gear. See Fig. 13
. Measure
backlash. Repeat procedure with plunger on other pinion gear.
2. Backlash readings should be less than .004" (.10 mm). If backlash is not within specification, adjust backlash by changing thrust
washers. Thrust washers are available in .079" (2.00 mm), .083" (2.10 mm) and .087" (2.20 mm) thicknesses. Use thrust washers of t h e
same thickness on both sides whenever possible.
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Fig. 16: Identifying Oil Pump Oil Passages

Courtesy of FORD MOTOR CO.
GOVERNOR ASSEMBLY
Disassembly & Reassembly
S e c u r e go ve r n o r a sse mb l y in vise . Usin g h a mme r a n d p in p u n c h , d r ive o u t go ve r n o r sh a ft ge a r sp r in g p in . R e mo ve ge a r . R e mo ve sl eeve from
shaft. Remove oil screen clamp and screen. See Fig. 17
. Clean all parts as needed. Lubricate parts with ATF. To assemble, reverse
disassembly procedure. Replace spring pin.

Fig. 17: Exploded View Of Governor Assembly

Courtesy of GENERAL MOTORS CORP.
IDLER GEAR ASSEMBLY
Disassembly & Inspection
Attach Idler Shaft Holder (J-35286) or hex wrench to idler shaft and support assembly in vise. Remove lock nut. See Fig. 18 . Remove
bearing, spacer, idler gear, adjustment shim(s) and remaining bearing. Press bearing outer races from idler gear. Check all gear teeth for wear or
damage and bearings for breakage or unusual wear.
Reassembly
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