1991 FORD FESTIVA clock

Fig. 6: Exploded View of Compressor Clutch (Ford FX
-15)
Courtesy of MAZDA MOTORS CORP.
HARRISON R4 4-CYL CLUTCH R & I
Removal
1. Clamp Holding Fixture (J-25008-A) in a vise and attach compressor to holding fixture with thumb screws. Use Clutch Hub Holder (J-
33027) to hold clutch. Remove shaft nut using Shaft Nut Socket (J-9399).
2. Thread Clutch Plate and Hub Assembly Remover (J-33013-B) into hub. Hold body of remover with a wrench and turn center screw into
remover body to remove clutch plate and hub assembly. Remove shaft key and retain for assembly. See Fig. 5
.
Installation
1. Install shaft key into hub key groove. Allow key to project approximately 1/8" out of key way. Shaft key is curved slightly to provide an
interference fit in hub key groove.
2. Ensure frictional surface of clutch plate and clutch rotor are clean before installing clutch plate and hub assembly. Align shaft key with
shaft key way and place clutch plate and hub assembly onto compressor shaft.
3. Hold hex portion of Installer (J-9480-B) with a wrench. Tighten center screw to press hub into shaft until there is .020-.040" (.5-1.0
mm) air gap between frictional plate and clutch rotor.
4. Install new shaft nut with small diameter boss of nut against crankshaft shoulder. Use Thin Wall Socket (J-9399) and Clutch Hub
Holder (J-25030). Tighten shaft nut to 10 ft. lbs. (14 N.m). Spin pulley rotor by hand to ensure rotor is not rubbing on clutch drive
plate.
HARRISON R4 4-CYL SHAFT SEAL R & I
Removal
1. Clamp Holding Fixture (J-25008-A) in a vise and attach compressor to holding fixture with thumb screws. Use Clutch Hub Holder (J-
33027) to hold clutch. Remove shaft nut using Shaft Nut Socket (J-9399).
2. Thread Clutch Plate and Hub Assembly Remover (J-33013-B) into hub. Hold body of remover with a wrench and turn center screw into
remover body to remove clutch plate and hub assembly. Remove clutch plate and shaft key. Pry out dust seal (if equipped). Remove seal
seat snap ring. Thoroughly clean compressor neck area and "O" ring groove surrounding shaft. Any dirt or foreign material may cause
compressor damage.
3. Use Seal Remover/Installer (J23128-A), remove seal with a twisting motion. Use "O" Ring Remover (J-9553-01) to remove "O" ring.
Installation
1. Coat new shaft seal with refrigerant oil and install shaft seal on remover/installer. Align compressor shaft machined surface with shaft
seal and install. Turn remover/installer slightly counterclockwise to secure shaft seal tangs.
2. Using Seal Installer (J-33011), install "O" ring and coat with refrigerant oil. Coat seal seat with refrigerant oil and install using seal seat
remover/installer. Install snap ring. Install dust seal (if supplied in seal kit). See Fig. 7
.
NOTE:DO NOT drive or pound on clutch hub or shaft.
Page 7 of 18 MITCHELL 1 ARTICLE - A/C COMPRESSOR SERVICING 1991 GENERAL SERVICING Compressor Service
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Fig. 10: Hitachi 6-Cylinder Compressor Shaft Seal Seat Removal
Courtesy of NISSAN MOTOR CO., U.S.A.

Fig. 11: Hitachi 6
-Cylinder Compressor Shaft Seal Removal
Courtesy of NISSAN MOTOR CO., U.S.A.
Inspection
Check carbon seal surface of shaft seal for damage. Check "O" ring and carbon seal contact surface of shaft seal seat for damage. Make sure
that "O" ring contact surface on front cover is not damaged. Make sure refrigerant oil is applied to oil seal in shaft seal seat.
Installation
1. To install, reverse removal procedure. Ensure shaft seal contact surface is free of dirt. Lubricate with refrigerant oil. Cap end of
compressor shaft.
2. Using Guard (KV994C1143), insert shaft seal. Be sure shaft seal case is aligned with shaft. Apply force to turn seal to left and right.
Ensure shaft seal seats properly in shaft cut-out.
3. Fit "O" ring to outside groove of shaft seal seat. Ensure "O" ring seats properly. Apply refrigerant oil on contact surfaces and around
shaft seal seat. Lightly coat surface of shaft with refrigerant oil.
4. Install key on compressor shaft. Using snap ring pliers, compress retainer ring and fit retainer ring into front cover. Seat retainer ring
firmly in groove. Thoroughly wipe grease or oil from shaft surface.
5. Connect Installer (KV99412329) to shaft of compressor, and turn shaft 5 or 6 times in a clockwise direction to seat seal. See
REFRIGERANT OIL & R-12 SPECIFICATIONS chart in this section for system capacities.
MATSUSHITA ROTARY VANE CLUTCH R & I
Removal & Installation
1. Insert two 5 mm bolts into threaded holes in armature. Using a screwdriver as lever in between bolts, remove center bolt. remove
armature and shim from shaft.
2. Remove snap ring. Using a puller, remove pulley. Disconnect electrical leads from field coil. Remove 3 field coil mounting bolts.
Remove field coil. See Fig. 12
. To install, reverse removal procedure.
Page 11 of 18 MITCHELL 1 ARTICLE - A/C COMPRESSOR SERVICING 1991 GENERAL SERVICING Compressor Service
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Fig. 17: Sanden Scroll Compressor

Courtesy of CHRYSLER MOTORS.
SANDEN 5-CYL CLUTCH R & I
Removal
1. Hold clutch hub stationary and remove shaft nut. Remove clutch plate using puller. Remove external front housing snap ring and
internal bearing snap ring. See Fig. 16
.
2. Install puller and pull rotor assembly off. remove 3 screws and clutch coil. Use driver and hammer to drive bearing out from hub.
Installation
1. Install new bearing; ensure installer contacts outer race of bearing. Install snap ring and ensure bearing turns freely. Install clutch coil on
compressor.
2. Support compressor on rear mounting ears. Align rotor on front housing hub. Use adapter and press to install rotor (or drive into place
with soft mallet). After rotor is seated, install front snap ring.
SANDEN 5-CYL SHAFT SEAL R & I
Removal
1. Hold clutch hub stationary and remove shaft nut with thin wall socket. Use clutch plate puller to remove clutch plate. Tap key out of
slot in crankshaft.
2. Remove seal retainer with seal remover and 3/4" socket wrench. Use seal seat remover tongs to pull seal seat off compressor shaft. Insert
seal remover into front housing and turn to engage tangs on seal. Lift seal out. Remove seal "O" ring from front housing, being careful
not to scratch shaft.
Installation
1. Coat "O" ring with refrigerant oil and install into groove. Load a new seal onto installer, being careful not to touch carbon sealing
surface with fingers. Install shaft protector. Dip seal in refrigerant oil and install on shaft. Rotate seal clockwise until seal fits into flats
on shaft. Remove seal installer by turning counterclockwise.
2. Coat seal seat with refrigerant oil and install with tongs. Reinstall seal seat retainer (with flat side down). Install shims and shaft key.
Rotate shaft several times to help break in seal.
3. Use a press to install clutch plate. Make sure that air gap is .016-.031" (.41-.79 mm). Hold plate stationary and install shaft n u t .
NOTE:Check com pressor refrigerant oil level when replacing seals.
Page 17 of 18 MITCHELL 1 ARTICLE - A/C COMPRESSOR SERVICING 1991 GENERAL SERVICING Compressor Service
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Fig. 18: Sanden 5
-Cylinder Compressor
Courtesy of CHRYSLER MOTORS.
SANDEN 7-CYL CLUTCH COIL & BEARING R & I
Removal
1. Hold clutch hub stationary and remove shaft nut. Remove clutch plate using Clutch Plate Puller (09977-21110). Remove clutch shims
and bearing dust cover. Remove external front housing snap ring.
2. Install puller, and pull drive pulley assembly off. Detach clutch coil lead from compressor housing. Remove clutch coil snap ring and
clutch coil. If necessary, invert drive pulley assembly and remove snap ring and bearing.
Installation
1. Ensure clutch coil protrusion aligns with hole in compressor housing, and install clutch coil snap ring. Install drive pulley assembly
using Drive Pulley Installer (09977-21811).
2. install external bearing snap ring. Using Seal Installer (09977-21800), install bearing dust cover. After dust cover installation, ensure
there is no contact between cover and front housing.
3. Install clutch shims and clutch plate. Tighten shaft nut to 12-14 ft. lbs. (17-19 N.m). Using a dial indicator, apply voltage to clutch coil
to check air gap between clutch plate and drive pulley assembly. Ensure air gap is .016-.032" (.41-.80 mm).
SANDEN 7-CYL SHAFT SEAL R & I
Removal
1. Hold clutch hub stationary and remove shaft nut. Remove clutch plate using Clutch Plate Puller (09977-21110). Tap shaft key out of
slot in compressor shaft. Remove clutch shims.
2. Remove seal retainer felt ring. Remove shaft seal seat snap ring with snap ring pliers. Insert Seal Seat Remover/Installer (09977-21400)
into front housing and turn to engage tangs on seat. Lift seal seat out.
3. Insert seal Remover/Installer (09977-21510) into front housing and turn to engage tangs on seal. carefully lift seal seat out without
scratching compressor shaft.
Installation
1. Install Shaft Seal Guide Sleeve (09977-21700) over compressor shaft. Dip seal in refrigerant oil and install seal on sleeve. Using seal
remover/installer, rotate seal clockwise until seal is engaged. Remove seal remover/installer by turning it counterclockwise.
2. Coat seal seat with refrigerant oil and install seal with seal seat remover/installer. Remove shaft seal guide sleeve. Install snap ring.
Install seal retainer felt ring using seal seat remover/installer. Install clutch shims and shaft key.
3. Install clutch plate. Tighten shaft nut to 12-14 ft. lbs. (17-19 N.m). Using dial indicator, apply voltage to clutch coil to check air gap
between clutch plate and drive pulley assembly. Ensure air gap is .016-.032" (.41-.80 mm).
NOTE:Check com pressor refrigerant oil level when replacing seals.
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00038955
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SCREW TYPE SEAL CANS
Ensure can tap is fully closed. Screw refrigerant can into can tap fitting until tight. This will pierce the can. Connect tap to center hose on
manifold gauge set. DO NOT open tap until ready to dispense R-12 into system.
CONNECTING LINES & FITTINGS
1. A new "O" ring should be used in all instances when connecting lines and fittings (dip "O" ring in clean refrigeration oil and make
certain it is not twisted during installation). Always use two wrenches to avoid twisting or distorting lines and fittings, tighten coupling
nuts securely.
2. Ford spring-coupling fittings require a special coupling tool (Motorcraft YT-1056) to open or close. Use the following procedure to
connect or disconnect the spring-coupling fitting.
Ford Spring-Coupling Fitting
1. Discharge system using approved refrigerant recovery/recycling equipment. Place proper end of tool over refrigerant line. Tool fits both
3/8" and 1/2" fittings. Push tool into fitting cage to release spring inside. Pull lines apart and remove tool.
2. Before connecting, check internal spring for damage. If necessary, pry spring out and replace it. Clean fittings and install new "O" rings.

Fig. 1: Assembling Ford Spring
-Coupling Fitting
PLACING SYSTEM IN OPERATION
After component replacement and/or system servicing has been completed and all connections have been made, proceed as follows:
1. Evacuate the system using a vacuum pump.
2. Charge the system with new R-12 (refrigerant) according to each individual vehicle as outlined in the GENERAL SERVICING article.
Also see Refrigerant Capacity in this Section.
3. Leak test the system, with particular attention to all new connections and components.
4. Make a performance test of the system. Never assume that a recharging has automatically corrected a problem.
COMPRESSOR REMOVAL INFORMATION - ISOLATION METHOD
On systems which have compressors equipped with stem-type service valves (Tecumseh), it is possible to isolate the compressor for removal.
Isolating
Turn both high and low pressure manual valves to extreme clockwise (front seat) position. Loosen cap on high pressure manual valve
connection to compressor and allow gas to escape until compressor is relieved of pressure.
COMPRESSOR REMOVAL INFORMATION-DISCHARGE METHOD
This procedure is to be used on vehicles which have compressor equipped with Schrader service valves. In these cases, the compressor cannot
be isolated and the system must be discharged, using approved refrigerant recovery/recycling equipment, prior to compressor removal. WARNING:DO NOT open high side hand valve while air conditioning system is in operation. T his high pressure
could rupture can or fitting at safety can valve, resulting in dam age and personal injury.
CAUT ION: Use ONLY "O" rings designed for these Ford fittings (Motorcraft YF-982). Norm al refrigerant "O" rings
will NOT seal.
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00039191
Page 2 of 2 MITCHELL 1 ARTICLE - A/C SYSTEM PRECAUTIONS A/C GENERAL SERVICING A/C System Servicing cautions
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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.
Page 3 of 4 MITCHELL 1 ARTICLE - STEERING COLUMN 1991 STEERING Ford Motor Co. - Steering Columns
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Fig. 2: Exploded View of Rear Suspension (Capri)

Courtesy of FORD MOTOR CO.
ADJUSTMENTS & INSPECTION
WHEEL BEARING
1. Raise and support vehicle. Ensure parking brake is fully released. Remove wheel and dust cap. Rotate brake drum and ensure there is no
brake drag. Using a small cape chisel, raise the staked portion of the lock nut. Remove and discard lock nut.
2. Install new lock nut. To seat bearings, use a torque wrench and tighten lock nut to 18-21 ft. lbs. (25-29 N.m) while rotating brake drum.
After tightening, loosen lock nut until it can be turned by hand. Measure seal drag using an INCH lb. torque wrench on a lug nut at 12
o'clock position. Measure and record amount of force required to rotate brake drum.
3. To determine preload, add amount of seal drag to specified preload of 1.3-4.3 INCH lbs. (.15-.49 N.m). As an example, if seal drag
measures 2.2 INCH Lbs. (.25 N.m), this amount must be added to required preload.
4. Tighten wheel bearing lock nut a small amount. Using an INCH lb. torque wrench on a lug nut at 12 o'clock position, measure amo u n t
of pull required to rotate brake drum. Tighten attaching nut until specified amount of preload is measured with torque wrench. Stake
lock nut with a blunt chisel. Install grease cap and wheel.
REMOVAL & INSTALLATION
WHEEL BEARING
Removal
1. Raise and support vehicle. Ensure parking brake is fully released. Remove wheel and dust cap. Using a small cape chisel, raise staked
portion of lock nut. Remove and discard lock nut. Remove brake drum, bearing and hub assembly from spindle.
2. Pry out grease seal from hub and remove inner bearing. Bearings must be marked for reassembly reference if they are to be reused. Using
Slide Hammer (T50T-100-A), Bearing Cup Puller (T77F-1102-A) or proper sized brass drift and hammer, remove inner and outer
bearing races.
Installation
NOTE:Right side lock nut has left-hand threads. Left side lock nut has right-hand threads.
NOTE:Nut m ust be replaced if lock flange splits or cracks during staking process. DO NOT stake with a sharp
edged tool.
NOTE:Right side lock nut has left-hand threads. Left side lock nut has right-hand threads.
Page 2 of 7 MITCHELL 1 ARTICLE - SUSPENSION - REAR 1991-92 SUSPENSION Rear
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1. Record direction of rotation one-way clutch locks and turns. Remove snap ring and pull out planetary carrier from one-way clutch inner
race. See Fig. 8
. Check for worn or damaged parts. Bushing wear on one-way clutch must not exceed 5.120" (130.06 mm).
2. Check clearance between pinion gears and washers in planetary carrier. If clearance exceeds .031" (.80 mm), replace planetary carrier.
Reverse disassembly procedure to reassemble. Install one-way clutch in inner race and ensure that it will turn in one direction
(clockwise) only.
REAR CLUTCH
Disassembly
1. Remove large snap ring. Lift out retaining plate, clutch plates, and dished plate. See Fig. 21 . Using appropriate compressor, compress
rear clutch spring retainer to remove small snap ring, spring retainer, and clutch return springs.
2. Place front clutch on oil pump and rear clutch hub on top of front clutch. Apply air pressure to rear clutch oil passage to remove piston.
See Fig. 16
. Remove and discard piston seal rings.
Inspection
Inspect for wear or damage. Ensure return spring free length is 1.031-1.071" (26.20-27.20 mm).
Reassembly
1. Install seal rings on piston and install in clutch drum by applying even pressure on perimeter of piston and rotate piston slowly. Install
return springs and spring retainer. Press spring retainer. Install snap ring. Note direction of dished plate and install. Install driven and
drive plates, retainer plate and snap ring. See Fig. 21
.
2. Ensure clearance between snap ring and retainer plate is .031-.039" (.80-1.00 mm). If clearance is not within specification, select correct
retaining plate. Retaining plates are available in thicknesses .189" (4.80 mm) to .244" (6.20 mm) in .20 mm increments.
3. Check rear clutch operation by placing forward clutch on oil pump and then rear clutch. Apply compressed air (70 psi maximum) to
rear clutch oil passage and check operation. See Fig. 16
.

Fig. 21: Exploded View Of Rear Clutch

Courtesy of FORD MOTOR CO.
REAR CLUTCH HUB
Disassembly, Inspection & Reassembly
Remove snap ring and separate hub from internal gear. Check for worn or damaged snap ring or gear and replace as needed. Reverse
disassembly procedure to reassemble hub.
VALVE BODY
Disassembly
1. Remove manual control valve. Remove oil strainer retaining bolts and oil strainer. Remove upper-to-lower valve body retaining bolts.
Separate valve bodies, separator plate and sub-body. DO NOT lose check balls and springs or orifice valve and spring. See Fig. 22
.
2. Remove, clean and install each valve individually as needed. See Fig. 22
. Lubricate moving parts with ATF. Ensure all valves move
(snap) freely. If valve sticks in its bore and cannot be freed, valve body must be replaced. DO NOT attempt to hone valve bores or
polish valves.
3. Inspect the valve springs for signs of damage or deformation. Measure valve spring free length and diameter. Refer to the VALVE
NOTE:Rem ove and clean one valve at a tim e to avoid incorrect installation. If any valves, valve springs, or
valve bodies are dam aged, the entire valve body assem bly m ust be replaced.
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