1991 FORD FESTIVA lock

Installation
1. Lubricate bearings with appropriate wheel bearing grease. Place inner bearing into steering knuckle. Install new inner bearing gr e a se
seal, and drive seal into place using appropriate seal installer.
2. Place original outer wheel bearing preload spacer (or spacer selected during preload inspection process) into steering knuckle bore.
Place outer wheel bearing into steering knuckle bore.
3. Liberally lubricate lip of NEW outer grease seal with appropriate lubricant. Drive seal into steering knuckle bore. Install brake rotor on
hub axle hub. Tighten bolts to 33-40 ft. lbs. (45-54 N.m). Position rotor/hub assembly into steering knuckle, and press assembly into
place using adapter from spacer selector set. To complete installation, reverse removal procedure.
REAR WHEEL BEARINGS
Removal & Installation
1. Raise and support rear axle. Remove wheel. Remove wheel bearing dust cap. On Capri, remove rear brake caliper. See REAR BRAKE
CALIPER & PADS under REMOVAL & INSTALLATION. On all models, carefully unstake rear axle lock nut using a chisel. DO NOT
damage threads on axle spindle. Remove and discard axle nut.
2. On Capri, remove rotor/hub assembly. On Festiva, remove brake drum/hub assembly. On all models, DO NOT allow outer wheel
bearing to fall out of hub. Remove inner bearing grease seal. Remove inner bearing. To install rear bearings, reverse removal procedure.
Adjust rear wheel bearings. See REAR AXLE BEARINGS under ADJUSTMENTS.
OVERHAUL

Fig. 5: Exploded View of Front Brake Assembly (Capri)

Courtesy of FORD MOTOR CO.
170.2726 (6.925)
180.2742 (6.965)
190.2758 (7.005)
200.2774 (7.045)
210.2789 (7.085)
NOTE:See Fig. 5
-12 for exploded views of brake assem blies and com ponents.
Page 7 of 12 MITCHELL 1 ARTICLE - BRAKE SYSTEM 1991-92 BRAKES Disc & Drum
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AXLE SHAFT S - FRONT
1988-93 Drive Axles - FWD Axle Shafts
DESCRIPTION & OPERATION
Axle shafts transfer power from transaxle to driving wheels. All axle shafts consist of a shaft with a flexible Constant Velocity (CV) joint at
each end. Inner CV joint is coupled to transaxle by splines. Outer CV joint is splined to hub assembly and secured by axle shaft nut.
Three different types of axle shaft CV joints are used: Double Offset Joint (DOJ) or Rzeppa type, Birfield Joint (BJ) and the Tripot Joint (TJ).
CV joint boots protect CV joints by maintaining proper lubrication and preventing contaminants from entering joint. Boots must be replaced
when signs of leakage or cracks are present. Inner CV joint may be disassembled and serviced. Outer CV joint boot may be replaced, but outer
Birfield CV joint must NOT be disassembled. It must be replaced as an assembly, if faulty.
To prevent torsional vibration and torque steer on turbocharged Capri vehicles, an intermediate shaft and conventional axle shaft are used on
the right side. Both shafts are of similar length and are supported by a bearing, which is attached to engine.
CV JOINT IDENTIFICATION
TROUBLE SHOOTING
REMOVAL, DISASSEMBLY, REASSEMBLY & INSTALLATION
FWD AXLE SHAFTS
Removal
1. Raise and support vehicle. Remove lower underbody splash shields. Drain transaxle fluid. Remove front wheels and loosen axle shaft
lock nut. On Capri, remove stabilizer bar-to-control arm attaching nuts, bolt, washers and bushings. On Festiva, remove stabilizer bar
attaching nuts and bracket. On all models, remove joint clamp bolt from lower control arm. Pry downward and separate steering knuckle
from ball joint, taking care not to damage ball joint dust boot.
2. On Capri turbo, remove bolts securing intermediate shaft bearing bracket to engine. On all models, slowly pry axle shaft from transaxle
using a flat-tip screwdriver or pry bar. Axle is held into transaxle by a circlip fitted to the end of the axle. Remove axle shaft from wheel
hub. If difficult to remove, use axle puller to remove axle from drive hub. Remove axle shaft from transaxle. Plug transaxle openings
with Plugs (T87C-7025-C ). Remove axle shaft assembly from vehicle. See Fig. 1
.

Fig. 1: Removing & Installing Axle Shafts

Courtesy of FORD MOTOR CO.
ApplicationJoint Type
Outer JointBirfield (BJ)
In n er Jo in t
Automatic TransaxleTripot (TJ)
Manual TransaxleRzeppa (DOJ)
NOTE:See TROUBLE SHOOTING - BASIC PROCEDURES article in GENERAL INFORMATION.
CAUTION: Dam age to CV joint will occur if a ham mer is used to separate half-shaft from wheel hub.
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Installation (All)
1. To install axle shaft, reverse removal procedure. Always install a NEW retaining circlip. Check seals at both ends of axle shaft. If
necessary, replace seals prior to installation. Lubricate transaxle seal lip with transaxle oil. See Fig. 1
.
2. After installing axle shaft into transaxle, pull axle shaft outward by hand to ensure proper engagement of retaining circlip and snap ring.
Install axle shaft into wheel hub. Align suspension alignment marks and tighten nuts.
INTERMEDIATE SHAFT
Removal
Intermediate shaft and axle shaft are removed as an assembly. See FWD AXLE SHAFTS under REMOVAL, DISASSEMBLY,
REASSEMBLY & INSTALLATION.
Disassembly
Separate intermediate shaft from axle shaft. Remove circlip from intermediate shaft and press off bearing and bracket assembly. See Fig. 4 .
Press bearing out of bracket. Inspect bracket for damage or wear and replace if necessary.
Reassembly
Press NEW bearing into bracket and install NEW seals. Install bearing and bracket assembly onto intermediate shaft. Install NEW circlip.
Assemble intermediate shaft to axle shaft.
Installation
Intermediate shaft and axle shaft are installed as an assembly. See FWD AXLE SHAFTS under REMOVAL, DISASSEMBLY,
REASSEMBLY & INSTALLATION.

Fig. 4: Exploded View Of Intermediate Shaft

Courtesy of FORD MOTOR CO.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS NOTE:Always install NEW cotter pin, washer and suspension lock nuts.
ApplicationFt. Lbs. (N.m)
Axle Nut (1) 116-173 (157-235)
Ball Joint Pinch Bolt32-40 (43-54)
Steering Knuckle-To-Strut Bolt69-86 (93-117)
Caliper Retaining Bolt29-36 (39-49)
Stabilizer Bar Bracket Nut40-50 (54-68)
Stabilizer Link Bolt9-13 (12-18)
Tie Rod End Nut21-32 (29-44)
Wheel Lug Nuts66-89 (90-120)
(1)Ensure locking flange on nut is staked into axle slot.
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00042994
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TROUBLE SHOOTING
OVERHAUL

Fig. 3: Exploded View of Mitsubishi Alternator

Courtesy of FORD MOTOR CO.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS NOTE:See T ROUBLE SHOOT ING - BASIC PROCEDURES article in the GENERAL T ROUBLE SHOOT ING
section.
NOTE:For exploded view of alternator, see Fig. 3
.
ApplicationFt. Lbs. (N.m)
Alternator Adjustment Bolt14-18 (19-25)
Alternator Mount Bolt27-38 (37-52)
Idler Pulley Attaching Nut23-34 (31-46)
Power Steering Pump Adjustment Lock Nut27-38 (37-52)
Power Steering Pump Mounting Bolt27-40 (37-54)
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00058012
Page 3 of 3 MITCHELL 1 ARTICLE - ALTERNATOR & REGULATOR 1991 ELECTRICAL Alternators & Regulators
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SOLENOIDS & SOLENOID VALVES
SOLENOIDS & SOLENOID VALVES LOCATION
SWITCHES
SWITCHES LOCATION
MISCELLANEOUS
MISCELLANEOUS LOCATION
COMPONENT LOCATION GRAPHICS

Fig. 1: Component Locations (1 Of 3)

FrontOn left rear corner of engine
bay, on firewall. See Fig. 1
.
RearIn liftgate, behind trim panel.
ComponentLocation
Canister Purge SolenoidOn center of firewall, to right of wiper motor. See Fig. 1 .
Idle-Up Speed Control (ISC) SolenoidOn left rear of engine, left of injector No. 4.
Kickdown Solenoid Valve (A/T)On lower right front corner of transaxle. See Fig. 1 .
ComponentLocation
A/C Pressure SwitchOn A/C line, near right front strut tower. See Fig. 1 .
A/C Thermostatic Switch (1992)On bottom of evaporator housing, below glove box.
Back-Up Light SwitchMounted on transaxle. See Fig. 1 .
Brake Fluid Level SwitchOn brake fluid reservoir.
Brake On-Off Switch (1992)On bracket, above brake pedal.
Clutch Interlock SwitchOn bracket, above clutch pedal.
Cooling Fan SwitchIn thermostat housing. See Fig. 1 .
Inertia SwitchIn left rear quarter panel.
Kickdown Switch (A/T)Mounted on accelerator pedal.
Neutral Safety SwitchOn right rear side of transaxle.
Oil Pressure SwitchOn rear center of engine block.
Parking Brake SwitchOn base of parking brake lever.
Passive Restraint Limit SwitchAt top of left & right "A" pillar.
Power Steering Pressure SwitchMounted on power steering pump assembly.
Seat Belt Switch (1991)On driver's seat belt buckle.
Stoplight SwitchOn brake pedal lever.
Wide Open Throttle A/C Cut-Off (WAC) Switch (1991)On left corner of engine bay, left of cooling fan.
ComponentLocation
Blower ResistorNear blower motor.
RPM Test ConnectorOn left rear of engine bay, next to ignition module. See Fig. 1 .
NOTE:Figures m ay show m ultiple com ponent locations. Refer to appropriate table for proper figure
references.
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FUSES & CIRCUIT BREAKERS
Fuses & Circuit Breakers 1988-93 Festiva
FUSES & FUSIBLE LINKS
FUSE PANEL & FUSIBLE LINK BLOCK LOCATIONS
The vehicle has a fuse block with fusible links and a fuse panel with circuit fuses. The fuse panel is located behind the instrument panel, left o
f
the steering column. The fuse block is located under the hood.
FUSE PANEL IDENTIFICATION

Fig. 1: Fuse Panel Identification

Courtesy of FORD MOTOR CO.
Fuse & Circuit Breaker Identification
1 - 15 Amp License Plate Light, Rear Side Marker Ligh t , Fr o n t P a r kin g Ligh t s, C l u st e r a n d Ta il Ligh t s
2 - 15 Amp Horn, Brakelights, High-Mount Brakelight
3 - 15 Amp (1988-89) Safety Belt Warning, Turn & Hazard Warning Flasher Lights, Radio, Trunk Light, Ignition Key Reminder Buzzer
3 - 15 Amp (1990-93) Safety Belt Warning, Turn & Hazard Warning Flasher Lights, Ignition Key Reminder Buzzer
4 - 15 Amp Audio System, Cigarette Lighter, Remote Control Mirror
5 - 15 Amp Rear Wiper/Washer, Daytime Running Light System (Canada)
6 - 15 Amp Heater & Air Conditioner
7 - 20 Amp Heater & Air Conditioner, Cooling Fan System
8 - 10 Amp (1988-89) Interior Courtesy Lights 10 Amp (1990-93) Radio, Interior Courtesy Lights, Luggage Compartment Light
9 - 15 Amp (1988-89) Front Wiper/Washer
9 - 15 Amp (1990-93) Front Wiper/Washer, Shift-Lock System (ATX), Engine Control System
10 - 10 Amp Charging System, Emission Control System
11 - 10 Amp (1988-90) Safety Belt Warning, Turn & Hazard Warning Flasher Lights, Back-Up Lights, Instrument Cluster, Warning
Lights,
11 - 10 Amp (1991-93) Safety Belt Warning, Turn & Hazard Warning Flasher Lights, Back-Up Lights, Instrument Cluster, Warning
Lights, Shift-Lock System
12 - 15 Amp Rear Window Defroster
13 - Not Used (1988-89) Spare
13 - 30 Amp (1990-93) Passive Restraint System (Automatic Seat Belt)
In-Line Fuse Identification
15 Amp (1990-93) Condenser Fan Motor (A/T Models Only)
10 Amp (1990-93) A/C System (located on left side of heater case)
FUSIBLE LINK BLOCK IDENTIFICATION
Page 1 of 3 MITCHELL 1 ARTICLE - FUSES & CIRCUIT BREAKERS Fuses & Circuit Breakers 1988-93 Festiva
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Fig. 2: Underhood Fusible Link Block Identification

Courtesy of FORD MOTOR CO.
Fusible Link Identification
A - Brown (PTC) (1988-89 Carburetor) EFE Carburetor Heater
A - Brown (EGI) (1989-93 EFI) EFI System (1989-92), EGI-EFI System (1993)
B - Red (Main) Back-Up, Interior & Parking Lights, Brakelights, Taillights, Horn, Luggage Compartment Light, Turn Signal & Hazard
F l a sh e r Ligh t s, C l u st e r & Wa r n in g Ligh t s, R a d io , C iga r e t t e Ligh t e r , C h a r gin g & E missio n C o n t r o l S yst e ms, Wip e r / Wa sh e r S yst e ms,
A/C-Heater System, Cooling Fan System, Rear Window Defroster, Ignition & Starting Systems, Shift Lock System, Remote Control
Mirror, Ignition Key Reminder, Passive Restraint System (1990-93)
C - Brown (Head) Headlights, Daytime Running Lights, Starting & Charging System
BATTERY SPECIFICATIONS
All 1988-92 models use a BX-35 battery. The 1993 Festiva uses a 50D 20L standard battery.
CAUTIONS & WARNINGS
BATTERY WARNING
REPLACING BLOWN FUSES
Before replacing a blown fuse, remove ignition key, turn off all lights and accessories to avoid damaging the electrical system. Be sure to use
fuse with the correct indicated amperage rating. The use of an incorrect amperage rating fuse may result in a dangerous electrical system
overload.
BRAKE PAD WEAR INDICATOR
Indicator will cause a squealing or scraping noise, warning that brake pads need replacement.
CAUT ION: When battery is disconnected, vehicles equipped with com puters m ay lose m em ory data. When battery
power is restored, driveability problem s m ay exist on som e vehicles. T hese vehicles m ay require a
relearn procedure. See COMPUTER RELEARN PROCEDURES
article in the GENERAL INFORMAT ION
section.
WARNING:When battery is disconnected, vehicles equipped with com puters m ay lose m em ory data. When battery
power is restored, driveability problem s m ay exist on som e vehicles. T hese vehicles m ay require a
relearn procedure. See COMPUTER RELEARN PROCEDURES
article in GENERAL INFORMAT ION
section.
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GENERAL INFORMATION
Using Mitchell1's Wiring Diagram s
INTRODUCTION
Mitchell1(R) obtains wiring diagrams and technical service bulletins, containing wiring diagram changes, from the domestic and import
manufacturers. These are checked for accuracy and are all redrawn into a consistent format for easy use. All system wiring diagrams are
available in color format and may be viewed and or printed in color or black and white, depending on your program settings and available
printer hardware.
In the past, when cars were simpler, diagrams were simpler. All components were connected by wires, and diagrams seldom exceeded 4 pages
in length. Today, some wiring diagrams require more than 16 pages. It would be impractical to expect a service technician to trace a wire from
page 1 across every page to page 16.
Removing some of the wiring maze reduces eyestrain and time wasted searching across several pages. Today, the majority of Mitchell1(R)
diagrams follow a much improved format, which permits space for internal switch details, and component and ground locations.
Components shown with a dashed line instead of a solid line indicate not all circuits are shown in this particular diagram (circuits shown in
system diagrams are typically applicable to that system only). The remaining circuits connected to that component will be shown in the
appropriate system that they apply to.
Today, the wiring diagram necessary to support a given repair procedure is included within that article or a link is provided to the appropriate
SYSTEM WIRING DIAGRAM article. For example, the wiring diagram for a Ford EEC-IV system may be included in ENGINE
PERFORMANCE and WIRING DIAGRAMS articles for Ford Motor Co. The wiring diagram for a cruise control system may be included in
ACCESSORIES & EQUIPMENT section for the specific vehicle manufacturer, and the wiring diagram for an anti-lock brake system may be
included in BRAKES and WIRING DIAGRAMS for the specific manufacturer.
WIRING DIAGRAMS contains all wiring diagrams not included in STARTING & CHARGING SYSTEMS and ACCESSORIES &
EQUIPMENT. This includes: Data Link Connectors, Ground Distribution, Power Distribution, Engine Performance, Electric Cooling Fans,
Anti-Lock Brakes, Electronic Suspension and Electronic Steering wiring diagrams. The Data Link Connectors wiring diagrams show the
circuits by which the various on-board computers exchange information, and the diagnostic connectors used for diagnosis and their location.
The Ground Distribution wiring diagrams show all vehicle ground points, their location, and the components common to those ground points.
The Power Distribution wiring diagrams show the power feed circuits and the components common to those power feeds.
Wiring diagrams used to support the information in ACCESSORIES & EQUIPMENT are drawn in a "top-down" format. The diagrams are
drawn with the power source at the top of the diagram and the ground point at the bottom of the diagram. Component locations are identified
on the wiring diagrams. Any wires that do not connect directly to a component are identified on the diagram to indicate where they go.
WIRING DIAGRAM COLOR ABBREVIATIONS
COLOR ABBREVIATIONS
WIRING DIAGRAM SYMBOLS
ColorNormalOptional
BlackBLKBK
BlueBLUBU
BrownBRNBN
ClearCLRCR
Dark BlueDK BLUDK BU
Dark GreenDK GRNDK GN
GreenGRNGN
GrayGRYGY
Light BlueLT BLULT BU
Light GreenLT GRNLT GN
OrangeORGOG
PinkPNKPK
PurplePPLPL
RedREDRD
TanTANTN
VioletVIOVI
WhiteWHTWT
YellowYELYL
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