1991 FORD FESTIVA Service Manual

A "howling" or "whining" noise from the ring and pinion gear can be caused by an improper gear pattern, gear damage, or improper bearing
preload. It can occur at various speeds and driving conditions, or it can be continuous.
Before disassembling axle to diagnose and correct gear ke sure that tires, exhaust, and vehicle trim have been checked as possible causes.
Chuckle
This is a particular rattling noise that sounds like a stick against the spokes of a spinning bicycle wheel. It occurs while decelerating from 40
MPH and usually can be heard until vehicle comes to a complete stop. The frequency varies with the speed of the vehicle.
A chuckle that occurs on the driving phase is usually caused ive clearance due to differential gear wear, or by a damaged tooth on the coast
side of the pinion or ring gear. Even a very small tooth nick or a ridge on the edge of a gear tooth is enough the cause the noise.
This condition can be corrected simply by cleaning the gear tooth nick or ridge with a small grinding wheel. If either gear is damaged or scored
badly, the gear set must be replaced. If metal has broken loose, the carrier and housing must be cleaned to remove particles that could cause
damage.
Knock
This is very similar to a chuckle, though it may be louder, and occur on acceleration or deceleration. Knock can be caused by a gear tooth that
is damaged on the drive side of the ring and pinion gears. Ring gear bolts that are hitting the carrier casting can cause knock. Knock can also be
due to excessive end play in the axle shafts.
Clunk
Clunk is a metallic noise heard when an automatic transmission is engaged in Reverse or Drive, or when throttle is applied or released. It is
caused by backlash somewhere in the driveline, but not necessarily in the axle. To determine whether driveline clunk is caused by the axle,
check the total axle backlash as follows:
1. Raise vehicle on a frame or twinpost hoist so that drive wheels are free. Clamp a bar between axle companion flange and a part of the
frame or body so that flange cannot move.
2. On conventional drive axles, lock the left wheel to keep it from turning. On all models, turn the right wheel slowly until it is felt to be in
Drive condition. Hold a chalk marker on side of tire about 12" from center of wheel. Turn wheel in the opposite direction until it is
again felt to be in Drive condition.
3. Measure the length of the chalk mark, which is the total axle backlash. If backlash is one inch or less, drive axle is not the source of
clunk noise.
Bearing Whine
Bearing whine is a high-pitched sound similar to a whistle. It is usually caused by malfunctioning pinion bearings. Pinion bearings operate at
drive shaft speed. Roller wheel bearings may whine in a similar manner if they run completely dry of lubricant. Bearing noise will occur at all
driving speeds. This distinguishes it from gear whine, which usually comes and goes as speed changes.
Bearing Rumble
Bearing rumble sounds like marbles being tumbled. It is usually caused by a malfunctioning wheel bearing. The lower pitch is because the
wheel bearing turns at only about 1/3 of drive shaft speed.
Chatter On Turns
This is a condition where the entire front or rear of vehicle vibrates when vehicle is moving. The vibration is plainly felt as well as heard. Extra
differential thrust washers installed during axle repair can cause a condition of partial lock-up that creates this chatter.
Axle Shaft Noise
Axle shaft noise is similar to gear noise and pinion bearing whine. Axle shaft bearing noise will normally distinguish itself from gear noise by
occurring in all driving modes (Drive, cruise, coast and float), and will persist with transmission in Neutral while vehicle is moving at problem
speed.
If vehicle displays this noise condition, remove suspect parts, replace wheel seals and install a new set of bearings. Re-evaluate vehicle for
noise before removing any internal components.
Vibration
Vibration is a high-frequency trembling, shaking or grinding condition (felt or heard) that may be constant or variable in level and can occur
during the total operating speed range of the vehicle.
The types of vibrations that can be felt in the vehicle can d into 3 main groups:
Vibrations of various unbalanced rotating parts of the vehicle.
Resonance vibrations of the body and frame structures caused by rotating of unbalanced parts.
Tip-in moans of resonance vibrations from stressed engine or exhaust system mounts or driveline flexing modes.
DRIVE AXLE - RWD TROUBLE SHOOTING
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. T he purpose of this T rouble Shooting inform ation is to provide a list
of com m on causes to problem sym ptom s. For m odel-specific T rouble Shooting, refer to SUBJECT ,
DIAGNOST IC, or T EST ING articles available in the section(s) you are accessing. For definitions of listed
noises or sounds, see DRIVE AXLE
- NOISE DIAGNOSIS under POWERTRAIN.
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DRIVE AXLE (RWD) TROUBLE SHOOTING
FWD AXLE SHAFTS & CV JOINTS TROUBLE SHOOTING
BASIC FWD AXLE SHAFTS & CV JOINTS TROUBLE SHOOTING CHART
STEERING & SUSPENSION
MANUAL STEERING GEAR TROUBLE SHOOTING
BASIC MANUAL STEERING GEAR TROUBLE SHOOTING CHART
CONDITION & POSSIBLE CAUSECORRECTION
Knocking or Clunking
Differential Side Gear ClearanceCheck Clearance
Worn Pinion ShaftReplace Pinion Shaft
Axle Shaft End PlayCheck End Play
Missing Gear TeethCheck Differential/Replace
Gear
Wrong Axle BacklashCheck Backlash
Misaligned DrivelineRealign Driveline
Clinking During Engagement
Side Gear ClearanceCheck Clearance
Ring and Pinion BacklashCheck Backlash
Worn/Loose Pinion ShaftReplace Shaft/Bearing
Bad "U" JointReplace "U" Joint
Sticking Slip YokeLube Slip Yoke
Broken Rear Axle MountReplace Mount
Loose Drive Shaft FlangeCheck Flange
Click/Chatter On Turns
Differential Side Gear ClearanceCheck Clearance
Wrong Turn On Plates (1)Replace Clutch Plates
Wrong Differential Lubricant (1)Change Lubricant
Knock Or Click
Flat Spot on Rear Wheel BearingReplace Wheel Bearing
Low Vibration At All Speeds
Faulty Wheel BearingReplace Wheel Bearing
Faulty "U" JointReplace "U" Joint
Faulty Drive ShaftBalance Drive Shaft
Faulty Companion FlangeReplace Flange
Faulty Slip Yoke FlangeReplace Flange
(1)Limited slip differential only.
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. T he purpose of this T rouble Shooting inform ation is to provide a list
of com m on causes to problem sym ptom s. For m odel-specific T rouble Shooting, refer to SUBJECT ,
DIAGNOST IC, or T EST ING articles available in the section(s) you are accessing.
CONDITIONPOSSIBLE CAUSE
Grease LeaksCV boot torn or cracked
Clicking Noise on CorneringDamaged outer CV
Clunk Noise on AccelerationDamaged inner CV
Vibration or Shudder on AccelerationSticking, damaged or worn CV Misalignment or spring height
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. T he purpose of this T rouble Shooting inform ation is to provide a list
of com m on causes to problem sym ptom s. For m odel-specific T rouble Shooting, refer to SUBJECT ,
DIAGNOST IC, or T EST ING articles available in the section(s) you are accessing.
CONDITION & POSSIBLE CAUSECORRECTION
Rattle or Chucking Noise in Rack and Pinion
Rack and pinion mounting bracket looseTighten all mounting bolts
Lack of/or incorrect lubricantCorrect as necessary
Steering gear mounting bolts looseTighten all mounting bolts
Excessive Play
Front wheel bearing improperly adjustedSee FRONT SUSPENSION
article
Loose or worn steering linkageSee STEERING LINKAGE
article
Loose or worn steering gear shiftSee MANUAL STEERING
GEAR article
Steering arm loose on gear shaftSee MANUAL STEERING
GEAR article
Steering gear housing bolts looseTighten all mounting bolts
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POWER STEERING TROUBLE SHOOTING
BASIC POWER STEERING TROUBLE SHOOTING CHART
Steering gear adjustment too looseSee MANUAL STEERING
GEAR article
Steering arms loose on knucklesTighten and check steering
linkage
Rack and pinion mounting looseTighten all mounting bolts
Rack and pinion out of adjustmentSee adjustment in STEERING
article
Tie rod end looseTighten and check steering
linkage
Excessive Pitman shaft-to-ball nut lashRepair as necessary
Poor Returnability
Lack of lubricant in ball joint or linkageLubricate and service systems
Binding in linkage or ball jointsSee STEERING LINKAGE
and SUSPENSION article
Improper front end alignmentSee WHEEL ALIGNMENT
article
Improper tire pressureInflate to proper pressure
Tie rod bindingInflate to proper pressure
Shaft seal rubbing shaftSee STEERING COLUMN
article
Excessive Vertical Motion
Improper tire pressureInflate to proper pressure
Tires, wheels or rotors out of balanceBalance tires then check
wheels and rotors
Worn or faulty shock absorbersCheck and replace if necessary
Loose tie rod ends or steeringTighten or replace if necessary
Loose or worn wheel bearingsSee SUSPENSION article
Steering Pulls to One Side
Improper tire pressureInflate to proper pressure
Front tires are different sizesRotate or replace if necessary
Wheel bearings not adjusted properlySee FRONT SUSPENSION
article
Bent or broken suspension componentsSee FRONT SUSPENSION
article
Improper wheel alignmentSee WHEEL ALIGNMENT
article
Brakes draggingSee BRAKES article
Instability
Low or uneven tire pressureInflate to proper pressure
Loose or worn wheel bearingsSee FRONT SUSPENSION
article
Loose or worn idler arm bushingSee FRONT SUSPENSION
article
Loose or worn strut bushingsSee FRONT SUSPENSION
article
Incorrect front wheel alignmentSee WHEEL ALIGNMENT
article
Steering gear not centeredSee MANUAL STEERING
GEARS article
Springs or shockCheck and replace if necessary
Improper cross shaftSee MANUAL STEERING
GEARS article
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. T he purpose of this T rouble Shooting inform ation is to provide a list
of com m on causes to problem sym ptom s. For m odel-specific T rouble Shooting, refer to SUBJECT ,
DIAGNOST IC, or T EST ING articles available in the section(s) you are accessing.
CONDITION & POSSIBLE CAUSECORRECTION
Rattle or Chucking Noise
Pressure hoses touching engine partsAdjust to proper clearance
Loose Pitman shaftAdjust or replace if necessary
Tie rods ends or Pitman arm looseTighten and check system
Rack and pinion mounts looseTighten all mounting bolts
Free play in worm gearSee POWER STEERING
GEAR article
Loose sector shaft or thrust bearing adjustmentSee POWER STEERING
GEAR
Free play in pot couplingSee STEERING COLUMN
article
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Worn shaft serrationsSee STEERING COLUMN
article
Growl in Steering Pump
Excessive pressure in hosesRestricted hoses, see POWER
STEERING GEAR article
Scored pressure platesSee POWER STEERING
GEAR article
Scored thrust plates or rotorSee POWER STEERING
GEAR article
Extreme wear of cam ringSee POWER STEERING
GEAR article
Rattle in Steering Pump
Vanes not installedSee POWER STEERING
PUMP article
Vanes sticking in rotorSee POWER STEERING
PUMP article
Swish noise in Pump
Defective flow control valveSee POWER STEERING
PUMP article
Groan in Steering Pump
Air in fluidSee POWER STEERING
PUMP article
Poor pressure hose connectionTighten and check, replace if
necessary
Squawk When Turning
Damper "O" ring on valve spool cutSee POWER STEERING
PUMP article
Moan or Whine in Pump
Pump shaft bearing scoredReplace bearing and fluid
Air in fluid or fluid level lowSee POWER STEERING
PUMP article
Hose or column groundedCheck and replace if necessary
Cover "O" ring missing or damagedSee POWER STEERING
PUMP article
Valve cover baffle missing or damagedSee POWER STEERING
PUMP article
Interference of components in pumpSee POWER STEERING
PUMP article
Loose or poor bracket alignmentCorrect or replace if necessary
Hissing When Parking
Internal leakage in steering gearCheck valved assembly first
Chirp in Steering Pump
Loose or worn power steering beltAdjust or replace if necessary
Buzzing When Not Steering
Noisy pumpSee POWER STEERING
PUMP article
Free play in steering shaft bearingSee STEERING COLUMN
article
Bearing loose on shaft serrationsSee STEERING COLUMN
article
Clicking Noise in Pump
Pump slippers too longSee POWER STEERING
PUMP article
Broken slipper springsSee POWER STEERING
PUMP article
Excessive wear or nicked rotorsSee POWER STEERING
PUMP article
Damaged cam contourSee POWER STEERING
PUMP article
Poor Return of Wheel
Wheel rubbing against turn signalSee STEERING COLUMN
SWITCHES article
Flange rubbing steering gear adjusterSee STEERING COLUMN
article
Tight or frozen steering shaft bearingSee STEERING COLUMN
article
Steering gear out of adjustmentSee POWER STEERING
GEAR article
Sticking or plugged spool valveSee POWER STEERING
PUMP article
Improper front end alignmentSee WHEEL ALIGNMENT
article
Wheel bearings worn or looseSee FRONT SUSPENSION
article
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Ties rods or ball joints bindingCheck and replace if necessary
Intermediate shaft joints bindingSee STEERING COLUMN
article
Kinked pressure hosesCorrect or replace if necessary
Loose housing head spanner nutSee POWER STEERING
GEAR article
Damaged valve leverSee POWER STEERING
GEAR article
Sector shaft adjusted too tightSee ADJUSTMENTS in
POWER STEERING GEAR
article
Worm thrust bearing adjusted too tightSee ADJUSTMENTS in
POWER STEERING GEAR
article
Reaction ring sticking in cylinderSee POWER STEERING
GEAR article
Reaction ring sticking in housing headSee POWER STEERING
GEAR article
Steering pump internal leakageSee POWER STEERING
PUMP article
Steering gear-to-column misalignmentSee STEERING COLUMN
article
Lack of lubrication in linkageService front suspension
Lack of lubrication in ball jointsService front suspension
Increased Effort When Turning Wheel Fast Foaming, Milky Power Steering Fluid, Low Fluid Level or Low Pressure
High internal pump leakageSee POWER STEERING
PUMP article
Power steering pump belt slippingAdjust or replace if necessary
Low fluid levelCheck and fill to proper level
Engine idle speed to lowAdjust to correct setting
Air in pump fluid systemSee POWER STEERING
PUMP article
Pump output lowSee POWER STEERING
PUMP article
Steering gear malfunctioningSee POWER STEERING
GEAR article
Wheel Surges or Jerks
Low fluid levelCheck and fill to proper level
Loose fan beltAdjust or replace if necessary
Insufficient pump pressureSee POWER STEERING
PUMP article
Sticky flow control valveSee POWER STEERING
PUMP article
Linkage hitting oil pan at full turnReplace bent components
Kick Back or Free Play
Air in pump fluid systemSee POWER STEERING
PUMP article
Worn poppet valve in steering gearSee POWER STEERING
PUMP article
Excessive over center lashSee POWER STEERING
GEAR article
Thrust bearing out of adjustmentSee POWER STEERING
GEAR article
Free play in pot couplingSee POWER STEERING
PUMP article
Steering gear coupling loose on shaftSee POWER STEERING
PUMP article
Steering disc mounting bolts looseTighten or replace if necessary
Coupling loose on worm shaftTighten or replace if necessary
Improper sector shaft adjustmentSee POWER STEERING
GEAR article
Excessive worm piston side playSee POWER STEERING
GEAR article
Damaged valve leverSee POWER STEERING
GEAR article
Universal joint looseTighten or replace if necessary
Defective rotary valveSee POWER STEERING
GEAR article
No Power When Parking
Sticking flow control valveSee POWER STEERING
PUMP article
Insufficient pump pressure outputSee POWER STEERING
PUMP article
Excessive internal pump leakageSee POWER STEERING
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STEERING COLUMN TROUBLE SHOOTING
BASIC STEERING COLUMN TROUBLE SHOOTING CHART
PUMP article
Excessive internal gear leakageSee POWER STEERING
PUMP article
Flange rubs against gear adjust plugSee STEERING COLUMN
article
Loose pump beltAdjust or replace if necessary
Low fluid levelCheck and add proper amount
of fluid
Engine idle too lowAdjust to correct setting
Steering gear-to-column misalignedSee STEERING COLUMN
article
No Power, Left Turn
Left turn reaction seal "O" ring wornSee POWER STEERING
GEAR article
Left turn reaction seal damaged/missingSee POWER STEERING
GEAR article
Cylinder head "O" ring damagedSee POWER STEERING
PUMP article
No Power, Right Turns
Column pot coupling bottomedSee STEERING COLUMN
article
Right turn reaction seal "O" ring wornSee POWER STEERING
GEAR article
Right turn reaction seal damagedSee POWER STEERING
GEAR article
Internal leakage through piston end plugSee POWER STEERING
GEAR article
Internal leakage through side plugsSee POWER STEERING
GEAR article
Lack of Effort in Turning
Left and/or right reaction seal sticking in cylinder headReplace, see POWER
STEERING GEAR article
Wanders to One Side
Front end alignment incorrectSee WHEEL ALIGNMENT
article
Unbalanced steering gear valveSee POWER STEERING
GEAR article
Low Pressure Due to Steering Pump
Flow control valve stuck or inoperativeSee POWER STEERING
PUMP article
Pressure plate not flat against cam ringSee POWER STEERING
PUMP article
Extreme wear of cam ringReplace and check
adjustments
Scored plate, thrust plate or rotorSee POWER STEERING
PUMP article
Vanes not installed properlySee POWER STEERING
PUMP article
Vanes sticking in rotor slotsSee POWER STEERING
PUMP article
Cracked/broken thrust or pressure plateSee POWER STEERING
PUMP article
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. T he purpose of this T rouble Shooting inform ation is to provide a list
of com m on causes to problem sym ptom s. For m odel-specific T rouble Shooting, refer to SUBJECT ,
DIAGNOST IC, or T EST ING articles available in the section(s) you are accessing.
CONDITION & POSSIBLE CAUSECORRECTION
Noise in Steering
Coupling pulled apartSee STEERING COLUMNS
article
Column not correctly alignedSee STEERING COLUMNS
article
Broken lower jointReplace joint
Horn contact ring notSee STEERING COLUMN
article
Bearing not lubricatedSee STEERING COLUMN
article
Shaft snap ring not properly seatedReseat or replace snap ring
Plastic spherical joint not lubricatedSee STEERING COLUMN
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SUSPENSION TROUBLE SHOOTING
BASIC SUSPENSION TROUBLE SHOOTING CHART
article
Shroud or housing looseTighten holding screws
Lock plate retaining ring not seatedSee STEERING COLUMN
article
Loose sight shieldTighten holding screws
High Steering Shaft Effort
Co l u mn assemb l y misal ign edSee STEERING COLUMN
article
Improperly installed dust shieldAdjust or replace
Tight steering universal jointSee STEERING COLUMN
article
High Shift Effort
Column is out of alignmentSee STEERING COLUMN
article
Improperly installed dust shieldAdjust or replace
Seals or bearings not lubricatedSee STEERING COLUMNS
article
Mounting bracket screws too longReplace with new shorter
screws
Burrs on shift tubeRemove burrs or replace tube
Lower bowl bearing assembled wrongSee STEERING COLUMN
article
Shift tube bent or brokenReplace as necessary
Improper adjustment of shift leversSee STEERING COLUMN
article
Improper Trans. Shifting
Sheared shift tube jointReplace as necessary
Sheared lower shaft leverReplace as necessary
Improper shift lever adjustmentSee STEERING COLUMN
article
Improper gate plate adjustmentSee STEERING COLUMN
article
Excess Play in Column
Instrument panel bracket bolts looseTighten bolts and check
bracket
Broken weld nut on jacketSee STEERING COLUMN
article
Instrument bracket capsule shearedSee STEERING COLUMN
article
Column bracket/jacket bolts looseTighten bolts and check
bracket
Steering Locks in Gear
Release lever mechanismSee STEERING COLUMN
article
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. T he purpose of this T rouble Shooting inform ation is to provide a list
of com m on causes to problem sym ptom s. For m odel-specific T rouble Shooting, refer to SUBJECT ,
DIAGNOST IC, or T EST ING articles available in the section(s) you are accessing.
CONDITION & POSSIBLE CAUSECORRECTION
Front End Noise
Loose or worn wheelSee Wheel Bearing
Adjustment in SUSPENSION
Worn shocks or shock mountingsReplace struts or strut
mo u n t in gs
Worn struts or strut mountingsReplace struts or strut
mo u n t in gs
Loose or worn lower control armSee SUSPENSION
Loose steering gear-to-frame boltsSee STEERING
Worn control arm bushingsSee SUSPENSION
Ball joints not lubricatedLubricate ball joints & see
Ball Joint Checking in
SUSPENSION
Front Wheel Shake, Shimmy, or Vibration
Tires or wheels out of balanceCheck tire balance
Incorrect wheel alignmentSee WHEEL ALIGNMENT
Drive shaft unbalancedCheck drive shaft balance
Loose or worn wheel bearingsSee WHEEL ALIGNMENT
Loose or worn tie rod endsSee SUSPENSION
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WHEEL ALIGNMENT TROUBLE SHOOTING
BASIC WHEEL ALIGNMENT TROUBLE SHOOTING CHART
Worn upper ball jointsSee Ball Joint Checking in
SUSPENSION
Worn shock absorbersReplace shock absorbers
Worn strut bushingsReplace strut bushings
Car Pulls to One Side
Mismatched or uneven tiresCheck tire condition
Broken or sagging springsSee SUSPENSION
Loose or worn strut bushingsSee SUSPENSION
Improper wheel alignmentSee WHEEL ALIGNMENT
Improper rear axle alignmentCheck rear axle alignment
Power steering gear unbalancedSee STEERING
Front brakes draggingSee BRAKES
Abnormal Tire Wear
Unbalanced tiresCheck tire balance & rotation
Sagging or broken springsSee SUSPENSION
Incorrect front end alignmentSee WHEEL ALIGNMENT
Faulty shock absorbersReplace chock absorbers
Scuffed Tires
Toe-In incorrectSee WHEEL ALIGNMENT
Suspension arm bent or twistedSee appropriate
SUSPENSION article
Springs Bottom or Sag
Bent or broken springsSee SUSPENSION
Leaking or worn shock absorbersReplace shock absorbers
Frame misalignmentCheck frame for damage
Spring Noises
Lo o se "U" Bo l t sSee SUSPENSION
Loose or worn bushingsSee SUSPENSION
Worn or missing interlinersSee SUSPENSION
Shock Absorber Noise
Loose shock mountingsCheck & tighten mountings
Worn bushingsReplace bushings
Air in systemBleed air from system
Undercoating on shocksRemove undercoating
Car Leans or Sways on Corners
Loose stabilizer barSee SUSPENSION
Faulty shocks or mountingsReplace shocks or mountings
Broken or sagging springsSee SUSPENSION
Shock Absorbers Leaking
Worn seals or reservoir tube crimpedSee SUSPENSION
Broken Springs
Lo o se "U" b o l t sSee SUSPENSION
Inoperative shock absorbersReplace shock absorbers
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. T he purpose of this T rouble Shooting inform ation is to provide a list
of com m on causes to problem sym ptom s. For m odel-specific T rouble Shooting, refer to SUBJECT ,
DIAGNOST IC, or T EST ING articles available in the section(s) you are accessing.
CONDITION & POSSIBLE CAUSECORRECTION
Premature Tire Wear
Improper tire inflationCheck tire pressure
Front alignment out of toleranceSee ALIGNMENT SPECS in
WHEEL ALIGNMENT
section
Suspension components wornSee SUSPENSION section
Steering system components wornSee STEERING section
Improper standing heightSee WHEEL ALIGNMENT
Uneven or sagging springsSee SUSPENSION section
Bent wheelSee WHEEL ALIGNMENT
Improper torsion bar adjustmentSee SUSPENSION section
Loose or worn wheel bearingsSee WHEEL BEARING ADJ.
in SUSPENSION section
Worn or defective shockReplace shock absorbers
Tires out of balanceCheck tire balance
Pulls to One Side
Improper tire inflationCheck tire pressure
Brake draggingSee BRAKE section
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