1991 FORD FESTIVA Service Manual

Fig. 2: Identifying Front Wiper/Washer Switch Terminals (Festiva)

Courtesy of FORD MOTOR CO.
FRONT WASHER MOTOR TEST
Remove washer fluid reservoir. Remove washer motor from reservoir. Connect fused jumper wire between washer motor terminal that
corresponds with Blue/Orange wire (Capri) or Blue wire (Festiva) and battery positive terminal. Connect other washer motor terminal to
ground. Washer motor should run smoothly. If washer motor does not run smoothly or does not run, replace motor.
REAR WIPER MOTOR TEST
Festiva
1. Place wiper in any position other than park. Disconnect wiper motor electrical connector. Using an ohmmeter, check for continuity to
ground at motor case. Continuity should exist. If continuity does not exist, repair wiper motor housing ground wire.
2. Check for continuity to ground at Blue terminal of wiper motor. Continuity should exist. If continuity does not exist, replace wiper
mo t o r.
REAR WIPER/WASHER SWITCH TEST
Festiva
Remove rear wiper/wash switch. Using a self-powered test light or an ohmmeter, ensure continuity exists between terminals listed in table at
specified switch positions. If switch does not test as specified, replace wiper/washer switch. See Fig. 3
. Also, refer to the REAR
WIPER/WASHER SWITCH CONTINUITY (FESTIVA) table.
REAR WIPER/WASHER SWITCH CONTINUITY (FESTIVA)
TerminalPositionContinuity
BLU - BLKOffNo
"OnYes
GRN/BLK - BLKOffNo
"OnYes
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Fig. 3: Identifying Rear Wiper/Washer Switch Terminals (Festiva)

Courtesy of FORD MOTOR CO.
REAR WASHER MOTOR TEST
See FRONT WASHER MOTOR TEST under TESTING.
REMOVAL & INSTALLATION
FRONT WIPER MOTOR
Removal
Disconnect negative battery cable. On Capri, gently pry linkage off ball socket at wiper motor arm. On Festiva, remove access plate then gently
pry linkage off ball socket at wiper motor arm. On all models, disconnect wiper motor electrical connector. Remove 4 mounting bolts and
rubber insulators and remove wiper motor.
Installation
Position wiper motor on firewall. Install 4 rubber insulators and mounting screws and tighten to 62-89 INCH lbs. (7-10 N.m). Reverse removal
procedure to complete installation. Check wipers for proper operation.
FRONT WIPER/WASHER SWITCH
Removal & Installation (Capri)
Remove center trim panel and access cover under steering column. Remove 2 screws and remove lower steering column shroud. Disconnect
wiper/washer switch electrical connector and pull wiring from routing clip. Firmly grasp switch and lever and remove from mounting. To
install, reverse removal procedure.
Removal & Installation (Festiva)
1. Disconnect negative battery cable. From back of steering wheel, remove 2 screws securing horn pad. Disconnect horn wire from horn
pad and remove pad. Remove steering wheel nut. Scribe reference mark on steering shaft and steering wheel hub for reassembly. Using
Steering Wheel Puller (T67L-3600-A), remove steering wheel.
2. Remove 4 screws from upper half of lower steering column cover. Remove cover. Remove upper steering column cover. Remove 5 clips
from lower half of lower steering column cover. Remove cover.
3. Release wiring harness clip and unplug 4 harness connectors from back of combination switch. From below steering column, loosen
band clamp securing switch hub to steering column jacket. Pull switch assembly from steering column.
4. To install, slide combination switch assembly onto steering column. Make sure switch assembly is seated and level against end of
column jacket. To complete installation, reverse removal procedure.
FRONT WASHER MOTOR & RESERVOIR
Removal & Installation (Capri)
Drain reservoir if necessary. Remove 2 bolts securing reservoir to inner finder. Disconnect electrical connector from washer pump mo t o r.
NOTE:Disconnect linkage from wiper m otor arm ball socket NOT by rem oving nut and wiper m otor arm . This
will elim inate the need to retim e wiper m otor and linkage. Replacem ent m otors are supplied with arm
attached. Manufacturer does not give procedure for tim ing m otor arm to wiper park position.
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Disconnect fluid lines and remove reservoir. To install, reverse removal procedure.
Removal & Installation (Festiva)
1. Disconnect negative battery cable. Remove washer reservoir filler neck attaching bolt. Remove coolant expansion reservoir. Disconnect
washer pump electrical connector. Remove left front splash shield.
2. Disconnect washer pump fluid lines and detach lines from reservoir clips. Remove reservoir attaching nuts and bolt. Detach washer
reservoir from filler neck and remove reservoir. To install, reverse removal procedure.
REAR WIPER MOTOR
Removal & Installation (Festiva)
Remove rear wiper arm and blade assembly. Remove boot from outer bushing attaching nut. Remove outer bushing attaching nut and remove
outer bushing. Remove liftgate trim panel. Disconnect wiper motor electrical connector. Remove 4 wiper motor mounting bolts and remove
motor. To install, reverse removal procedure.
REAR WIPER/WASHER SWITCH
Removal & Installation (Festiva)
Disconnect negative battery cable. Remove steering column covers. Remove screws securing instrument panel bezel to instrument panel. Pull
instrument bezel away from instrument panel. Disconnect electrical connectors from switches in bezel. Compress wiper/washer switch lock
tabs and remove switch from bezel. To install, reverse removal procedure.
REAR WASHER MOTOR & RESERVOIR
Removal & Installation (Festiva)
Open liftgate and detach reservoir cap. Remove rear quarter trim panel. Remove reservoir mounting bolts. Disconnect electrical connector
from washer pump. Disconnect fluid lines. Remove reservoir. To install, reverse removal procedure.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
WIRING DIAGRAMS
See appropriate chassis wiring diagram in the WIRING DIAGRAMS Section.
ApplicationINCH Lbs. (N.m)
Front Wiper Arm Retaining Nut89-124 (10-14)
Front Wiper Motor Mounting Bolts62-89 (7-10)
Rear Outer Bushing Retaining Nut27-44 (3-5)
Rear Wiper Arm Nut53-62 (6-7)
Rear Wiper Motor Mounting Bolts71-97 (8-11)
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00028304
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Back To Article
BRAKE SYST EM
1991-92 BRAKES Disc & Drum
DESCRIPTION & OPERATION
On Capri, vehicle braking is provided by front and rear disc brakes. Front and rear brakes are a full-floating, single piston design. The rear
caliper houses a self-adjusting parking brake.
On Festiva, vehicle braking is provided by front disc brakes and rear drum brakes. Rear brakes are a standard non-servo, self-en e r giz in g d e sign .
Front brakes are a full-floating, single piston design with caliper attached to steering knuckle.
BLEEDING BRAKE SYSTEM
BLEEDING PROCEDURES
Manual Bleeding
1. Exhaust vacuum from power brake unit by depressing brake pedal several times. Fill master cylinder with clean brake fluid. Install clear
vinyl bleeder hose onto first bleeder valve to be serviced. See BRAKE LINE BLEEDING SEQUENCE table. Place other end of hose in
clean transparent container.
2. Partially fill container with clean brake fluid. Open the bleeder valve 3/4 turn. Slowly depress brake pedal through its full travel. Close
bleeder valve and release pedal. Pump pedal several times to push air toward wheel cylinders. Repeat procedure until flow of brake
fluid is clear and shows no signs of air bubbles. Proceed to next bleeder valve in sequence and repeat procedure.
BRAKE LINE BLEEDING SEQUENCE
Pressure Bleeding
1. Exhaust vacuum from power brake unit by depressing brake pedal several times. Fill master cylinder with clean brake fluid. With
pressure bleeder at least 1/2 full, connect pressure bleeder to master cylinder using appropriate adaptor.
2. Install clear vinyl bleeder hose onto first bleeder valve to be serviced. See BRAKE LINE BLEEDING SEQUENCE table. Place other
end of hose in clean transparent container. Partially fill container with clean brake fluid. Open bleeder valve 1-2 turns. Allow fluid to
run until flow of fluid is clear and shows no signs of air bubbles. Proceed to next bleeder valve in sequence and repeat procedure.
Remove pressure bleeder and fill master cylinder with clean brake fluid.
ADJUSTMENTS
BRAKE PEDAL HEIGHT (FESTIVA)
1. Block wheels to prevent vehicle from rolling. Start engine and place transmission in Neutral. Fully release parking brake. Move carpet
and insulation away from firewall and brake pedal. Measure distance horizontally between upper center of brake pedal pad and firewall.
Distance should be 8.03-8.23" (204-209 mm).
2. If pedal height is incorrect, inspect pedal assembly for missing, worn or damaged bushings or for loose attaching bolts. Ensure firewall is
not distorted and pedal is not bent. If pedal height is still not within specifications, check brake pedal, booster or master cylinder for
correct and/or correctly installed parts
BRAKE PEDAL FREE PLAY (FESTIVA)
Pump brake pedal several to bleed vacuum from power brake booster. Gently depress brake pedal by hand and measure and measure play
before resistance is felt. Free play should be .16-.28" (4-7 mm). If free play is not within specifications, adjust brake pedal push rod.
BRAKE PEDAL FLOOR CLEARANCE
Capri
1. Move carpet and insulation away from floor board and brake pedal. With engine running and using Brake Pedal Effort Gauge (021-
00001), apply 132 lbs. (59.9 kg) of force to brake pedal. Measure distance from upper surface of brake pedal pad to floor board. If
distance is less than 3.27" (83 mm), inspect pedal assembly for missing, worn or damaged bushings or for loose attaching bolts.
2. Verify that floor board is not distorted and pedal is not bent. If pedal height is still not within specifications, check brake pedal, booster
or master cylinder for correct and/or correctly installed parts. Check for air in hydraulic system.
Festiva
Move carpet and insulation away from floor board and brake pedal. Using Brake Pedal Effort Gauge (021-00001) or equivalent, apply 132
lbs. (59.9 kg) of force to brake pedal. Measure distance from upper surface of brake pedal pad to floor board. If distance is less than 2.68" (68
mm), check for air in hydraulic system, faulty automatic adjusters or excessive shoe clearance.
POWER BRAKE UNIT PUSH ROD
Capri
ApplicationSequence
CapriRR, LF, LR & RF
FestivaRR, LR, RF & LF
NOTE:Check fluid level in m aster cylinder frequently during the bleeding sequence.
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Power brake push rod length is not adjustable.
Festiva
Remove master cylinder. See MASTER BRAKE CYLINDER under REMOVAL & INSTALLATION. Place Adjustment Gauge (T87C-2500-
A) on master cylinder. Loosen set screw on gauge and place plunger against master cylinder. See Fig. 1
. Invert gauge and position on power
booster. Check clearance between gauge and power booster. Adjust push rod until clearance is zero.

Fig. 1: Measuring Brake Booster Push Rod Length (Festiva)

Courtesy of FORD MOTOR CO.
PARKING/EMERGENCY BRAKE
Capri
1. Ensure parking brake lever is released. Remove parking brake console. Loosen parking brake cable lock nut. Loosen or tighten adjusting
nut so parking brake begins to apply when lever is pulled up 5 notches and is fully applied at 7-11 notches.
2. Using Spring Scale (T74P-3504-Y), check force required to apply parking brake. A properly operating system will require 44 lb. (97 kg)
of force to fully apply parking brakes. Tighten lock nut. Ensure brake warning light operates when parking brake lever is raised.
Festiva
1. Ensure parking brake lever is released. Remove parking brake console insert. Remove locking clip from cable adjuster nut. Raise and
support rear of vehicle. Tighten parking brake adjuster until slight drag is felt when rotating wheels.
2. Loosen adjuster in small increments until drag is eliminated. As parking brake lever is lifted, parking brake should lock rear wheels in
11-16 notches. Ensure brake warning light operates when parking brake lever is raised.
REAR BRAKE SHOES
Festiva
1. Raise and support vehicle. Release parking brake. Unstake and remove axle lock nut. Remove brake drum. Insert screwdriver between
adjusting plate and quadrant. See Fig. 2
. Twist screwdriver to disengage teeth.
2. Push quadrant adjusting lever toward backing plate. Install brake drum and NEW axle lock nut. Adjust wheel bearings and secure nut
by crimping. See REAR AXLE BEARINGS. Operate brake pedal a few times to reset adjuster. Adjust parking brake (if necessary). See
PARKING/EMERGENCY BRAKE.
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Fig. 2: Moving Quadrant on Drum Brake Adjuster (Festiva)

Courtesy of FORD MOTOR CO.
FRONT AXLE BEARINGS
Front bearing preload is adjusted during bearing replacement by changing preload spacer. See FRONT WHEEL BEARINGS under
REMOVAL & INSTALLATION.
REAR AXLE BEARINGS
With bearings installed, tighten NEW lock nut to 18-22 ft. lbs. (24-30 N.m) while rotating wheel. Slightly loosen lock nut so it can be turned
by hand. Install a lug nut into axle hub. Attach an inch-pound torque wrench to lug nut at 12 o'clock position. Measure bearing preload.
Tighten lock nut until bearing preload, including seal drag, is 3.5-6.2 INCH lbs. (.4-.7 N.m). Stake NEW lock nut into notch on spindle.
TESTING
POWER BRAKE UNIT
Functional Test
1. Check master cylinder fluid level and hydraulic system for leaks. Place transaxle in Neutral or Park, turn ignition off and apply parking
brake. Pump brake pedal several times to eliminate vacuum from system, and hold pedal in depressed position.
2. Start and idle engine. If vacuum system is functioning properly, pedal moves downward under constant foot pressure. If no pedal motion
is felt, vacuum booster is not functioning properly. Go to next step.
3. Run engine for at least one minute and turn ignition off. Depress brake pedal several times. Booster is okay if pedal stroke is long at first
and becomes shorter with each stroke. If stroke does not shorten, check for a damaged, restricted or improperly connected check va l ve
vacuum hose. Repair and recheck. Go to next step.
4. Restart engine. Depress and hold pedal down. Turn ignition off and wait 30 seconds. Booster is okay if pedal height remains unchanged.
If pedal height changes, check for a damaged, restricted or improperly connected check valve or vacuum hose. Go to next step.
5. Connect a pressure gauge to master cylinder output line. Connect a vacuum gauge to booster and a pedal depression force gauge to
brake pedal. Bleed air from pressure gauge. Start engine. When vacuum gauge reads 19.7 in. Hg, turn ignition off. Watch vacuum ga u ge
for 15 seconds. Booster is okay if vacuum gauge reads 18.7-19.7 in. Hg. If vacuum gauge reads less than 18.7 in. Hg, proceed to next
step.
6. Restart engine. Apply and hold 44 lbs. (196 N) force to brake pedal. When vacuum gauge reading reaches 19.7 in. Hg, turn ignition off.
Watch vacuum gauge for 15 seconds. Booster is okay if vacuum gauge reads 18.7-19.7 in. Hg. If vacuum gauge reads less than 18.7 in.
Hg, proceed to next step.
7. With engine stopped and vacuum gauge at zero, check pressure gauge. Apply 44 lbs. (196 N) force to brake pedal and check pressure
gauge. Booster is okay if pressure gauge reads 256 psi (18 kg/cm
2 ).
8. Remove pedal force and start engine. When vacuum gauge reaches 19.7 in. Hg, apply 44 lbs. (196 N) force to pedal. Booster is okay if
pressure gauge read 768 psi (54 kg/cm
2 ).
Diagnosis
If booster does not function properly, see Fig. 3 .
NOTE:Axle lock nut on right side has left-hand threads. Always install NEW lock nut when rem oved.
NOTE:Inspect all vacuum hoses for holes, collapsed areas and secure connections. Ensure all unused
vacuum ports are capped.
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Fig. 3: Power Brake Unit Troubleshooting

CHECK VALVE
On Capri, check valve is located on power brake unit. On Festiva, check valve is located in vacuum hose connecting power booster to intake
manifold. Disconnect check valve vacuum hose from manifold. Alternately apply vacuum and pressure to hose. Ensure air flows only toward
engine. If pressure by-passes check valve or if check valve blocks vacuum, replace hose and check valve.
REMOVAL & INSTALLATION
FRONT BRAKE CALIPER & PADS
Removal & Installation (Capri)
1. Raise and support front of vehicle. Remove wheels. Using needle-nose pliers, remove brake pad pin retainer spring. Remove brake pad
pins. Remove brake pads and shims. Mark shims so they can be reinstalled in their original position. DO NOT discard shims from inner
brake pad.
2. Remove flex hose-to-caliper banjo bolt. Remove caliper retaining bolts and caliper. To install, reverse removal procedure. Ensure brake
pad shims are installed behind inner brake pad.
Removal & Installation (Festiva)
1. Raise and support front of vehicle. Remove wheels. Remove brake pad pin retainer clip. Remove brake pad pins and anti-rattle spring.
Remove brake pads and shims. Mark shims so they can be reinstalled in their original position. DO NOT discard shims from inner brake
pad.
2. To install, reverse removal procedure. Ensure brake pad shims are installed behind inner brake pad.
FRONT BRAKE ROTOR & HUB
Removal
1. Raise and support front of vehicle. Remove wheel. Unstake axle shaft lock nut tab. Apply brakes (to lock hub) and remove drive shaft
NOTE:On Festiva, check valve is pressed into hose. An arrow on hose indicates direction of vacuum flow.
NOTE:Front knuckle, disc brake rotor and hub are rem oved as an assem bly.
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lock nut. Discard axle lock nut. Separate tie rod end from knuckle.
2. Disconnect brake hose from strut (if necessary). Remove brake caliper assembly from knuckle and wire out of way. Remove nuts and
bolts holding ball joint and strut to knuckle assembly.
3. Remove knuckle assembly from ball joint and drive shaft. If binding occurs, use a dual-jawed puller to force knuckle/hub/rotor assembly
off drive axle shaft.
4. Using a puller, separate knuckle from wheel hub. Retain original outer bearing preload spacer to maintain bearing preload setting. If
replacing bearing, change spacer to maintain proper bearing preload (if necessary). See FRONT WHEEL BEARINGS under REMOVAL
& INSTALLATION. Scribe match marks between hub and rotor assembly. Remove rotor-to-hub bolts. Separate hub from rotor.
Installation
Align marks and install rotor on hub. Press knuckle and preload spacer into wheel hub assembly. To complete installation, reverse removal
procedure. Tighten axle shaft lock nut to 117-175 ft. lbs. (159-237 N.m).
REAR BRAKE CALIPER & PADS
Removal (Capri)
1. Raise and support vehicle. Remove tire and wheel assembly. Using needle-nose pliers, remove parking brake return spring. Loosen
parking brake cable housing adjusting nut. Remove cable housing from bracket on lower control arm. Loosen parking brake cable
bracket-to-caliper attaching bolt. Remove parking brake cable from caliper.
2. Remove lower caliper retaining bolt. Pivot caliper upward on upper caliper guide pin. Remove brake pad retaining spring, pads and
shims. If replacing rear brake pads only, reverse removal procedure to install. If removing caliper, proceed to next step.
3. Remove attaching clip from brake flex hose. Remove flex hose banjo bolt from caliper and discard copper washers. Remove lower
caliper retaining bolt. Using a cold chisel, remove upper caliper guide pin dust cap. Using an Allen wrench, remove upper caliper guide
pin. Lift caliper off rotor.
Installation
1. To install, fit brake pads and shims into caliper anchor plate. Remove upper guide pin and lower guide pin bushing from caliper.
Remove guide pin and guide pin bushing dust boots. Lubricate upper guide pin and lower guide pin bushing with Disc Brake Caliper
Slide Grease (D7AZ-19590-A).
2. To complete installation, reverse removal procedure. To fit caliper over new brake pads, it may be necessary to rotate caliper piston into
caliper bore. Use NEW copper washers on flex hose. Bleed brakes, and then pump brake pedal several times to seat pads.
REAR BRAKE ROTOR
Removal & Installation (Capri)
See REAR WHEEL BEARINGS under REMOVAL & INSTALLATION.
REAR BRAKE SHOES
Removal & Installation (Festiva)
Remove brake drum. Remove hold-down springs. Remove return springs. Remove self adjuster. See Fig. 8 . To install, reverse removal
procedure. Apply brake grease to all shoe contact points. See REAR BRAKE SHOES under ADJUSTMENTS.
REAR WHEEL CYLINDER
Removal & Installation (Festiva)
Remove rear brake shoes. Disconnect brake line from wheel cylinder. Remove wheel cylinder. To install, reverse removal procedure. Bleed
brake system.
MASTER BRAKE CYLINDER
Removal
Disconnect low fluid level sensor wiring (if equipped). Drain some brake fluid from reservoir. Disconnect brake lines from master cylinder.
Cap lines and master cylinder ports. Remove attaching nuts and master cylinder.
Installation
To install, reverse removal procedure. Fill master cylinder to proper level and bleed hydraulic system (if necessary).
POWER BRAKE UNIT
Removal & Installation
Remove master cylinder. Disconnect vacuum line. Remove clevis pin at brake pedal. Remove power brake unit. To install, reverse removal
procedure.
FRONT WHEEL BEARINGS NOTE:Hub and rotor are a m atched and balanced assem bly. Before rem oving rotor, locate paint or etch
m ark indicating proper hub-to-rotor alignm ent. If m arks are not present, m ark hub and rotor for
assem bly alignm ent. Failure to properly align hub and rotor can result in an im balance condition.
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