1991 FORD FESTIVA Service Manual

WHEEL ALIGNMENT
After performing appropriate service procedures, refer to WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in the WHEEL
ALIGNMENT section.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
ApplicationFt. Lbs. (N.m)
Pinion Adjusting Screw Lock Nut29-36 (39-49)
Mounting Bracket Bolt23-34 (31-46)
Tie Rod End Castle Nut26-30 (35-40)
Tie Rod-to-Rack Ball Joint43-58 (58-79)
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00054859
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ST EERING SYST EM - POWER
1991-92 ST EERING Ford Motor Co. - Steering - Power Rack & Pinion
DESCRIPTION & OPERATION
Power steering system consists of a rack and pinion steering gear, valve body, power steering pump, fluid reservoir and interconnecting
hydraulic lines. Pressure and return lines from pump are connected to valve body. A vane-type power steering pump draws fluid from the
steering reservoir. Fluid is compressed by rotor and vanes inside steering pump and sent to steering gear. Pressure is monitored and controlled
by a pressure switch and a control valve located inside of steering pump.
TROUBLE SHOOTING
Refer to TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL TROUBLE SHOOTING section.
LUBRICATION
CAPACITY
Information is not available.
FLUID TYPE
Use Dexron-II ATF type fluid.
FLUID LEVEL CHECK
Check fluid level before engine is started, while fluid is still cool. Remove reservoir cap fluid indicator on steering pump. Check fluid level.
Fluid should be between the "L" and "H" marks on the level gauge dipstick. If fluid is needed, fill to the "L" mark on dipstick. Run engine until
warm and turn steering wheel fully in both directions about 10 times. Return steering to straight-ahead position and shut engine off. Ensure
fluid level is between "L" and "H" marks. Add fluid if necessary.
HYDRAULIC FLUID BLEEDING
1. Raise and support front of vehicle. Ensure pump reservoir is filled to specified level. With ignition coil wire disconnected, crank engine
and add fluid to steering pump until fluid level remains constant. While cranking engine, rotate steering from stop to stop. Recheck and
add fluid as necessary.
2. Start engine and allow to idle for several minutes. Turn steering wheel completely lock-to-lock several times. Check fluid level. Add
fluid as necessary. Continue this procedure until there is no bubbling or decrease in fluid level.
ADJUSTMENTS
BELT TENSION
On Festiva, remove air duct and air cleaner. On all models, loosen steering pump mounting pivot bolt and the adjusting bolt lock nut. Using
Belt Tension Gauge (021-0028A), fit gauge to longest available belt span for testing. Adjust belt to specification. See BELT TENSION
SPECIFICATIONS . Tighten adjuster lock nut to 32-45 ft. lbs. (43-61 N.m) on Capri or 27-38 ft. lbs. (37-52 N.m) on Festiva.
BELT TENSION SPECIFICATIONS
REMOVAL & INSTALLATION
STEERING GEAR
Removal
1. Disconnect negative battery cable. On Capri, mark and loosen intermediate lower U-joint. On Festiva, mark and remove steering gear
intermediate shaft connecting steering gear to column shaft. On all models, disconnect high pressure and return lines and plug them.
Loosen front wheel lug nuts.
2. Raise vehicle. Remove front wheels. Remove tie rod end cotter pins and nuts. Separate tie rod ends from steering knuckles using Tie
Rod Remover (T85M-3395-A). Remove tie rod end splash shields. Remove right fender splash shield. Remove front catalytic converter
nuts and separate converter from inlet pipe.
3. Place reference marks on tie rod end and tie rod for reassembly reference. Loosen tie rod jam nut and remove right tie rod end. Remove
steering gear mounting bolts and washers. Slide steering gear to the left and pull right tie rod through fender opening. Remove steering
gear by sliding it to the right.
Installation
Application
(1) Deflection: In.
(mm)Gauge Tension:
Lbs. (kg)
New Belt
Capri & Festiva.31-.35 (8-9)110-132 (50-60)
Used Belt
Capri.31-.35 (8-9)110-132 (50-60)
Festiva.35-.39 (9-10)95-110 (43-50)
(1)Apply approximately 22 lbs. (9.9 kg) of pressure.
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1. Position steering gear in its mounting position. Attach intermediate shaft to steering gear pinion and tighten clamp bolt to 13-20 ft. lbs.
(18-26 N.m). Guide intermediate shaft into steering column hole. Lower vehicle.
2. Lift steering gear and align intermediate shaft with universal joint and install clamp bolt. Raise vehicle. Install steering gear mounting
bolts and tighten to 23-34 ft. lbs. (31-46 N.m). Install right tie rod end, using marks made during removal for installation reference.
Attach tie rod ends to steering knuckles. Install tie rod end nuts and tighten to 22-33 ft. lbs. (29-44 N.m).
3. Install tie rod end cotter pins. Attach catalytic converter to inlet pipe and install attaching nuts. Tighten nuts to 23-34 ft. lbs. (31-46
N.m). Install tie rod end splash shields. Install right fender splash shield. install front wheels. Lower vehicle.
4. Connect high pressure and return lines. Connect negative battery cable. Add power steering fluid and bleed air from system and check
for leaks. See HYDRAULIC FLUID BLEEDING
under LUBRICATION.
POWER STEERING PUMP
Removal (Capri)
1. Remove right radiator support and brace. Remove pump drive belt. Disconnect intercooler outlet hose at throttle intake (if equipped).
R e mo ve gr o u n d wir e fr o m e n gin e l ift in g e ye .
2. Remove pressure and return hoses and plug. Remove wire from pressure switch. Remove adjusting screw, nut and block from pump
bracket. Remove pivot bolt. Remove bracket retaining bolts then remove pump.
Removal (Festiva)
Remove air duct and air cleaner. Disconnect electrical connector from fluid pressure switch on power steering pump. Disconnect and plug
return and pressure lines. Remove adjustment bolt. Remove lock nut, washer and bracket bolt. Loosen mounting bolt and disconnect drive
belt. Remove mounting bolt. Remove power steering pump.
Installation (Capri & Festiva)
To install pump, reverse removal procedure. Adjust steering belt tension. Tighten all nuts and bolts to specification. See TORQUE
SPECIFICATIONS . Add power steering fluid and bleed air from system and check for leaks. See HYDRAULIC FLUID BLEEDING
under LUBRICATION.
OVERHAUL
STEERING GEAR
Disassembly (Capri)
1. Remove steering gear and place in soft-jawed vise. Remove external hydraulic lines. See Fig. 1 . Remove mount brackets and rubber
mount bushings. Remove brass tubing seats using a self-tapping screw and 2 screwdrivers.
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Fig. 1: Exploded View of Power Steering Gear (Capri)

Courtesy of FORD MOTOR CO.
2. Use cold chisel to remove pinion shaft dust boot. Use No. 40 Torx bit to remove valve body attaching bolts. Remove, disassemble and
inspect valve body components. Remove burrs from spool valve with crocus cloth if necessary. Mark tie rod ends and jam nuts for
installation reference.
3. Remove tie rod ends and jam nuts. Remove tie rod dust boots. Use dull cold chisel to uncrimp tie rod end tab washers. Remove tie rod.
Remove adjusting plug, spring and yoke. Protect outer bulkhead with cloth and remove with pipe wrench.
4. Discard bulkhead "O" ring. Pull pinion shaft out from lower bearing side. Remove upper pinion bearing by driving it out with wooden
dowel. Remove rack from outer bulkhead end.
5. Remove inner guide and inner rack seal using Inner Rack Seal Remover T87C-3504-A. Mount rack on "V" blocks to check runout.
Runout should be no more than .012" (.03 mm). Replace rack if runout exceeds specification.
Reassembly
1. Install a new "O" ring on spool valve. Apply Long Life Lubricant (C1AZ-19590-BA) to pivot lever hole in spool valve and to pivot lever
hole in valve body. Apply ATF to rest of spool valve. Install spool valve. Apply Long Life Lubricant to pivot lever/collar and to
bushing.
2. Install pivot lever into spool valve housing. Make sure longest end of pivot lever/collar is seated in spool valve. Install end plug in spool
valve housing. Apply ATF to inner guide. Push inner guide and inner rack seal into rack housing with Inner Rack Seal Remover (T87C-
3504-A).
3. Apply Long Life Lubricant to rack teeth. DO NOT plug rack air hole with grease. Install Rack Oil Seal Protector (D83P-3504-K).
Install a new rack piston seal on rack using Piston Seal Replacer (T81P-3504-L) with Pusher (T75L-3517-A2) and Sizer (T81P-3504-
K).
4. Apply ATF to rack piston and cover rack with electrical tape. Coat inside of rack housing with ATF and carefully slide rack into
housing. Slide rack as far as it will go into housing. Remove rack seal protector. Install a new bushing into outer bulkhead using Pinion
Cover Centering Tool T18P-3504-Y.
5. Install a new sealing ring, oil seal and "O" rings at bulkhead end of rack housing. Lubricate all parts with ATF before installation. Wrap
outer bulkhead with towel and install with pipe wrench. Stake bulkhead to rack housing with punch. Install lower bearing on pinion
shaft. Install and tighten retaining nut to 29-36 ft. lbs. (40-50 N.m).
6. Stake nut to pinion shaft. Install pinion shaft into housing with rack extending 2.70" (68.7 mm) out of housing on pinion shaft end or
centered in housing. Also, notch on pinion shaft spline must be located 60 degrees from horizontal center. See Fig. 2
.
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Fig. 2: Installing Pinion Shaft (Capri)

Courtesy of FORD MOTOR CO.
7. Grease upper pinion bearing and install in housing using Upper Pinion Seal Replacer (T78P-3504-D). Tighten pinion bearing cover to
44-79 INCH lbs. (5-9 N.m). Then loosen it 10-20 degrees. Tighten lock nut to 29-36 ft. lbs. (40-50 N.m).
8. Using a new gasket, attach valve body to rack housing. Install yoke, spring, adjusting plug and lock nut. Tighten cover to 39-47 INCH
lbs. (4.5-5.5 N.m). Loosen cover 45 degrees. Measure pinion torque using inch lb. torque wrench and Pinion Adapter (T87C-3504-C).
9. Pinion torque should be .52-1.3 INCH lbs. (.6-1.5 N.m). If pinion torque is not within specification, loosen or tighten adjusting plug.
After pinion torque is set, tighten lock nut to 29-36 ft. lbs. (40-50 N.m). Mount steering gear in soft-jawed vise and install damper ring,
washer and tie rod.
10. Tighten tie rod to 43-58 ft. lbs. (60-80 N.m). Stake tab washer in 2 places. Position damper ring in washer. Install other damper ring,
washer and tie rod. Install tie rod dust boots and secure outer ends with clamps and inner sides with mechanics wire.
11. Install tie rod ends and adjust according to index marks put on during disassembly. Wrap electrical tape around and apply grease to
pinion shaft. Apply grease to lips of pinion shaft seal. Install pinion shaft seal using Pinion Bearing Replacer (T78P-3504-D).
12. Remove electrical tape from pinion shaft. Install support brackets and rubber bushings. Install external oil lines and 2 new copper
sealing rings.
Disassembly (Festiva)
1. Remove steering gear from vehicle and place in a soft-jawed vise. Remove fluid lines. See Fig. 3 . Place reference marks on left tie rod
end and tie rod for reassembly reference. Loosen jam nut and remove left tie rod end. Remove outer boot clamps. Remove inner boot
wires. Remove boots.

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Fig. 3: Exploded View of Power Steering Gear (Festiva)
Courtesy of FORD MOTOR CO.
2. Remove tie rod lock nut pins using Lock Nut Pin Remover (T78P-3504-N). Remove tie rods from rack. Remove yoke plug lock nut
using Yoke Lock Nut Wrench (T90C-3504-BH). Remove yoke plug, spring and support yoke. Remove snap ring which retains pinion
and control valve assembly.
3 . R e mo ve se a l u sin g Lo c k Nu t P in R e mo ve r ( T7 8 P - 3 5 0 4 - N) . R e mo ve va l ve h o u sin g a t t a c h in g b o l t s. R e mo ve va l ve h o u sin g a n d p in io n and
control valve assembly. If present, remove shims from steering gear housing. Remove "O" ring. Remove lower pinion bearing using
Collet (D80L-100-L) and Blind Hole Puller Set (D80L-100-A).
4. Remove pinion and control valve assembly from valve housing by tapping lightly with a rubber mallet. Remove 4 Teflon seals from
pinion and control valve assembly. Press bearing out of valve housing using Pinion Seal Replacer (T88C-3504-MH) and Handle (T87P-
3504-D).
5. Using Outer Box Torque Adapter (T88C-3504-CH), rotate the rack bushing until the hooked end of the retaining wire is aligned with
the slot in the steering gear housing. Pry the retaining wire from the bushing hole. Rotate the bushing and remove the retaining wir e .
Remove the rack from the right side of the steering gear.
6 . R e mo ve b u sh in g fr o m r a c k. R e mo ve "O" r in g. R e mo ve se a l u sin g Rack Oil Seal Remover (T87C-3504-A) by bottoming seal into rack
with plastic hammer. Pull seal out with Slide Hammer T50T-100-A. Remove the rack mounting brackets and grommets.
Reassembly
1. Install grommets and mounting brackets. Install new seal using Rack Oil Seal Replacer T81P-3504-C. Install new "O" ring using Piston
Seal Replacer (T81P-3504-L) and Rack Piston Seal Sizer (T81P-3504-K). Place Short Rack Seal Replacer (T81P-3504-N) over end of
rack to protect bushing.
2. Install bushing on rack. Place Rack Seal Protector (T87P-3504-H) on rack. See Fig. 4
. Install rack. Remove rack seal protector. Insert
rack retaining wire through slot and into bushing hole. Install retaining wire using Outer Box Torque Adapter (T88C-3504-CH).

Fig. 4: Installing Rack Seal Protector (Festiva)

Courtesy of FORD MOTOR CO.
3. Install lower pinion bearing using Pinion Bearing Replacer (T90C-3504-DH). If valve housing, steering gear, or pinion and control valve
assembly have been replaced, go to step 4). If none of these components have been replaced, go to step 6).
4. Measure valve housing, lower bearing and spacer, and steering gear housing. See Fig. 5
. Use the following formula to determine proper
shim thickness: T = A C - B Where "T" is the shim thickness.
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Fig. 5: Determining Replacement Shim Thickness (Festiva)

Courtesy of FORD MOTOR CO.
5. Having calculated required shim thickness, divide the required shim thickness by .0020" (.05 mm). This is the thickness of replacement
shims. Round off to the nearest equal shim thickness.
6. Install previously removed shim(s) into valve housing. Install new Teflon pinion seals on pinion and control valve assembly using Pinion
Valve Seal Installation Set (T81P-3504-M). Install first seal (seal closest to bearing) by sliding Mandrel (T81P-3504-M1) over va l ve
assembly to first seal groove.
7. Push seal into groove with Pusher (T81P-3504-M2). Size the seal by sliding large end of Sizer (T81P-3504-M3) over seal. Before
installing second seal, place Spacer (T81P-3504-M4) on valve assembly near splined end. Install and size using Mandrel (T81P-3504-
M1) and Pusher (T81P-3504-M2).
8. Before installing third seal, place 2 Spacers (T81P-3504-M4) on valve assembly near splined end. Install and size third seal. To install
fourth seal, turn second spacer around so the small ends of each spacer are facing. Install an size fourth seal.
9. Insert pinion and control valve assembly into valve housing, making sure it seats properly. Install New "O" ring. Install valve h o u sin g
mount bolts and tighten to 15-19- ft. lbs. (21-25 N.m). Install upper pinion bearing and seal using Pinion Seal Replacer/Torque Adapter
(T90C-3504-EH).
10. Install snap ring, support yoke and spring. Install yoke plug and tighten to 86 INCH lbs. (9.8 N.m). Loosen yoke plug and install Yoke
Plug Torque Gauge T90C-3504-CH over yoke plug. Tighten yoke plug to 38-48 INCH lbs. (4.4-5.4 N.m). Make scribe mark on support
yoke at zero point on yoke plug torque gauge.
11. Loosen yoke plug until 45 degree mark on yoke plug torque gauge is aligned with scribe mark on support yoke. Apply sealant to
exposed threads of yoke plug. Install lock nut and tighten to 36-43 ft. lbs. (49-59 N.m). Install tie rods and tie rod lock pins. Install
boots, boot wires and clips, and fluid lines.
POWER STEERING PUMP
Disassembly (Capri)
1. Drain pump. Remove rear bracket, mount bolts and brackets. Remove reservoir and "O" ring. Remove rear pump body and "O" ring.
Remove pump center body and "O" ring. Remove cam ring and pump shaft snap ring. Remove vanes from rotor. See Fig. 6
.
2. Remove rotor from shaft and note rotor position. Remove pump shaft from front of pump. Remove front bracket. Remove shaft oil seal.
Check clearance between vane and rotor. Clearance should .0004-.0024" (.01-.06 mm). Replace vanes as necessary.
3. Check clearance between bushing and shaft. Clearance should be .001-.004" (.03-.1 mm). Replace shaft or bushing as necessary.
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Fig. 6: Exploded View of Power Steering Pump (Capri)

Courtesy of FORD MOTOR CO.
Reassembly (Capri)
1. Install pressure switch and pressure regulator valve (if removed). Lubricate and install a new shaft oil seal. Install front bracket and
bolts. Install pump shaft from front of body. Install rotor onto rear of shaft in same position as removed.
2. Install shaft snap ring. Tap shaft on rear to seat snap ring onto rotor splined hole below rotor rear face. Install vanes in rotor with
rounded edges facing out. Install cam ring, center pump body and front "O" ring. Install rear pump body and "O" ring.
3. Install reservoir and "O" ring. Install short bolt into hole used by reservoir bracket. Install rear mount bracket. Rotate pulley to check for
smooth operation.
Disassembly (Festiva)
1. With pump removed from vehicle, secure pump in a soft-jawed vice. Remove nut and washer that secure high pressure line. Remove cap
screw and support bracket. Remove high pressure line. Remove return line attaching bolts. See Fig. 7
and Fig. 8 .

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