1991 FORD FESTIVA wheel

Fig. 6: Identification Label Locations

Courtesy of FORD MOTOR CO.
SERVICE LABOR TIMES
WHEEL & TIRE SPECIFICATIONS
TIRE INFLATION
Tire inflation pressure is listed on a decal attached to right door pillar.
WHEEL TIGHTENING
Tighten wheel lug bolts to 65-87 ft. lbs. (88-118 N.m). If wheels are equipped with locking type lug nuts, ALWAYS position the "keyed" nut
opposite the valve stem.
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
NOTE:For 1990 and newer vehicles, labor tim es are provided, where available, within appropriate SERVICE
INT ERVAL table in SCHEDULED SERVICES article.
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 COMPUT ER 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 COMPUT ER RELEARN PROCEDURES article in GENERAL INFORMAT ION
section.
CAUT ION: Before replacing a blown fuse, rem ove ignition key, turn off all lights and accessories to avoid
dam aging the electrical system . Be sure to use fuse with the correct indicated am perage rating. T he use
of an incorrect am perage rating fuse m ay result in a dangerous electrical system overload.
Page 5 of 9 MITCHELL 1 ARTICLE - MAINTENANCE INFORMATION 1988-93 MAINTENANCE Ford Motor Co. Maintenance Inform...
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ST EERING SYST EM - MANUAL
1991 ST EERING Ford Motor Co. - Steering - Manual Rack & Pinion
DESCRIPTION
Rack and pinion type steering is mounted on rubber insulators to the chassis bulkhead. Adjustment is provided for pinion gear preload. Pinion
shaft is coupled to steering shaft. Tie rods connect end of rack to steering knuckles.

Fig. 1: Exploded View of Manual Steering Gear Assembly

Courtesy of FORD MOTOR CO.
TROUBLE SHOOTING
Refer to TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL TROUBLE SHOOTING section.
ADJUSTMENTS
Necessary adjustments are made during reassembly procedure. See OVERHAUL .
REMOVAL & INSTALLATION
STEERING GEAR
Removal
1. Raise and support vehicle. Remove front wheels. Remove vehicle battery. Remove cotter pins and castle nuts from tie rod ends. Using
tie rod puller, separate tie rod ends from steering knuckles. Remove the catalytic converter.
2. Remove plastic splash shield from right side lower inner fender panel. Mark the lower steering column "U" joint for reassembly
reference and disconnect steering column and intermediate shaft. Remove steering gear bracket bolts. Lower steering gear until steering
shaft is clear of column boot.
3. Slide steering gear to the right, through the inner fender tie rod opening until the left tie rod clears the left fender opening. Lower left
side of steering gear until it can be removed from the left side. Ensure rack boots are not pinched or damaged during removal.
Installation
To install, reverse removal procedure. Check and adjust toe-in. See WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in
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the WHEEL ALIGNMENT section.
OVERHAUL
STEERING GEAR
Disassembly
1. With steering gear removed from vehicle, place steering gear in a soft-jawed vise. Mark threaded portion of tie rod for reassembly.
Remove tie rod ends. Remove tie rod boots. Remove lock pins from both ends of rack. See Fig. 1
.
2. Remove tie rod ball socket from end of rack. Remove both tie rods. Remove lock nut from yoke plug. Remove yoke plug, spring and
yoke support. Use a small screwdriver to remove pinion oil seal from pinion shaft. Remove pinion bearing snap ring.
3. Remove pinion and bearing assembly. If necessary use Valve Body Puller (T78P-3504-B) to remove pinion and bearing assembly.
Remove rack from pinion side of housing. If lower pinion bearing needs replacing, use Blind Hole Bearing Puller (D80L-100-L) and
Slide Hammer (T50T-100-A) to remove.
4. Press bushing lock tabs into the 3 slots located at end of rack housing. Use Blind Hole Bearing Puller (D80L-100-L), to remove rack
support bushing from right end of rack housing.
Inspection
1. Check rubber boots, ball bearings and tooth surface of rack for wear or damage. Using a dial indicator and "V" blocks, check rack for
straightness. Maximum allowable runout is 0.012" (0.3 mm). If rack support bushings are worn, use a screwdriver to release the tab lock
on the side opposite the pinion. Use blind hole Bearing Puller (D80L-100R) with slide hammer to remove bushing.
2. Check tie rod ball joints for smooth operation. Replace parts as necessary. Check sliding surface of rack support and gear housing for
cracks or damage. Check rack bushing for excessive wear. Replace entire gear housing assembly if any of these parts are worn or
damaged.
Reassembly
1. Apply lithium grease to ball bearing, roller bearing, inside of gear housing, lip of oil seal, sliding surface and back of rack support,
sliding surface of rack bushing, rack pinion teeth and ball joints. Install rack support bushing into right end of rack housing. Ensure lock
tabs engage with slots in housing.
2. If previously removed, install a new lower pinion bearing using a bushing installer or a piece of wooden dowel stock. Carefully insert
non-toothed side of rack into left end of rack housing, with rack teeth facing pinion bore. Position rack in housing so rack protrudes
2.4" (62 mm) from the left side of housing. Install pinion and upper bearing assembly so that when bearing is seated, notch (for "U" joint
clamp bolt) in pinion splines forms a 35-55 degree angle with the centerline of the housing. See Fig. 2
.

Fig. 2: Removing & Installing Rack Components

Courtesy of FORD MOTOR CO.
3. Install snap ring and spacer, with beveled side of snap ring facing upward (toward oil seal). Install oil seal spacer with tab side down,
locating tab in snap ring gap. Protect pinion shaft splines with tape. Coat tape with a thin coat of grease and install new seal. Using a soft
hammer, tap lightly on seal until it is flush with end surface of housing. Remove protective tape.
4. Mount rack in a soft-jawed vise and install new lock tabs and tie rods. Tighten tie rod with a "crows foot" wrench to 44-58 ft. lbs. (59-
78 N.m). Use a center punch to stake lock tabs washer in 2 places. Slide tie rod boot over tie rod and position on rack. Secure with
mechanic's tie wire. Install other boot and other boot clamps.
5. Center rack so that tie rods are equally extended. Grease rack support yoke. Install rack support yoke, spacer and spring in housing.
Apply sealer to adjusting cover (yoke plug) threads and install in housing. Install adjusting bolt and lock nut.
6. Tighten adjusting cover to 80-97 INCH lbs. (9-11 N.m). Slowly cycle rack back and forth 5 times through 90 percent of its full stroke.
Center rack so tie rods are equally extended. Loosen adjusting cover and retighten to 22-30 INCH lbs. (2.5-3.4 N.m). Using a spring pull
scale, measure force needed to turn pinion 180 degrees from center rack position.
7. Adjust pinion to position where most force was needed to turn it. Tighten adjusting cover to 48 INCH lbs. (5.4 N.m), then back off 5-10
degrees. Hold adjusting bolt with a wrench and tighten the lock nut with a "crows foot" to 29-36 ft. lbs. (39-49 N.m). 8) To comp l et e
reassembly, reverse disassembly procedure. Install tie rod ends and jam nuts. Ensure index marks align. See Fig. 1
. CAUT ION: If rack is taken out of wrong side, dam age m ay result to rack bushing.
NOTE:If fit between housing and bearing is too tight, strike outer ring of bearing lightly while checking
m esh of rack and pinion.
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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. 7: Power Steering Pump Mounting & Pressure Hose (Festiva)
Courtesy of FORD MOTOR CO.

Fig. 8: Exploded View of Power Steering Pump (Festiva)

Courtesy of FORD MOTOR CO.
2. Remove return line and "O" ring. Remove pulley nut and washer. Remove pulley using Pulley Remover (OTC-1024). Remove keyway,
front bracket bolts and washers. Remove front bracket, rear bracket bolts and washers and rear bracket. Remove rear body bolts and
washers. Remove rear body. Remove shaft retaining ring. Remove shaft and rotor.
3. Remove vanes, "O" ring, and center body. Remove "O" ring and cam ring. Remove seal using Collet (D80L-100-Q) and Slide Hammer
( T5 0 T- 1 0 0 - A) . R e mo ve va l ve fit t in g. R e mo ve 4 "O" r in gs fr o m va l ve fit t in g. R e mo ve c o n t r o l va l ve , sp r in g, p r e ssu r e swit c h fit t ing a n d
spring. Remove "O" ring from pressure switch fitting. Remove spring seat. Remove plunger.
Reassembly (Festiva)
1. Coat pump vanes, rotor and control valve with ATF. Install new "O" ring on pressure switch fitting. Install plunger, spring seat, spring
and pressure switch fitting. Install new "O" rings on valve fitting. Install spring, control valve and valve fitting. Coat lip of new seal with
grease and install seal using suitable installer.
2. Install cam ring, new "O"ring, center body, new "O" ring and rotor. Ensure rounded edge of vanes face toward center of rotor. In st al l
vanes, shaft and retaining ring. Position rear body and install washers and bolts. Position rear bracket and install washers and bolts.
Position front bracket and install washers and bolts.
3. Position key in keyway and install pulley. Install pulley washer and nut. Tighten nut to 22-29 ft. lbs. (29-39 N.m). Install new "O" ring
at return line port. Position high pressure line and install support bracket and cap screw. Install high pressure line attaching washer and
nut. Tighten to 29-36 ft. lbs. (39-49 N.m).
4. Ensure pump rotates freely. If not, disassemble and repair as necessary. Install pump on vehicle. Bleed air from hydraulic system before
starting engine. See HYDRAULIC FLUID BLEEDING
under LUBRICATION.
WHEEL ALIGNMENT
After performing appropriate service procedures, refer to WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in the
WHEEL ALIGNMENT section.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
ApplicationFt. Lbs. (N.m)
Pinion Cover Lock Nut29-36 (40-50)
Pinion Shaft Nut29-36 (39-49)
Power Steering Pump Bracket27-38 (37-52)
Power Steering Lock Nut32-45 (43-61)
Tie Rod-To-Rack44-58 (60-80)
Tie Rod-To-Steering Knuckle26-29 (35-40)
Valve Body Cover Lock Nut29-36 (40-50)
Wheel Lug Nut67-88 (90-120)
INCH Lbs.
Pinion Bearing Cover39-47 (4.5-5.5)
ApplicationFt. Lbs. (N.m)
Intermediate Shaft Clamp Bolt13-20 (18-26)
Pinion Adjusting Plug Lock Nut36-43 (49-59)
Pressure Hose Fitting29-36 (39-49)
Power Steering Pump Lock Nut27-38 (37-52)
Power Steering Pump Mounting Bolt27-40 (36-54)
Steer Gear Mount Bolts23-34 (32-47)
Tie Rod-To-Steering Knuckle22-33 (30-45)
Page 8 of 9 MITCHELL 1 ARTICLE - STEERING SYSTEM - POWER 1991-92 STEERING Ford Motor Co. - Steering - Power Rack & Pi
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ST EERING COLUMN
1991 ST EERING Ford Motor Co. - Steering Colum ns
DESCRIPTION
The steering column assembly consists of a steering shaft, steering shaft tube, upper and lower bearings, mounting brackets, ignition lock and
combination switch assembly.

Fig. 1: Exploded View of External Steering Column Assembly (Typical)

Courtesy of FORD MOTOR CO.
TROUBLE SHOOTING
Refer to TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL TROUBLE SHOOTING section.
REMOVAL & INSTALLATION
STEERING WHEEL & HORN PAD
Removal & Installation (Capri)
1. 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. Remove 4 mount nuts from back of steering wheel and remove air bag module.
2. Disconnect air bag module connector. Loosen steering wheel nut 4-6 turns. Using Steering Wheel Remover (T67L-3600-A), remove
steering wheel. To install, reverse removal procedure.
Removal & Installation (Festiva)
Remove 2 screws from back of steering wheel. Disconnect horn wire and remove cover. Remove steering wheel retaining nut. Mark steering
wheel and steering shaft. Using Steering Wheel Remover (T67L-3600-A), remove steering wheel. To install, reverse removal procedure.
COMBINATION SW ITCH NOTE:Steering colum n is not repairable and m ust be replaced as a unit.
WARNING:On m odels with Supplem ental Restraint System (SRS), observe the following precautions. Before any
repairs are perform ed, disconnect and shield battery ground cable and air bag back-up power supply.
Back-up power supply is a Blue rectangular unit located behind glove box, attached to instrum ent
panel.
CAUT ION: DO NOT use a knock-off type steering wheel puller or strike steering wheel or shaft with a
ham m er. Sudden im pact could dam age a bearing or begin to collapse steering colum n.
Page 1 of 4 MITCHELL 1 ARTICLE - STEERING COLUMN 1991 STEERING Ford Motor Co. - Steering Columns
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