1991 FORD FESTIVA brake pads

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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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.
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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.
Page 2 of 3 MITCHELL 1 ARTICLE - FUSES & CIRCUIT BREAKERS Fuses & Circuit Breakers 1988-93 Festiva
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BRAKES
BRAKE SYSTEM TROUBLE SHOOTING
BRAKE SYSTEM TROUBLE SHOOTING CHART
CONDITIONPOSSIBLE CAUSE
Insufficient, Erratic, or No HeatLow Coolant Level
.....Incorrect thermostat.
.....Restricted coolant flow through core.
.....Heater hoses plugged.
.....Misadjusted control cable.
.....Sticking heater control valve.
.....Vacuum hose leaking.
.....Vacuum hose blocked.
.....Vacuum motors inoperative.
.....Blocked air inlet.
.....Inoperative heater blower motor.
.....Oil residue on heater core fins.
.....Dirt on heater core fins.
Too Much HeatImproperly adjusted cables.
.....Sticking heater control valve.
.....No vacuum to heater control valve.
.....Temperature door stuck open.
Air Flow Changes During AccelerationVacuum system leak.
.....Bad check valve or reservoir.
Air From Defroster At All TimesVacuum system leak.
.....Improperly adjusted control cables.
.....Inoperative vacuum motor.
Blower Does Not Operate CorrectlyBlown fuse.
.....Blower motor windings open.
.....Resistors burned out.
.....Motor ground connection loose.
.....Wiring harness connections loose.
.....Blower motor switch inoperative.
.....Blower relay inoperative.
.....Fan binding or foreign object in housing.
.....Fan blades broken or bent.
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
Brakes Pull Left or Right
Incorrect tire pressureInflate tires to proper pressure
Front end out of alignmentSee WHEEL ALIGNMENT
Mismatched tiresCheck tires sizes
Restricted brake lines or hosesCheck hose routing
Loose or malfunctioning caliperSee DISC BRAKES or
BRAKE SYSTEM
Bent shoe or oily liningsSee DRUM BRAKES or
BRAKE SYSTEM
Malfunctioning rear brakesSee DRUM, DISC BRAKES
or BRAKE SYSTEM
Loose suspension partsSee SUSPENSION
Noises Without Brakes Applied
Front linings worn outReplace linings
Dust or oil on drums or rotorsSee DRUM, DISC BRAKES
or BRAKE SYSTEM
Noises With Brakes Applied
Insulator on outboard shoe damagedSee DISC BRAKES or
BRAKE SYSTEM
Incorrect pads or liningsReplace pads or linings
Brake Rough, Chatters or Pulsates
Excessive lateral runoutCheck rotor runout
Parallelism not to specificationsReface or replace rotor
Wheel bearings not adjustedSee SUSPENSION
Rear drums out-of-roundReface or replace drums
Disc pad reversed, steel against rotorRemove and reinstall pad
Excessive Pedal Effort
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ENGINE MECHANICAL
COOLING SYSTEM TROUBLE SHOOTING
COOLING SYSTEM TROUBLE SHOOTING
Malfunctioning power unitSee POWER BRAKES or
BRAKE SYSTEM
Partial system failureCheck fluid and pipes
Worn disc pad or liningReplace pad or lining
Caliper piston stuck or sluggishSee DISC BRAKES or
BRAKE SYSTEM
Master cylinder piston stuckSee MASTER CYLINDERS
or BRAKE SYSTEM
Brake fade due to incorrect pads for liningsReplace pads or linings
Linings or pads glazedReplace pads or linings
Worn drumsReface or replace drums
Excessive Pedal Travel
Partial brake system failureCheck fluid and pipes
Insufficient fluid in master cylinderSee MASTER CYLINDERS
or BRAKE SYSTEM
Air trapped in systemSee BRAKE BLEEDING or
BRAKE SYSTEM
Rear brakes not adjustedSee Adjustments in DRUM
BRAKES or BRAKE
SYSTEM
Bent shoe or liningSee DRUM BRAKES or
BRAKE SYSTEM
Plugged master cylinder capSee MASTER CYLINDERS
or BRAKE SYSTEM
Improper brake fluidReplace brake fluid
Pedal Travel Decreasing
Compensating port pluggedSee MASTER CYLINDERS
or BRAKE SYSTEM
Swollen cup in master cylinderSee MASTER CYLINDERS
or BRAKE SYSTEM
Master cylinder piston not returningSee MASTER CYLINDERS
or BRAKE SYSTEM
Weak shoe retracting springsSee DRUM BRAKES BRAKE
SYSTEM
Wheel cylinder piston stickingSee DRUM BRAKES or
BRAKE SYSTEM
Dragging Brakes
Master cylinder pistons not returningSee MASTER CYLINDERS
BRAKE SYSTEM
Restricted brake lines or hosesCheck line routing
Incorrect parking brake adjustmentSee DRUM BRAKES BRAKE
SYSTEM
Parking Brake cables frozenSee DRUM BRAKES BRAKE
SYSTEM
Incorrect installation of inboard disc padRemove and replace correctly
Power booster output rod too longSee POWER BRAKE UNITS
BRAKE SYSTEM
Brake pedal not returning freelySee DISC, DRUM BRAKES
BRAKE SYSTEM
Brakes Grab or Uneven Braking Action
Malfunction of combination valveSee CONTROL VALVE or
BRAKE SYSTEM
Malfunction of power brake unitSee POWER BRAKE UNITS
or BRAKE SYSTEM
Binding brake pedalSee DISC, DRUM BRAKES
or BRAKE SYSTEM
Pulsation or Roughness
Uneven pad wear caused by caliperSee DISC BRAKES or
BRAKE SYSTEM
Uneven rotor wearSee DISC BRAKES or
BRAKE SYSTEM
Drums out-of-roundReface or replace drums
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
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BRAKE PAD WEAR INDICATOR
CATALYTIC CONVERTER
COOLANT (PROPYLENE-GLYCOL FORMULATIONS)
ELECTROSTATIC DISCHARGE SENSITIVE (ESD) PARTS
ENGINE OIL
FUEL PUMP SHUTOFF SWITCH
This switch stops flow of fuel to engine after a collision. The impact does not have to be great for switch to be triggered. Switch must be reset
after collision. Switch is located under left rear speaker in luggage compartment. Press button to reset switch.
FUEL SYSTEM SERVICE
HALOGEN BULBS
PASSIVE RESTRAINTS
RADIATOR CAP
RADIATOR FAN
WARRANTY INFORMATION
BASIC NEW CAR LIMITED WARRANTY
All parts of the vehicle, except tires, are covered against defects in factory-supplied materials and workmanship for 12 months or 12,000 miles, CAUT ION: Indicator will cause a squealing or scraping noise, warning that brake pads need replacem ent.
CAUT ION: Continued operation of vehicle with a severe m alfunction could cause converter to overheat, resulting
in possible dam age to converter and vehicle.
CAUT ION: T o avoid possible dam age to vehicle use only ethylene-glycol based coolants with a m ixture ratio from
44-68% anti-freeze. DO NOT use 100% anti-freeze as it will cause the form ation of cooling system
deposits. T his results in coolant tem peratures of over 300° F (149°C) which can m elt plastics. 100% anti-
freeze has a freeze point of only -8° F (-22°C).
CAUT ION: Propylene-Glycol Mixtures has a sm aller tem perature range than Ethylene-Glycol. T he tem perature
range (freeze-boil) of a 50/50 Anti-Freeze/Water Mix is as follows: Propylene-Glycol -26° F (-32°C) - 257° F
(125°C) Ethylene-Glycol -35° F (-37°C) - 263° F (128°C)
CAUT ION: Propylene-Glycol/Ethylene-Glycol Mixtures can cause the destabilization of various corrosion inhibitors.
Also Propylene-Glycol/Ethylene-Glycol has a different specific gravity than Ethylene-Glycol coolant,
which will result in inaccurate freeze point calculations.
WARNING:Many solid state electrical com ponents can be dam aged by static electricity (ESD). Som e will display a
warning label, but m any will not. Discharge personal static electricity by touching a m etal ground point
on the vehicle prior to servicing any ESD sensitive com ponent.
CAUT ION: Never use non-detergent or straight m ineral oil.
WARNING:Relieve fuel system pressure prior to servicing any fuel system com ponent (fuel injection m odels).
WARNING:Halogen bulbs contain pressurized gas which m ay explode if overheated. DO NOT touch glass portion
of bulb with bare hands. Eye protection should be worn when handling or working around halogen
bulbs.
CAUT ION: Before operating vehicle, securely fasten passive shoulder restraints to the em ergency release buckles.
T he buckle fits in only one way. Ensure to position it properly.
CAUT ION: Always disconnect the fan m otor when working near the radiator fan. T he fan is tem perature controlled
and could start at any tim e even when the ignition key is in the OFF position. DO NOT loosen or rem ove
radiator cap when cooling system is hot.
WARNING:Keep hands away from radiator fan. Fan is controlled by a therm ostatic switch which m ay com e on or
run for up to 15 m inutes even after engine is turned off.
CAUT ION: Due to the different warranties offered in various regions and the variety of after-m arket extended
warranties available, please refer to the warranty package that cam e with the vehicle to verify all
warranty options.
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whichever occurs first.
POWERTRAIN WARRANTY
Under this warranty, certain parts of the engine, transmission, axle and driveline are warranted against defects in materials and workmanship
for either 4 years/50,000 or 6 years/60,000 miles, depending on the model year. This coverage begins after 12 months or 12,000 miles. See
copy of warranty for specific components covered and length of coverage.
BUMPER-TO-BUMPER COVERAGE
All 1992-93 vehicles have complete warranty coverage against defects in materials and workmanship for 3 years or 36,000 miles, whichever
occurs first. There is no deductible with this warranty. Items not covered include tires and parts that are subject to normal wear and tear, such
as windshield wiper blades, brake linings, brake pads, clutch linings and scheduled maintenance items. There is no extended powertrain
coverage included in this warranty.
BATTERY COVERAGE
Begins at warranty start date and lasts up to 3 years or 36,000 miles, whichever occurs first. For the first 12 months in service (less than
36,000 miles), battery will be replaced at no charge. After that, battery will be replaced on a customer-participation basis: For the 13th-24th
month in service, Ford will pay 50%; for the 25th-36th month, Ford will pay 25%. Labor is covered for 3 years or 36,000 miles, whichever
occurs first.
SAFETY RESTRAINT SYSTEM COVERAGE
Begins at warranty start date and lasts for 5 years or 50,000 miles, whichever occurs first. Covers safety restraint problems not related to
comfort or appearance. Coverage for model years earlier than 1990 is 3 years with unlimited miles.
CORROSION COVERAGE
Begins at warranty start date and lasts for 6 years or 60,000 miles, whichever occurs first. 1992-93 models are covered for 6 years or 100,000
miles, whichever occurs first. Covers any holes in body sheet metal caused by corrosion.
EMISSIONS DEFECT & PERFORMANCE WARRANTIES (EXCEPT CALIFORNIA)
Defect Warranty ensures that vehicle meets applicable EPA regulations and that vehicle's emission control system is free from defects in
materials and workmanship for a period of 5 years or 50,000 miles, whichever occurs first.
The Performance Warranty covers all costs of repairing or adjusting any components or parts as needed for the vehicle to pass a Federally
required state or local emissions test.
Other emission control parts related to these components are covered by the Performance Warranty, where applicable. If another part fails due
to the failure of one of these components, both parts are covered. See customer's copy of warranty information for specific items co vered .
Performance Warranty coverage is limited to fewer components after 2 years or 24,000 miles.
EMISSIONS PERFORMANCE WARRANTY (CALIFORNIA)
If vehicle fails a Smog Check inspection, all necessary repairs and adjustments will be made by manufacturer to ensure that vehicle passes the
inspection. Warranty begins at warranty start date and lasts for a period of 3 years or 50,000 miles, whichever occurs first.
EMISSIONS DEFECT WARRANTY (CALIFORNIA)
If any emission-related part on the vehicle is defective, the part will be repaired or replaced by manufacturer. Warranty begins at warranty start
date and lasts for a period of 3 years or 50,000 miles, whichever occurs first.
Some emission-related parts are warranted for 7 years or 70,000 miles whichever occurs first, and will be repaired or replaced by manufacturer
if found to be defective in material or workmanship. See customer's copy of warranty information for specific items covered.
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 NOTE:Powertrain Warranty varies in coverage length (4 years/50,000 m iles or 6 years/60,000 m iles) depending
on model year.
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