1991 FORD FESTIVA flat tire

If temperature gauge always reads hot, check these items:
Check for temperature gauge wire shorted to ground.
Check for defective temperature sender.
Check for defective temperature gauge.
Check for defective instrument panel voltage regulator (Festiva).
Temperature Gauge Inaccurate
If temperature gauge is inaccurate, check these items:
Check for faulty (loose or corroded) wire connections.
Check for defective temperature sender.
Check for defective instrument panel voltage regulator (Festiva).
SPEEDOMETER
Speedometer Does Not Operate
If speedometer does not operate, check these items:
Check for broken speedometer drive cable.
Check for broken drive gear in transmission.
Check for defective speedometer head.
Speedometer Needle Bounces
If speedometer needle bounces, check these items:
Check for binding speedometer drive cable.
Check for missing teeth on drive gear in transmission.
Check for defective speedometer head.
Speedometer Does Not Indicate Correct Vehicle Speed
If speedometer does not indicate correct vehicle speed, check these items:
Check for incorrect size tires.
Check for improper tire inflation.
Check for defective speedometer head.
TACHOMETER (CAPRI)
Tachometer Does Not Work, But All Other Gauges Work Properly
-If tachometer does not work, but all other gauges function properly, check these items:
Check for defective tachometer.
Check for open Yellow/Black tachometer signal wire from ignition coil to instrument panel.
Check for faulty Black ground wire to instrument panel.
Tachometer & All Gauges Do Not Function
If tachometer and all other gauges do not function properly, check these items:
Check for blown 10-amp METER fuse in fuse panel.
Check for open in Black/Yellow wire to fuse panel to instrument panel and Black/White wire from ignition switch to fuse panel
Tachometer Reading Low
If tachometer reading is lower than normal, check these items:
Check for defective tachometer.
Check for faulty Black ground wire at instrument panel.
TURBO BOOST GAUGE (CAPRI)
Turbo Boost Gauge Always Reads Low
If turbo boost gauge always reads low, check these items:
Check boost gauge for open or damaged wires.
Check for defective boost sensing unit.
Check for defective boost gauge.
Check for blown 10-amp METER fuse in fuse panel.
Check for loose or corroded connections.
Page 2 of 5 MITCHELL 1 ARTICLE - INSTRUMENT PANEL 1991 ACCESSORIES & SAFETY EQUIPMENT Ford Motor Co. Switches
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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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DRIVE AXLE - NOISE DIAGNOSIS
Unrelated Noises
Some driveline trouble symptoms are also common to the engine, transmission, wheel bearings, tires, and other parts of the vehicle. Ensure
cause of trouble actually is in the drive axle before adjusting, repairing, or replacing any of its parts.
Non-Drive Axle Noises
A few conditions can sound just like drive axle noise and have to be considered in pre-diagnosis. The 4 most common noises are exhaust, tires,
CV/universal joints and wheel trim rings.
In certain conditions, the pitch of the exhaust gases may e gear whine. At other times, it may be mistaken for a wheel bearing rumble.
Tires, especially radial and snow, can have a high-pitched tread whine or roar, similar to gear noise. Also, some non-standard tires with an
unusual tread construction may emit a roar or whine.
Defective CV/universal joints may cause clicking noises or excessive driveline play that can be improperly diagnosed as drive axle problems.
Trim and moldings also can cause a whistling or whining noise. Ensure none of these components are causing the noise before disassembling
the drive axle.
Gear Noise
Broken clutch return springReplace return spring
Worn splines on clutch disc or input shaftReplace clutch disc and/or input
shaft
Worn clutch release bearingReplace release bearing
Dry or worn pilot bearingLubricate or replace pilot bearing
Unequal release lever contactAlign or replace release lever
Incorrect pedal free playAdjust free play
Warped or damaged clutch discReplace damaged components
Slipping
Pressure springs worn orRelease pressure plate
Oily, greasy or worn facingsClean or replace clutch disc
Incorrect clutch alignmentRealign clutch assembly
Warped clutch disc or pressure plateReplace damaged components
Binding release levers or clutch pedalLubricate and/or replace release
components
Squeaking
Worn or damaged releaseReplace release bearing
Dry or worn pilot or release bearingLubricate or replace assembly
Pilot bearing turning in crankshaftReplace pilot bearing and/or
crankshaft
Worn input shaft bearingReplace bearing and seal
Incorrect transmission alignmentRealign transmission
Dry release fork between pivotLubricate release fork and pivot
Heavy and/or Stiff Pedal
Sticking release bearing sleeveReplace release bearing and/or
sleeve
Dry or binding clutch pedal hubLubricate and align components
Floor mat interference with pedalLay mat flat in proper area
Dry or binding ball/fork pivotsLubricate and align components
Faulty clutch cableReplace clutch cable
Noisy Clutch Pedal
Faulty interlock switchReplace interlock switch
Self-adjuster ratchet noiseLubricate or replace self-adjuster
Speed control interlock switchLubricate or replace interlock
switch
Clutch Pedal Sticks Down
Binding clutch cableSee CLUTCH article
Springs weak in pressure plateReplace pressure plate
Binding in clutch linkageLubricate and free linkage
Noisy
Dry release bearingLubricate or replace release
bearing
Dry or worn pilot bearingLubricate or replace bearing
Worn input shaft bearingReplace bearing
Transmission Click
Weak springs in pressureReplace pressure plate plate
Release fork loose on ball studReplace release fork and/or
ball stud
Oil on clutch disc damperReplace clutch disc
Broken spring in slave cylinderReplace slave cylinder
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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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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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Mismatched tiresSee WHEEL ALIGNMENT
Broken or sagging springSee SUSPENSION section
Broken torsion barSee SUSPENSION section
Power steering valve not centeredSee STEERING section
Front alignment out of toleranceSee WHEEL ALIGNMENT
section
Defective wheel bearingSee WHEEL BEARINGS in
SUSPENSION section
Uneven sway bar linksSee SUSPENSION section
Frame bentCheck for frame damage
Steering system bushing wornSee STEERING section
Hard Steering
Idler arm bushing too tightSee STEERING LINKAGE in
STEERING section
Ball joint tight or seizedSee SUSPENSION section
Steering linkage too tightSee STEERING LINKAGE in
STEERING section
Power steering fluid lowAdd proper amount of fluid
Power steering drive belt looseSee STEERING section
Power steering pump defectiveSee STEERING section
Steering gear out of adjustmentSee STEERING section
Incorrect wheel alignmentSee WHEEL ALIGNMENT
Damaged steering gearSee STEERING section
Damaged suspensionSee SUSPENSION section
Bent steering knuckle or supportsSee SUSPENSION section
Vehicle "Wanders"
Strut rod or control arm bushing wornSee SUSPENSION section
Loose or worn wheel bearingsSee WHEEL BEARINGS in
SUSPENSION section
Improper tire inflationCheck tire pressure
Stabilizer bar missing or defectiveSee SUSPENSION section
Wheel alignment out of toleranceSee Adjustment in WHEEL
ALIGNMENT section
Broken springSee SUSPENSION section
Defective shock absorberReplace shock absorbers
Worn steering & suspension componentsSee SUSPENSION section
Front End Shimmy
Tire out of balance/roundCheck tire balance
Excessive wheel runoutSee WHEEL ALIGNMENT
Insufficient or improper casterSee WHEEL ALIGNMENT
section
Worn suspension or steering componentsSee SUSPENSION section
Defective shock absorbersReplace shock absorber
Wheel bearings worn or looseSee WHEEL BEARING ADJ.
in SUSPENSION section
Power steering reaction Bracket looseSee STEERING section
Steering gear box (rack) mounting looseSee STEERING section
Steering gear adjustment looseSee STEERING section
Worn spherical jointsSee SUSPENSION section
Toe-In Not Adjustable
Lower control arm bentSee SUSPENSION section
Frame bentCheck frame for damage
Camber Not Adjustable
Control arm bentSee SUSPENSION section
Frame bentCheck frame for damage
Hub & bearing not seated properlySee SUSPENSION section
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00027342
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GENERAL INFORMATION
Wheel Alignm ent T heory & Operation
* PLEASE READ THIS FIRST *
PRE-ALIGNMENT INSTRUCTIONS
GENERAL ALIGNMENT CHECKS
Before adjusting wheel alignment, check the following:
Each axle uses tires of same construction and tread style, equal in tread wear and overall diameter. Verify that radial and axial runout is
not excessive. Inflation should be at manufacturer's specifications.
Steering linkage and suspension must not have excessive play. Check for wear in tie rod ends and ball joints. Springs must not be
sagging. Control arm and strut rod bushings must not have excessive play. See Fig. 1
.

Fig. 1: Checking Steering Linkage

Vehicle must be on level floor with full fuel tank, no passenger load, spare tire in place and no load in trunk. Bounce front and rear end
of vehicle several times. Confirm vehicle is at normal riding height.
Steering wheel must be centered with wheels in straight ahead position. If required, shorten one tie rod adjusting sleeve and lengthen
opposite sleeve (equal amount of turns). See Fig. 2
.
Wheel bearings should have the correct preload and lug nuts must be tightened to manufacturer's specifications. Adjust camber, caster
and toe-in using this sequence. Follow instructions of the alignment equipment manufacturer. NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. For m odel-specific inform ation see appropriate articles where
available.
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. For m odel-specific inform ation see appropriate articles where
available.
CAUT ION: DO NOT attem pt to correct alignm ent by straightening parts. Dam aged parts MUST be replaced.
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A/C SYST EM PRECAUT IONS
A/C GENERAL SERVICING A/C System Servicing cautions
BEFORE OPENING THE SYSTEM
Before disconnecting any lines or fittings, the system must be completely discharged using approved refrigerant recovery/recycling equipment.
DISCHARGING A/C SYSTEM
1. Remove service valve caps and install gauges. For high side gauge hose, Adapter (D81L-19703-A) must be used to connect to high side
service valve.
2. Place open end of center hose in garage exhaust outlet or in a well ventilated area. Slightly open low side gauge valve and let refrigerant
escape slowly without loosing refrigerant oil.
3. When system is nearly discharged, using approved refrigerant recovery/recycling equipment, open high side gauge valve to release any
pressure trapped in compressor. Close valves immediately after discharging to prevent entry of moisture.
DISCONNECTING LINES & FITTINGS
1. After system is discharged, using approved refrigerant recovery/recycling equipment, carefully clean entire area around coupling nut to
prevent dirt entering system. Always use two wrenches to avoid twisting or distorting lines and fittings (hold fitting with one wrench
while loosening coupling nut with second wrench).
2. Ford spring-coupling fittings require a special coupling tool (Motorcraft YT-1056) to open or close. See procedure under Connecting
Lines and Fittings.
3. Cap or plug all LINES and FITTINGS immediately to prevent entry of air and moisture into system. Do not remove these caps until
connections are being made.
COMPONENT REPLACEMENT
When components are replaced, system oil level must be adjusted. Add refrigeration oil to replacement component. See Compressor oil Check
article, as well as COMPONENT OIL REPLACEMENT QUANTITIES chart under A/C SYSTEM SPECS article in this section.
USING R-12 REFRIGERANT - SAFETY PRECAUTIONS
1. Always work in a well-ventilated, clean area. Refrigerant (R-12) is heavier than oxygen, and will displace oxygen in a confined area.
Always wear eye protection when working around air conditioning systems and R-12. The system's high pressure can cause severe injury
to eyes and skin if a hose were to burst. R-12 evaporates quickly when exposed to atmosphere, freezing anything it contacts.
2. Use care when handling refrigerant containers. DO NOT drop or strike containers or expose refrigerant containers to excessive heat.
Containers must never be heated more than 125°F (52°C). Never expose R-12 directly to open flame.
USING INDIVIDUAL R-12 CANS
Disposable refrigerant cans (referred to as one pound cans) have a flat type seal or a screw type seal, and proper can tap must be used for each
type. Be sure sealing gasket on can tap is in good condition. A proper safety can tap will prevent refrigerant from flowing back into open can,
as tap has a one-way flow control.
MULTI-CAN DISPENSING VALVES
A multi-can dispensing valve allows attachment of several cans of refrigerant, and is a good substitute when a bulk container is not available.
Cans are installed onto each leg of multi-can dispensing valve in the same manner as the individual cans, and each leg has its own can tap.
CAN TAP INSTALLATION FLAT TYPE SEAL CANS
On cam-lock or one-piece can taps, first turn the handle outward to the fully open position. Securely engage locking lugs over the can flange,
and lock them in place by turning cam lock or locking nut. Screw tap assembly into adapter so sealing gasket is fully seated against the can
top. Turn tap inward to pierce the can and close the tap. DO NOT open tap until ready to purge the service hose or dispense refrigerant into
the system.
On 2-piece can taps, be certain tap handle is turned fully inward to the closed position. Check that locking base is turned to its outer limit.
Securely engage locking lugs over the can flange. Turn entire tap assembly (without disturbing the closed setting) downward into the locking
base to pierce the can. DO NOT open tap until ready to dispense into system. CAUT ION: When discharging air conditioning system , use only approved refrigerant recovery/recycling
equipm ent. Make every attem pt to avoid discharging refrigerant into the atm osphere.
NOTE:Recent findings by the EPA indicate that R-11, R-12 and R-113 are harm ful to the Earths' protective
Ozone layer. Make every attem pt possible, to avoid discharging R-11, R-12 or R-113 into the
atm osphere.
CAUT ION: When R-12 is exposed to an open flam e, drawn into a running engine, or detected with a Halide
(propane) leak tester, poisonous phosgene gas is form ed. Keep work areas ventilated and avoid
running engines near work area.
NOTE:Recent findings by the EPA indicate that refrigerant is harm ful to the Earth's protective Ozone layer.
When discharging refrigerant avoid allowing refrigerant to enter the atm osphere. Refrigerant recovery
system should be used when discharging the system .
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