Ford Festiva. Instruction - part 11

Installation (All)

1. To install axle shaft, reverse removal procedure. Always install a NEW retaining circlip. Check seals at both ends of axle shaft. If

necessary, replace seals prior to installation. Lubricate transaxle seal lip with transaxle oil. See

Fig. 1

2. After installing axle shaft into transaxle, pull axle shaft outward by hand to ensure proper engagement of retaining circlip and snap ring.

Install axle shaft into wheel hub. Align suspension alignment marks and tighten nuts.

INTERMEDIATE SHAFT

Removal

Intermediate shaft and axle shaft are removed as an assembly. See

FWD AXLE SHAFTS

under REMOVAL, DISASSEMBLY,

REASSEMBLY & INSTALLATION.

Disassembly

Separate intermediate shaft from axle shaft. Remove circlip from intermediate shaft and press off bearing and bracket assembly. See

Fig. 4

Press bearing out of bracket. Inspect bracket for damage or wear and replace if necessary.

Reassembly

Press NEW bearing into bracket and install NEW seals. Install bearing and bracket assembly onto intermediate shaft. Install NEW circlip.
Assemble intermediate shaft to axle shaft.

Installation

Intermediate shaft and axle shaft are installed as an assembly. See

FWD AXLE SHAFTS

under REMOVAL, DISASSEMBLY,

REASSEMBLY & INSTALLATION.

Fig. 4: Exploded View Of Intermediate Shaft

Courtesy of FORD MOTOR CO.

TORQUE SPECIFICATIONS

NOTE:

Always install NEW cotter pin, washer and suspension lock nuts.

Application

Ft. Lbs. (N.m)

Axle Nut

(1)

116-173 (157-235)

Ball Joint Pinch Bolt

32-40 (43-54)

Steering Knuckle-To-Strut Bolt

69-86 (93-117)

Caliper Retaining Bolt

29-36 (39-49)

Stabilizer Bar Bracket Nut

40-50 (54-68)

Stabilizer Link Bolt

9-13 (12-18)

Tie Rod End Nut

21-32 (29-44)

Wheel Lug Nuts

66-89 (90-120)

(1)

Ensure locking flange on nut is staked into axle slot.

Article GUID: A00042994

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ALTERNATOR & REGULATOR

1991 ELECTRICAL Alternators & Regulators

DESCRIPTION

Mitsubishi alternator is a 50-amp, conventional 3-phase, self-rectifying type unit, containing 6 diodes (3 main diodes and a smaller diode trio)
and a case-mounted Integrated Circuit (IC) regulator. A charge indicator light in the instrument panel indicates charging system malfunctions.
See

Fig. 1

Fig. 1: Charging System Wiring Schematic

Courtesy of FORD MOTOR CO.

ADJUSTMENTS

BELT TENSION

BELT ADJUSTMENTS

(1)

ON-VEHICLE TESTING

ALTERNATOR OUTPUT

Application

New Belt

Used Belt

A/C & P/S Belts

110-125 (50-57)

92-110 (42-50)

Alt. Belt

110-130 (50-60)

95-110 (43-50)

(1)

Tension in Lbs. (Kg) Using Strand Tension Gauge

NOTE:

Before testing, check alternator wiring harness connections, drive belt tension and battery voltage.
Ensure battery cables and engine ground cable are clean and tight. Wait at least 30 seconds after
starting engine before measuring voltage.

CAUTION:

DO NOT start engine with "L" and "S" terminal connectors disconnected from alternator. DO NOT allow
"L" terminal to contact ground while engine is running. See

Fig. 2

Fig. 2: Identifying Alternator Test Terminals

Courtesy of FORD MOTOR CO.

1. Turn ignition switch to OFF position. Connect positive voltmeter lead wire to alternator "B" terminal and negative wire to ground. See

Fig. 2

. Ensure voltmeter indicates battery voltage. If voltmeter indicates zero volts, an open circuit exists in wire between "B" terminal

and battery positive terminal.

2. Remove voltmeter. Disconnect negative battery cable. Remove output lead from alternator terminal "B". Connect a 100-amp ammeter in

series between "B" terminal and disconnected output lead. Connect positive lead of ammeter to "B" terminal and negative lead to
disconnected output wire.

3. Connect voltmeter in parallel between alternator "B" terminal and battery positive terminal. Connect positive lead wire of voltmeter to

"B" terminal and negative lead wire to positive terminal of battery. Reconnect negative battery cable.

4. Install tachometer (if necessary) to monitor engine RPM. Start engine. Turn all lights and accessories on and depress brake pedal to load

system. Increase engine speed to 2500-3000 RPM. Ensure alternator output is at least 35 amps.

5. Observe voltmeter reading. If voltmeter indicates .2 volt and amperage output is at least 35 amps, system is okay. If voltage drop is

greater than .2 volt, wiring is defective between alternator "B" terminal and battery positive terminal.

6. Allow engine to idle. Turn off all accessories to remove load from system. Disconnect voltmeter. Connect negative lead of voltmeter to

ground. Using positive lead of voltmeter, backprobe "S" terminal connector at rear of alternator. See

Fig. 2

7. Increase engine speed to 2500-3000 RPM. With no load on system, ammeter should read 5 amps or more. Battery voltage with no load

at indicated speed should be 14.1-14.7 volts. If amperage output is less than indicated with or without load and no external faults exist
in alternator circuit, overhaul or replace alternator.

BENCH TESTING

Rotor

Check continuity across rotor slip rings. If no continuity exists, replace rotor. Check continuity between individual slip rings and rotor
core/shaft. If continuity exists, rotor coil or slip ring is grounded. Replace rotor.

Stator

Ensure no continuity exists between stator coil leads and stator core. Check continuity between leads of stator coil. If continuity does not
exist, replace stator.

Brushes

Inspect brushes. Replace brushes if worn to wear line (leading edge of small square cast into brush). Use a spring pressure gauge to push each
NEW brush into its holder until .079" (2 mm) projects from holder. Spring force should be 10.6-15.6 oz. (.3-.4 kg). If spring force is not
within specification, replace brush spring.

Rectifier

1. Using an ohmmeter, check for continuity between positive side of diode leads and heat sink. If no continuity exists from any positive

diode lead to heat sink, replace rectifier assembly.

2. Reverse ohmmeter leads, and check for continuity between negative side of diodes and heat sink. If continuity exists from any negative

diode lead to heat sink, replace rectifier assembly.

3. Check diode trio (smaller diodes between main diode leads) for continuity in both directions. Continuity should exist in one direction

only. If any diode shows continuity in both directions or does not show continuity in either direction, replace diode trio.

TROUBLE SHOOTING

OVERHAUL

Fig. 3: Exploded View of Mitsubishi Alternator

Courtesy of FORD MOTOR CO.

TORQUE SPECIFICATIONS

NOTE:

See TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL TROUBLE SHOOTING
section.

NOTE:

For exploded view of alternator, see

Fig. 3

Application

Ft. Lbs. (N.m)

Alternator Adjustment Bolt

14-18 (19-25)

Alternator Mount Bolt

27-38 (37-52)

Idler Pulley Attaching Nut

23-34 (31-46)

Power Steering Pump Adjustment Lock Nut

27-38 (37-52)

Power Steering Pump Mounting Bolt

27-40 (37-54)

Article GUID: A00058012

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