detailed assembly manual - Era Replica Automobiles
Contents
1. Use thin washer here SECTION B PARTS PREPARATION CONTROL ARMS Install a male right hand thread rod end onto each front lower radius arm so that the bushing center to rod end center distance is 16 Leave the jam nuts loose Install the steel brake lines onto the subframe Install the front lower radius arms onto the lower differential bracket as shown leaving the inner bolt loose Install the coil over damper onto the upper mount using a x 2 4 L bolt with flat washers and stover nut Install the coil over onto the lower arm spacers too tightening the top and bottom bolts Collar go YX ER li ro E Trailin la ln TE AA pe A IF LE 9 arp tbl aaa de i atri ga pa b a i a io IL Lower damper mount E Sway bar mount Se AIN Re en ee ae i ga w Toe in pe DI _ XxX Adjustment MB Connecting plates Thrust Washer Emergency brake cable fia man d rsasblyt Insert the thrust washers and inner bushings into the hub carrier assembly Lightly lubricate the inside with heavy grease silicone or moly base is best Install the hub carrier onto the front radius arm Loosely install the second bush half washer and castle nut Install the rear radius arm onto the hub carrier in the same manner Slide the other inside end into the bracket on the subframe and temporarily secure with a bolt Insert the 16 x s L bolts through the connecting plates Tighten2. hose 117
3. red and the nuts to 35 Ib ft If you ever need to remove the pins they will have to be heated to 300 deg to weaken the bond Excessive heat will weaken the pins Always grind the rotor after installing the wheel Early Design bearing races If you don t have a special driver for NEI the races let the auto machine shop install them Clean off the grinding dust thoroughly before putting grease in the hub and installing the bearings and inner seals Install the dust shields onto the steering knuckles if desired Install the hub onto the stub axle with a special tanged washer and castle nut 69 SECTION F MECHANICAL COMPONENTS With new wheel bearings torque the axle nut to 20 e Bolt the bar in place with the rubber urethane lb ft Loosen the nut and re torque to 15 lb inches bushes and clamps The ends slant up then tighten to the nearest cotter pin hole Install slightly toward the outside the cotter pin through the access hole in the side of e Install the connecting links between the tab on the pin drive hub the lower control arm and the pads on the ends Install the brake calipers and pads using new of the sway bar hardware kits Use silicone grease on all sliding e Tighten the link bolts so that the rubber bush surfaces expands to the diameter of the cupped washer Connect the brake line to the caliper using the Do not over tighten supplied banjo bolt and copper washer If you still get seepage
4. space saver See note on page 119 24 Dan Williams GT Performance Mustangs Unlimited GT Performance E R A Richmond Gear Ford dealer E R A Mustangs Unlimited auto parts supplier Auto parts supplier Dealer E R A Dealer E R A Mid sixties Ford E R A E R A 1965 67 Mustang and some other Ford cars of this period Ford dealer E R A has electronic regulators with the sam cover that the mechanical regulator NLA used E R A E R A Lucas parts dealer E R A E R A Lucas parts dealer Summit Racing others E R A PS Engineering SECTION B PARTS PREPARATION RADIATOR HOSES LOWER A single hose hose can be cut to function as the two connectors used between the radiator and water pump Cut and trim the hoses as shown as appropriate for the exit side of your water pump See page 89 for installation of the hoses FOR LEFT EXIT WATER PUMP Con tube radiator DISCARD Hose Gates 20390 FOR RIGHT EXIT WATER PUMP Con tube radiator End piece from end section of upper hose may fit better fia man b LWATHOSE UPPER 4 bbl and single outlet Weber manifold FOR 4BBL MANIFOLD ALUMINUM CONNECTOR TO THERMOSTAT HOUSING 70 e along oute CUTHERE CUT HERE n e 8 3 along ours b uwathosel Use a short neck thermostat housing 20 up on the intake manifold Cut and trim the hose as shown Weber Manifold two outlets Use a drilled freeze plug in the upper hose
5. suspension assembly into position with a floor jack guiding the forward ends of both trailing arms into the brackets on the sides of the frame Lubricate the insides of the upper chassis brackets with lithium grease so that the sides of the rubber bushing will slide into them Guide the suspension assembly into the chassis brackets Using a little light oil on the threads install the bolts with flat washers but don t tighten yet Note Jag suspension in top hole ERA suspension in bottom hole d jagrs Thread the trailing arms onto the rod ends with jam nuts already installed on the lower control arms See page 37 Thread on until two or three threads are left showing but leave the jam nuts loose Support the chassis with jack stands so that there is at least 19 20 between the spare tire well bottom and the floor This will allow you to fit the ooo J assembly on the jack and still slide it under the car ae Ap Na fromthe back Note angle TOP VIEW OF TRAILING ARM fia man d trailarm Note that the trailing arm bushing is angled slightly relative to the trailing arm tube On one side of the car Rotate the trailing arm so that the bushing angle matches the chassis bracket Holding the bushing against the inside of the chassis bracket sight through from the outside hole Use a large screwdriver to move the assembly so that the sight is straight into the threaded portion of the chassis bracket 71 SECTION
6. ASSEMBLY AND SERVICE MANUAL FOR THE E R A 289FIA USRRC Revision 3b Era Replica Automobiles 12 2004 The Manual The text and layout of this manual was done with Word for Windows Some of the illustrations were hand drawn and scanned some were done in DesignCad 2D and 3D Spelling errors are the fault of the spel chekker NOTE ON MANUAL UPDATES This manual was current at the time of your car s delivery Any critical corrections will be mailed to you If we can think of any thing that can be helpful but are non critical I will post them on the internet at http www erareplicas com fiaman The latest entire manual in PDF format is posted at http www erareplicas com owners Thanks Bob Putnam ERA e mail teracars sbcglobal net Parts inquiries to eraparts sbcglobal net Contents This manual is arranged by assembly sequence not topic For information on a specific topic assembly or service see the index NOTE ON MANUAL UPDATES read me first Picking up your kit special notes ENGINE Alternator Clutch Notes Ignition Notes TRANSMISSION Bell housing Speedometer drive gears Shift linkage Rear Drive Suspension Assembly Steering Gear Front Rotors and Calipers Drive Shaft Oil Cooler and oil Filter Steering Column Upper Steering Wheel Seat Belts Wiper Motor and Components Front Shock Absorbers Front Coil Springs Exhaust System Wheels Tires Radiator Hoses Expans
7. CH PEDAL Adjust pedal face angle here Temporarily install the brake master box It will have to be removed later to connect the brake switch wiring VIEW FROM UNDER CAR Abrpedal BODY MOUNTING Preparation Is Everything Before starting have all tools and materials ready and read the text below INSTALLATION If necessary clean and grease the needle bearings in the chassis and in the brake pedal Slide the pivot shaft through the chassis bearings with the splined end toward the inside If the engine is installed the shaft must be installed from the outside of the chassis Install the thrust washer s brake pedal and clutch pedal onto the shaft Secure the clutch pedal with the shoulder screw Install the clutch throw out arm onto the splined end of the shaft Orient the throw out arm approximately opposite the pedal See the illustration on page 117 To adjust the orientation of the clutch arm change the length of the connecting rod between the clutch pedal throw out arm and the clutch master cylinder Remove the retaining clip and the clevis pin Loosen the jam nut at the clevis Turn the threaded rod to change the length as necessary When finished tighten the arm set screw 56 Attach the body with sealant and rivets With assistance carefully spread the body sides while slipping the lower body flanges over the door hinge mounts Lower the body down over the cowl supports and onto the c
8. EL SHIFT LEVER 61 62 62 63 63 65 65 67 67 68 71 73 74 75 76 79 SECTION G BODY Il 81 82 83 88 88 90 91 91 92 93 93 94 95 96 97 98 98 99 Tunnel Carpets Hand Brake Lever Cover Seat mounting Seat belt shoulder harness Grill BUMPERS Jack pads Lights License plate light BACK UP LIGHT optional Mirrors Grab handle Top Snaps Door trim Emblems License plate s Convertible top Side curtains Fitting the tonneau cover Install wiper arms Brake Hydraulics Jacking the car Bolt on wheel notes Pin drive wheel notes SUSPENSION ADJUSTMENTS Brake balance adjustment Add Fluids cooling system Headlight ADJUSTMENT Final Checks RECOMMENDED SERVICE Fuses REFERENCE 99 101 103 104 104 105 105 106 107 107 108 109 109 110 110 111 112 114 114 SECTION H FINAL OPERATIONS 115 117 118 119 119 119 120 123 124 124 125 126 127 127 128 SECTION A PARTS NEEDED PICKING UP YOUR KIT The kit can be transported from our factory in an enclosed trailer standard automobile trailer or rampback hauler Shipping space for the parts in cartons will also be required although most will fit inside the kit We have used several shipping commercial companies with excellent results See page 26 for names DIMENSIONS AND WEIGHTS 800 lb bare 200 Ib of boxes 600 Ib for roller a shipdim TRAILER REQUIREMENTS If you didn t buy a roller from us the
9. F MECHANICAL COMPONENTS Remove the wire holding the carburetor linkage and check whether the pedal is at a convenient height ACCELERATOR PEDAL AND LINKAGE If it is too high change the link footbox link to a l lower hole on the cross shaft If it 1s too low All components come preassembled in the standard Lui l change the engine link to a lower hole on the cross kit See also the picture on page 67 shaft Install the return springs and check whether you re 5 16 Rod end still getting full throttle Tighten all bolts and jam nuts check for interference and grease all the pivot points If you want the smooth look shown below cut some 6 brake line to length to cover the middle Engine Par CITT section of the threaded rods bracket a e Note This linkage can be adapted to most engines If yours requires something different call us For Weber carburetors a duplicate of the original bellcrank pivot stand is available from E R A If you are using a blow shield with a wide flange on a 289 302 the flange must be trimmed around the bracket Trim for 351 Throttle pedal d throtlnk When assembling the longitudinal links onto the sides of the bellcranks pick the straightest front to rear paths The diagram above is typical but may not be ideal for your setup To remove the pedal from the pivot box remove the setscrew through the access hole in the casting Remove the bellcrank and slide the shaft out ADJUST
10. ING THE LINKAGE Wire the carburetor linkage fully open Install the cross shaft support onto the engine ENGINE AND TRANSMISSION orienting it so that the shaft is as parallel to the firewall as possible and fairly horizontal Install the link from the carb to the cross shaft adjusting the length so that the cross shaft bellcrank is angled back about 30 degrees toward the firewall Adjust the bellcrank on the pedal shaft so that it is angled back toward the firewall about 20 degrees when the pedal is bottomed out on the floor Install the link from the pedal to the cross shaft so that the pedal is about from hitting the floor 76 Refer to page 31 for engine and transmission preparation To check compatibility trial fit the transmission to the engine before any attempt to install either into the chassis Note that the engine and transmission are offset toward the passenger side of the car by one inch to balance the driver s weight and to give more legroom for the driver If you are using a blow shield check the concentricity of the hole that locates the transmission Put a dial indicator on the flywheel and indicate the hole ID If the eccentricity exceeds the recommendations generally about 0 010 you must use offset dowels to locate the bell housing on the engine block SECTION G BODY Il HOOD STAY The upper and lower hood stay brackets are factory attached as shown _ screws or blind rivets n
11. ap screws n A ks i i Glue the half round weatherseal provided with the kit onto the trunk opening flange of the body a SN ee leaving about distance between the edge of Bracket on under side 2 the seal and the up curve of the outer lip To keep of body lip anni from making a mess with the contact cement you can use masking tape to border where the weatherseal will be placed PASTA Do not stretch the seal while installing Start the TRUNK LATCH process at the center of the bottom lip in front of the latch Continue over the top and back down to the center Trim the excess so that the ends meet tightly See the picture on page 87 Attach the latch striker and bracket to the trunk floor n i Ma Attach the trunk handle and latch to the trunk lid as shown Don t forget the gasket under the handle 87 SECTION G BODY Il 15 REAR MOUNTED 1 4 20 bolts into x inner panel i fia man e radmt Fit the rubber grommets and steel sleeves to the upper radiator support Install the support over the studs on top of the radiator with the large washers lockwashers and nuts Move the radiator forward and attach the support to the body Attach the support straps or optional rear fan see below between the upper and lower ARE radiator supports HOSES OPTIONAL FANS Mounting for the optional expansion tank is shown on page 34 Install the radiator into the chassis as shown above Th
12. e E R A Canton Racing 289 351W pan can have a maximum depth of 8 5 F or R Products Aviaid sump Deeper pans will hang below the chassis 351 Cleveland Canton 15 710 pan 15 711 pickup Oil Filter See the note on page 17 Exhaust System Under car complete E R A Competition style pipes w primaries E R A Fuel Filter In line between tank and steel line on chassis 7 Hand Brake Lever Jaguar XKE Series I II 1961 1970 Jaguar Dealer or E R A Reproduction Lever E R A Hand Brake Lever Cable Custom for E R A subframe E R A Emergency brake linkage Custom by E R A ERA rear suspension Cooling system parts Water neck thermostat Ford Motorsport M8592 B302 angled 30deg up housing Hoses Upper Gates 21178 or equivalent requires trimming Local auto parts store Lower w L or R outlet Gates 20390 or equivalent See page 35 for trim Bypass Gates 28466 0 x 0 5 28474 34 x 34 or 20662 CA x Heater Gates 28472 to thermostat housing ID straigth hose 50 to water pump Radiator expansion tank Harrison 3155416 E R A 22 SECTION A PARTS NEEDED Rear suspension Jaguar based or custom ERA design with outboard brakes Jaguar Rear Suspension 1964 1974 Jaguar XKE Series 2 1965 1983 Jaguar Wrecking yard or E R A Assembly Core XJ 6 Sub frame Custom E R A for Jag based or ERA outboard E R A braked design Rebuilding Parts for rear Bearings brake parts etc
13. e hose part numbers and instructions for modifying the front lower hose are covered on page 35 Note that a connecting tube availble from ERA is required for the upper hose Assemble the upper hose as shown on page 35 STANDARD Thermo switch water SY PUMP aAA r ih n STI mM Il l i PI r LIE J re 1 T 1 lit r I LLI La T a k 1 F ALE na ee 4 Fat 1 4 har ih Sf 4 i Dh i A i j ier La F Anti sway ALUMINUM CONNECTING TUBE gt bar fiat man e lwathose ANN zi The radiator cooling fan thermostatic switch is in STANDARD FAN the lower hose connector Connect the harness wires as shown on page 82 and detailed in the wiring instructions There is also an over ride switch on the dashboard fia man e stdfan 89 SECTION G BODY Il BATTERY AND CABLES The battery is mounted in a hidden compartment behind the right rear wheel Installation of the support tray is described on page 75 BATTERY INSTALLATION SERVICE See the illustration on page 75 If necessary remove the right rear wheel Remove the screws and nuts holding the splash panel at the rear of the wheel well Place the battery onto the tray with the posts toward the outside away from the chassis Attach the 135 long battery cable use a 60 if you are using the cut off switch See page 75 to the positive terminal on the battery toward the rear of the car The cable is routed arou
14. each castle nut to 15 lb ft and back off to the nearest hole Secure with a cotter pin 40 fia man d hsaxlflg Bolt the half shaft inner ends and spacer onto each differential output flange If you wish install Jaguar shims with about 060 total thickness between the half shaft and the spacer This will make minor camber adjustments easier after basic alignment has been done Slide the axle into the hub carrier using a small amount of light grease on the splines For competition you might want to use a little shaft and bearing mount on the splines but be aware that disassembly requires heat Secure with a flat washer and castle nut Tighten all the lower hub carrier pivot shaft nuts to 20 Ibft back off of a turn to the nearest cotter pin hole and insert cotter pin Insert any shim washers necessary between the rear flank of the rod ends and the cage bracket Install a flat washer and lock nut Install the caliper using M10 x 30 allen screws and ribbed lock washers Install the upper trailing arm bracket with bolts flat washers and lock nuts so that the bracket angles in toward the front Install the upper trailing arms onto the hub carrier bracket Install the lower trailing arm onto the lower radius arm with flat washers and lock nut Tighten nut to 35 Ibft The front of the trailing arm is attached the same as the Jag suspension EMERGENCY BRAKE CABLE Route the long cables through the hole in the sub
15. frame as shown above Pass it through the internal holes the holes above the front mount page 39 and into the balance bar shown on page 36 If you supplied the calipers cut a slot in the cable mount big enough for the cable to fit through Section D Body Chassis assembly FOOTBOXES D footbox For installation of stereo speakers in the sides of the FRESH AIR CONTROL VALVES footboxes holes must be cut into the fiberglass Inquire for the exact location of the holes and recommended speaker size RIGHT Push the box forward into the corner and clamp into place so that the original assembly holes line up If there are no problems remove the footbox apply caulking and fasten the foot box to the chassis in the same manner as the floors LEFT Lift the footbox up and slip in from the center of the car towards the outside Don t rivet the area where the foot boxes overlap one another The PIO rivets will show in the engine compartment Just add sealant and rivet the portion against the Passenger s side assembly is a mirror image transverse support tube and the lower rear section Screw on top of the drivers foot box after putting a that extends towards the transmission Footbox bead of caulk on the bottom flange components Clamp the duct hose in place The actuating cable will be attached later 55 Section D Body Chassis assembly For balance bar parts installation see page 123 BRAKE AND CLUT
16. hassis Watch for the left front brake line that runs behind the wheelhouse panel Use small blocks of wood etc to keep the body at least 3 above the bonding strips and chassis Mix a trial batch of bonding adhesive see Supplies and Materials on page 27 to check the set up time before you start You must have enough time to apply the adhesive and carry out the all the subsequent installation steps before hardening Use less catalyst or hardener to increase working time Use a caulking gun to apply body sealant also used on the floors and foot boxes to the chassis and corresponding body parts Apply the bonding adhesive between the surfaces indicated on the diagram Section D Body Chassis assembly Check the body and chassis seams from underneath FRONT BRAKE SCOOPS and seal openings with either the brush on undercoating or the caulking used to mount the Using two 10 sheet metal screws mount the body Pay particular attention to the rear closing scoops 5 4 from the centerline of the car and set panels where they overlap onto the upper trunk back as shown A strap attached to the inside of the panel and the junction at the upper front corner of chassis supports the rear edge these panels If you wish to rust proof the inside of the chassis main rails drill holes in the bottom of the chassis at the front and rear of the bottom rails You may then spray a wax type material into the chassis even up above the rear suspe
17. ion Tank 2 6 SECTION A PARTS NEEDED __7 8 9 Jack etc PART NUMBERS AND SOURCES SOURCE MASTER LIST TOOLS NEEDED Shipping companies partial list SUPPLIES NEEDED SECTION B PARTS PREPARATION ENGINE components Rear Suspension jaguar Rear suspension E R A Shift handle Shift LInkage steering gear Steering Column Upper Wipers DAMPERS AND SPRINGS REAR HUB ADAPTERS BOLT ON WHEELS SECTION C CHASSIS PREPARATION BODY REMOVAL CHASSIS PAINT SECTION D BODY CHASSIS ASSEMBLY Interior panels Horns BRAKE AND CLUTCH PEDAL BODY MOUNTING Attach Rocker panels BODY PREParation AND PAINT Front Splash Panels Fresh Air Inlet Ducts fresh Air hoses Rear wheelhouse panels 20 21 25 26 26 27 29 31 35 37 41 41 42 42 43 46 46 47 49 51 53 54 54 56 56 57 58 60 60 61 61 Detail Undercoating Tonneau snaps Front brake scoops SECTION E CHASSIS ASSEMBLY BRAKE FUEL LINES Battery cables SECTION F MECHANICAL COMPONENTS FRONT SUSPENSION REAR SUSPENSION Jaguar Rear suspension E R A DRIVE SHAFT Voltage Regulator ENGINE AND TRANSMISSION LOWER STEERING COLUMN WIRING AND ELECTRICAL INTERIOR PANELS Roll bar RADIATOR fans OIL COOLER optional Fuel Tank Fuel Filler Cap Windshield Wipers Windshield Washer Windwings and sunvisors Windshield HEATER DEFROSTER Dashboard Speedometer Cable Battery and Cables STEERING COLUMN and WHE
18. kit is usually shipped on the dolly wheels that we use for assembly if your trailer is well sprung The dolly wheels require a 300 refundable deposit Many people keep the wheels until their kit is completed it s very convenient for the kit to be mobile and at the correct height during construction The track of the Cobra dolly wheels is only about 20 Your trailer may require additional boards to support the dolly wheels Without tires or dolly wheels you can put tires as buffer between the chassis and the trailer The kit will have to be lifted on and off the trailer manually Have 3 strong friends to unload If you re coming on a weekend to pick up your kit please warn us if you aren t coming with extra people too Don t tie down the dolly wheels to secure the kit Tie to the chassis or suspension In the absence of suspension pieces to tie to wrap soft tie straps around the front crossmember and the upper mounting bolts for the rear subframe TIE DOWNS You or your shipping agent will require ratchet tie downs come alongs and or strong straps We recommend either 4 diagonal connections or 2 longitudinal and 4 lateral ones for a total of 6 Don t forget that the trailer must have anchor points to tie to To avoid scratching the paint on the chassis use 2 wide loops or double 1 wide loops or ratchet straps 5000 Ib minimum rating Make sure that your trailer has places to tie to If you use chains or a come along bring padding or
19. lower column with the notch in the upper tube and fit the clamp over the column tube Snug the bolts slightly but don t tighten SECTION H FINAL OPERATIONS Without the arms installed cycle the motor through HOSE INSTALLATION high and low speed When you turn off the switch check to see that the drive posts return to the far See page 33 for an illustration of the slave cylinder right passenger s side position Ask about oncentric slave cylinder installations eea Bracket may vary Pull type release Press the arm onto the post so that the blade falls at the base of the windshield just above the frame See above Check the sweep of the wiper and adjust 1f necessary Push type Removal release Use a screwdriver to pry between the post base and the edge of the arm opposite to the blade fc aa ra SITI PATITI 122 A di E rey Ma pirata shakes le Om EE Special Tilton MC h clhose Check the tightness of all fittings before bleeding BLEEDING The car must be level for this operation Fill the brake clutch reservoir with DOT 3 or DOT 4 fluid Silicone fluid is not recommended Attach a small hose to the slave cylinder bleeder nipple emersing the other end of the hose in a small cup of fluid Loosen the nipple about turn with a 2 or 7 mm wrench Work the arm on the clutch pedal shaft instead of pushing on the clutch pedal itself until only clear fluid comes out of the
20. n oa j m a AAI a app r ete at a lt Fy i piil x Wat LEL ELULE mN r Sy s toyer al nu 2 Trunkweatherseal Retaining clip Grease baita 2 ai ebod TRNKSEAL Habenan Hopdotep Bolt the trunk hinges they are marked with a T on the lid side loosely onto the body with any shims If you removed the keyhole receptacle from the odiati hood inner panel when it was painted install as shown Loosely bolt the trunk lid with factory shims onto the hinges Carefully close the lid not letting the front edge contact the body Center the lid in the opening Slowly lift the lid just enough to get your arm and a wrench inside and snug the bolts on the The plastic rod retainer fits into a square hole in the wheelhouse panel It may be removed by squeezing from the backside TRUNK LID lid part of the hinges Remember to check the front instali hetrik edge while lifting lid lid liner the The lid can be adjusted further by moving the lid and hinges in unit at the connection on the inner panel Tighten bolts and recheck fit TRUNK STAY Attach the trunk stay to the trunk lid as shown using the sheet metal screws at the bottom stainless steel dome head screws at the top fuzzy stuff that was with the optional street carpet kit onto the inside of the trunk lid with contact cement Trim the material so that it can be pushed just under edge of the fiberglass inner panel Socket A c
21. nd the back of the battery support The power cable is then routed as per the instructions on page 66 Attach the ground cable to the front terminal Slide the hold down rods up through the holes at the front and back of the bottom of the battery support and through the holes in the corner bracket Secure with lock nuts and washers STEERING COLUMN AND WHEEL Before the Triumph steering column is installed check that the signal canceling cam on the steering column shaft is oriented correctly See page 43 The steering wheel center cap see page 99 is installed after final suspension alignment Lower steering column installation is described on page 79 Prepare the triumph steering column as described on page 42 The steering wheel center cap see page 99 is installed after final suspension alignment 98 ASSEMBLY Insert the upper column and housing through the hole in the dashboard engaging the lower column as the upper one is slid in Hold the clamp halves of the upper column around the column oriented as shown and slide the clamps together back into the mounting bracket Insert the cross bolts as shown below On j n Es n With the driver s seat correctly positioned in relationship to the pedals slide the steering column and housing in or out to suit your driving position Adjust the height of the column to your preference and tighten the cross bolts Align the flat of the
22. nsion Close the holes with plastic or metal plugs TONNEAU SNAPS This operation can be left until last so that the paint can be buffed one final time Chase the holes with a 25 drill 150 Install the tonneau snaps with the fiber washers Don t force The snap screws may twist off leaving you with half a broken screw in the body For extra safety and ease use a 10 steel screw to chase the threads into the fiberglass before you install the snaps 62 SECTION F MECHANICAL COMPONENTS Install the arms with 3 shims front and rear between FRONT SUSPENSION the pivot shaft and the chassis mounting brackets as a preliminary camber setting Leave the pivot shaft LOWER CONTROL ARM end nuts slightly loose Tighten the nuts to 60 Ibft Lubricate the chassis receptacle brackets and the after the suspension is at normal ride height sides of the control arm bushings with silicone STEERING KNUCKLE grease or petroleum jelly Use a gentle oscillating osccc motion when inserting the control arm into the Install the knuckle on the lower ball joint with a mounts washer and nut Torque to 40 lb ft Tighten further to where the cotter pin can be inserted Insert the 5 x bolt with a heavy washer P through the front bushing into the chassis Use a Rotate the upper control arm down engaging the flat washer under the lock nut ball joint stud into the knuckle Use the 3 x 5 4 bolt through the rear mount with I
23. nstall washers and nuts torque to 30 lb ft flat washers and lock nut minimum and install cotter pin at the next line up Torque the pivot bolts to 50 ft lb Insert the tie rod stud into the steering arm from the bottom Fit the washer and nut torquing to 20 Ib ft minimum Install the cotter pin pe If you have difficulty getting grease into a ball Joint Note pivot back off the Zerk fitting about one turn shaft offset ROTOR HUB GM BRAKES tari fy A i ii fe oe a fa ea flore iE i Awr f iP 3 ili ill ni ter a ILA i M Vesa ee I O Fi a PIN DRIVE WHEEL dfhubasb fia man d fsusp UPPER CONTROL ARM The arms are installed with the ball joint hole offset towards the front of the car The inner pivot axis is offset to the outside of the chassis mount See above Use a little silicone sealer where the ball Joint passes through the hole in the control arm This will prevent grease from leaking out of the rubber boot 68 SECTION F MECHANICAL COMPONENTS 12 BRAKES HUB AND ROTOR MOUNTING GM assembly GO ait tive ore BOLT ON WHEEL PIECES Mifz2 gif OPTIONAL WILWOOD CALIPER MOUNTING With Wilwood or JFZ Caliper Late Design with cutom uprights GENERAL INSTALLATION Replacement parts are listed on page 128 Pin drive If the rotor is not already installed on the pin drive hub torque the drive pins to 35 lb ft with high strength thread locking compound 1 e Locktite
24. nylon straps for intermediate connections to the chassis INCLEMENT WEATHER A plastic cover will quickly shred at highway speeds A high quality cloth car cover can be used to cover up the plastic but it must be held down with rope all over Looseness will allow any cover to quickly beat itself and your paint job to death SECTION A PARTS NEEDED PART NUMBERS AND SOURCES Source addresses etc are found on page 25 PART Alternator Ford Small Block Insert to reduce head threads Ballast resistor Fan belt Front Brakes Suspension Brake Rotor Hub bolt on wheels Brake Calipers Front Pads Mounting pin kit Banjo bolt Dust Shield Brake reservoir standard optional 3 Bearings Front Wheel Outer Inner Seal inner Spindle nut Spindle washer Shock absorbers See spec s on page 46 Coil Springs PART NUMBER Delco 321 147 rebuilt or any 70 s Ford with separate regulator F4ZZ 6E086 A see mounting page 31 Nieh FF 109 Borg RU 6 SMP RU 4 Wells F795 1 4 1 6 ohms Gates 7450 XL most app s GM 334348 Bendix 141040 GM 18002421 18003761 Rebuilts Bendix L55001 L55002 Includes pads Bendix D52S Semi metallic for street use GM 487293 GM 344023 344024 BMW 34 32 1 112 399 ERA steel cans optional GM 7450627 Timken LM11910 LM11949 GM 7450630 Timken LM67010 LM67048 GM 3966202 National 8871 GM 387137 GM 457707 Spax G135 PAS 200 Koni 8212 1126SPA1 Do
25. past the copper washer but the seat is not too bad you may use a special sealing washer available from Earls or E R A COIL OVER DAMPER See page 68 Spacers for the lower mounts are provided with the dampers Orient the damping screw adjuster toward the centerline of the car Use a washer on either side of the top mount Secure the top with a 2 long bolt in from the back A 2 7 bolt is supplied for the bottom attachment Again slide the bolt in from the back STEERING GEAR dyswayb With the ERA Mustang steering gear conversion the lower steering column must be installed before the steering gear See page 79 Prepare the rack and pinion assembly as described on page 42 gie ur Tr e ear nt ae All r F ee d subaru Raise the rack into position into the chassis mounts and secure with the mounting clamps provided Note the spacers used between the left side clamp and the chassis Torque the nuts to 18 Ibft ANTI SWAY BAR Threaded holes are already on the chassis Chase any paint in the threads before installing the 5 18 bolts washers and nuts The front bar is mounted under the front frame extensions just behind the radiator 70 SECTION F MECHANICAL COMPONENTS REAR SUSPENSION JAGUAR en a a ae atto aa nn _ ea et et a I pe a a woe gt Ri any eon ys SEE rif ni INSTALLATION es AN te 3 fff SS iP A la i Bottom View d eracage Raise the rear
26. s with E R A column Steering wheel Center button Reproduction of original either AC or Cobra E R A motif 23 Transmission See notes on pagel2 Mounts Ford Top loader w 2 holes along longitudinal centerline or 2 holes perpendicular to centerline 5 6 apart Ford C 6 Automatic Ford T 5 Richmond Gear Tremec 5 speed Throw out fork Pivot bracket for above Shift Linkage 4 spd Top loader Richmond Gear 5 speed Shift Lever duplicates original Voltage Regulator Windshield Wipers Motor and Drive Parts Arms Blades Chrome Bezels Bush Kit Wheels Bolt on Pin drive Spare Tire Wheel Bolt on SECTION A PARTS NEEDED Ford Top Loader T 5 Tremec Richmond Gear 5 spd Ford C8ZZ 6068 A or Republic 31 2284 Ford C9AZ 6068H or Republic 31 2375 Ford C8ZZ 6068 A or Republic 31 2284 Republic 31 2224 Tremec requires adapter from E R A Ford C8OZ 7515D must be narrowed for all but big spline Top Loader Ford C8AZ 7522B Original Ford unit Hurst or other after market units Long or Hurst To adapt to all transmissions Ford Regulator D4TZ 10316 A D9PZ 10316 A or aftermarket equivalent for 1967 on Ford alternator with external regulator From 1969 1976 Triumph Spitfire GT 6 or TR 6 Lucas BHA 5201 Lucas GWB 164 Lucas 60600 429 American Racing Torq Thrust 15 x 7 15 x 8 5 For 12 brakes see notes on page 17 7 2 x 15 and 9 x 15 Various widths in 17 GM Camaro
27. see page 128 SICP E R A Jag Dealer suspension Coil over dampers See length specifications on page 46 Standard XKE W O height Spax S 200 415 Externally adjustable damping E R A Jag rear adjustment Height adjustable Spax G640 S200 E R A Coil Spring 4 rqd std Spax 10 x 350 Ibs in E R A Carrera Dillon Spax with height adjustment 8 x 350 Ibs in AFFCO Eibach Differential LSD rebuilding Various ratios of Dana 44 gears Reider Racing Michigan Driveline only Speedo cable drive See notes on page 13 and 15 for gears E R A dealer auto parts Richmond Gear Cable Champ 400020 Adapter GM 345212 store O Ring 7 OD x ID Retainer 3708148 Drive gear GM 39879XX where XX number of teeth Speedo cable drive gears etc See calculation notes on page15 E R A Dan Williams Top Loader T 5 Tremec Cable AC 11589234 67 Mustang Speedo drive gear C4DZ 17285A LH 7 tooth black Ford dealer C8AZ 17285A RH 7 tooth yellow Speedo driven gears 20LH tooth C2DZ 17271H 19LH tooth C4DZ 17271A 18LH tooth C2DZ 17271K 17LH tooth C2DZ 17271G Retaining clip CIDZ 17292A Steering gear Subaru 631 300 540 Subaru 1977 79 Stage 2 E R A Dealer wrecking yard Steering column upper E R A Reproduction or E R A wrecking yard Triumph Spitfire GT 6 1972 mid 1977 Steering wheel Moto Lita E R A Wheel hub Triumph column Moto Lita wheel must be drilled for pattern E R A E R A column Come
28. to restrict flow 35 TO UPPER RADIATOR ______ CUT HERE 1 75 inside 1 5 inside Albona 15 _ Ong uko ae ae FOR EXTERNAL WEBER MANIFOLD ge fia man b uwathose2 SMALL HOSES If you are not using a heater connect the water pump inlet to the expansion tank REAR SUSPENSION JAGUAR DISASSEMBLY Components must be thoroughly checked and rebuilt if necessary brake calipers emergency brake pads and linkage universal joints on half shafts hub carrier and lower control arm bearings Bearings etc are listed on page 128 We have found that the Spicer U joints listed are the only brand that meets the standards required of the Jaguar half shafts and we ve tried quite a few Replace any corroded or damaged brake lines Be sure to use lines with the proper end flare and fittings Note that some British fittings have a convex bubble flare that mates with a concave receptacle in the caliper While this is similar to some metric fittings the threads are SAE It is not possible to make these flares with a conventional flaring tool Aftermarket suppliers and Jaguar dealers have these British style lines Mount the brass junction block on the left front of the cage with the fitting for the flex hose up If your rear suspension core has the junction block pointing forward fabricate a small bracket from steel strap Install the hose mounted on the chassis originally onto the junction with a copper 0 ring
29. uble external damping adjustment w aluminum body 12 x 250 Ibs in or 12 x 275 Ibs in See page 18 SOURCE Most Fords 1971 1980 Ford Aftermarket GM dealer or many Front GM cars 1970 78 see page 17 GM dealer Local parts place GM dealer ERA BMW dealer GM or local auto parts E R A E R A Summit Racing Jegs E R A Carrera Dillon AFFCO Eibach Battery Group 45 preferred or Group 51 Get the heaviest Misc duty possible in this size Bell housing See mod s necessary on page 32 Cables Battery Trans case to chassis ground Battery pos to starter solenoid Battery neg to ground Starter solenoid to starter 12 long s eye eye woven style 135 long eye terminal clamp 1 gage min If you want an in line cutoff see page 66 32 long eye terminal clamp 1 gage min 24 long eye eye 4 gage min Lakewood 15202 for Top Loader R G Lakewood 15203 for T 5 Tremec Various E R A E R A parts supplier Drive Shaft Components see page 41 for parts reference RUE 21 SECTION A PARTS NEEDED ENGINES AND ENGINE Complete rebuilt Ford units are available from PARTS several suppliers Mounts Ford 260 289 302 351 63 65 Mustang w 260 289 cid Ford C4DZ 6038A Aftermarket Mustangs right C4DZ 6038B left Unlimited E R A Dealer Republic 31 2221 right 31 2220 left MityMount HD FM132 Oil Pan Extra Capacity Custom steel pan as used on original Cobra Th
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