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ERA GT - Era Replica Automobiles

1. Filer ON Fare Edu Floor board passenger nnrnnnnrrrrrrnnnnvvvnnvssnnnnnnnnnnnneneeee Flywheel ERA beordre Pantera DEN HOUSING Sean Frame Prise Freshair ventilation 1 Front body removal ccccccceccceeccececeaesesssseseeeeeeeeeeees Fuel FUD Cares hd Rane INDEX 118 Gage Oil pressure fitting on block 21 Water temperature 21 Ger Riis 61 H BES a EE 37 th et nnana a aa 16 Handle DOO rn 80 Header Tankaan Aaa 70 Headlights CON ELS 92 cant 67 100 105 86 Homser 76 Hoses Air conditioning LES EE EEE EEE N 102 Cooling system 68 Pl 67 Hub Front DOMFON dunan aus 37 Pin Dvd tana seo dierent eae ae 35 Hub carrier 35 26 74 Ignition system Ballast resistor 7 DISH DUNLOP sedan assess dase F 115 Seut i vadginaiseceneiaecsnetes 112 Tnsulation exhau
2. 59 NOUSING 29 Finger Henk 29 Fanteria E 28 Return spino 59 Selection E 8 E iv 8 Slave cylinder 27 Throwout beanna r tene 59 Throw out beating sessies 8 OVER kodes armeene 4 COMP COON 12 Controls Air 101 Cooling Water pump 21 rele 67 Covers Head ei 92 Cowl Weatherstripping 78 Crankshaft Gam per 21 D Paper Cranks halt vare 22 Dampers PDS PAU GE 41 Feb sved 11 SPE ONS sje Sed 11 22 Dashboard Re ape 98 Derre 100 Differential PN Disassembly Door Tider 5 PLN ven E senere A A SESA Emergency Engine ANETT DA DUO Fono nokia 59 Moi Mounts stalin SR NC ies Fasteners Application 18 1 MT Fler
3. 46 Pedal 95 Periodic Service 61 107 Poes Wiel 76 Pokureth ne 73 20 Pressure plates ANM eee 8 Presse dte 44 Pump UG hessen derweceenaercandtnetencueueeditets 63 Pump Pe 16 FR ACHING 12 Rack 12 Rear 20 Reciever Drier A 102 RCO ES EATON va gata 112 Replacement parts 108 Required Parts DES CODON 5 Ring Sear Transaxle ri 24 Rocker Panels Fiberglas Sencie 89 Roll bar REMOVA Noar TECE 20 119 Rollbar salbronvuuvsdsdsmeseudvmsekssruvdamst 74 Roof instalati Oies aiee AEAEE EEEE A 75 KO 12 Bk 46 Rues install ann 97 ote 73 6 ADe 99 SS OS researches ean 99 Sender FN Se ed 63 See FE asna 4 See Ard 3 Pen ale 107 Shift linkage ETNE oxic A 53 Ron Mand iy seven 56 SHIPPING COMPANIES 113 SHOU LACH dene 99 Slave CY NCEE Ave
4. Charging the system with Freon Caution Charging must be done through the fitting on the compressor only not at the fitting near the drier in front HEATER ERA offers a heater blower for the GT that is similar to the original setup using some parts from our air conditioning assembly It therefore looks virtually identical to the original setup but its function is somewhat more sophisticated Wa ter is bypassed from the front radiator through fit tings on the aluminum longitudinal tubes and is regulated by a cable controlled in line valve Not much water will flow naturally through the by pass so if you need more than defroster heat we recommend that you use a separate electric water pump in the heater water circuit electrically pow ered by the heater blower circuit Inquire The blower is 3 speed and controlled by an un der dash panel similar to the A C panel on page 104 108 ROOF VENT Air is exhausted through the inside louvers in the cab ceiling and out the louver on the roof A wa ter drain runs along the roll bar and down the left side of the car by the forward trailing arm mount When washing the car don t direct water into the roof vent It will overload the drainage system The system may be cleaned by removing the 4 screws holding the box to the roof and removing the drain tube INDEX UPKEEP REFERENCE REGISTRATION 109 INDEX RECOMMENDED SERVICE EVERY GASOLINE FILL
5. have protective gt plastic wrapping on them for shipping protection HEADLIGHT COVERS The windows may need final trimming and bevel ing for a perfect fit Leave at least clearance around the perifery of the acrylic for thermal ex pansion Trial fit the covers onto the front body before the body is painted Some sanding of the mounting surfaces of the body may be necessary for the cover to properly follow the outer body contour The covers are held in place by stainless steel screws The covers are not pre drilled and have the protective plastic wrap on them The covers may need final trimming for a perfect fit Cover screw locations have been pre marked the body After trimming the covers hold them in position on the body with tape Drill through the cover into the body marks underneath Size the bit for the screws to be threaded into the body Once the holes in the body have been drilled enlarge the holes in the cover at least 50 larger than the screws for expansion tolerance G ventwind 95 BODY When attaching the covers do not over tighten the WIPER DRIVE POST screws Also see page 33 and 34 for wiper drive details IF YOU USE RUBBER GASKETS The added thickness of the gasket will effect the trimming size and the location of the holes Drill the holes in the cover first Use the pattern to transfer the holes to gasket Finally drill through side of the car On the
6. FHINGE 87 Install the subframe with 2 35 x 5 bolts at the top and x 5 bolts at the bottom noting the orientation of insertion shown below The front rub strips and alignment blocks must be in place on chassis before installing the body Thread the pivot bushings on the studs on the front and rear subframes as they were when the kit was delivered If you have notes from the disassem bly duplicate the shim pack underneath the mounting plates Loosely bolt the mounting plates to body The front plates have bolt on locking blocks to hold them in place on the pivot bushings the rear plates are open slots Tilt the front body forward about 30 degrees rear body 90 degrees back and slip the pivot plates onto the chassis pivot bushings Carefully lower the body to the closed position The fiber glass rocker panel or an equivalent shim must be in place BODY ALIGNMENT To adjust the body side to side alignment thread the pivot bushings in or out With body positioned in If the mounting plates have not been moved since proper alignment carefully tighten bolts delivery changing the alignment should not be nec essary Use jack stands or blocks to support the body under the pivot points Do not place jack stands etc under flexible lower panels of front or rear body See the diagram for areas to use With the latch plates loose the body may easily be shifted vertically and front to rear Change the body in
7. Since the tunnel houses the water hoses it is strongly recommended that the tunnel be insulated as much as possible Foil adhesive backed foam such as used for hot water heaters works well in this application If you cannot find it at your local hardware store it 15 available E R A in bulk If you have air conditioning wrap the lines along the tunnel with the same material using tie wraps at regular intervals for security You may also pack the bulkhead behind the seats with simple foil backed fiberglass insulation Don t allow the insulation to interfere with the LHD shift linkage however Close off the holes in the lower bulkhead behind the seats with thin film plastic held in place with contact cement Leave only a small slot for the shift linkage if pos sible INSTALLATION Slide the small housing end of the throttle cable into the tube on the drivers side of the tunnel from the rear The other end of the cable goes through the oval hole above the tunnel and toward the left side of the car Pass the cable rearward through the grommet on the left side of the firewall See page The wire for the fuel pump 15 fed through the same hole Install the small rod end and jam nut on the cable end and slide over the stud on the bellcrank Secure with the lock nut provided When assembling the bellcrank into the bushing on the tunnel use light oil not grease 98 Interior Ventilation There are 3 threaded
8. tion Camber 0 degrees 1 4 deg Toe in 1 5 1 35 0 5 deg 0 1 deg King pin inclination 7 1 4 deg deg not ad justable First adjust caster by shifting shims from in front of each inner pivot bushing of the upper control arm to the back or vice versa Moving the arm 1 will result in a change of approxi mately 1 degree Be sure that there is minimal or no gap at each side of the inner pivots when the bolt is still slightly loose Don t forget the in CAMBER ternal star washer under the head of each upper control arm inner pivot bolt Tighten the bolts to 40 Ib ft and check that all the shim packs are tight If they can be moved insert more shims as necessary Caster is the inclination of the front up right axis through the upper and lower ball joint centers toward the rear More caster increases straight line stability but also increases steering effort The car Because of the plan angle of the arm changing tends to turn away from the side of the the caster will simultaneously change the cam car with the most caster ber although to a lesser degree Therefore after caster adjustment the camber must always be checked 46 SUSPENSION AND BRAKES Camber is adjusted by threading the nuts secur ing the upper ball joint to the upper control arm in or out Hold the ball joint so that it is in line with the king pin axis while adjusting and tight ening the nuts After the adjustment
9. 2 Cap bleeder screw 14089150 2 Bleeder screw 14071826 2 Repair kit includes 10112656 parts below 15 Pushrod 17 Retainer 18 Boot 19 Actuating Collar 20 Boot 21 Bushing 22 Clamp rod 24 2 Bracket parking E R A alfcalips brake L or R special REAR BOLT ON 11 4 Spring collar re 10112650 The components are late 87 94 Corvette with 12 2 Bolt ancho 10112649 rotors The emergency brake built into the caliper 14 3 28 13 14 27 10 ANNARA PARTS PREPARATION Washer cal mt E R A Bolt caliper plate supplied Spring levr arm ret 10112651 Plate caliper mounting 10112652 Guide pin 14067560 Boot guide pin 14067552 Pad Set with 4 guide 10132836 pins bolts below Bolt guide pin 14067559 Also used on front brakes See above HUB AND BRAKE PARTS PIN DRIVE WHEELS E R A supplies pin drive conversion parts in various combinations The following list shows the stock parts not normally supplied with our Basic conversion kit BRAKE CALIPER I Caliper housing and pis 10104471 ton LH I Caliper housing and pis 10104472 ton RH 1 Anchor plate LH 10181205 1 Anchor plate RH 10181206 1 Pad kit 10104485 2 Pin caliper guide 10140586 4 Clip caliper damping 10104481 PARTS SUPPLIED WITH THE ERA PIN DRIVE KIT Qua Description 2 Front spindle assbly 2 Front hub 12 Pin wheel locating w nut washers 2 Wing nut 2 Hat rotor 20 Bolt hat to rotor w nut and washer 2 Rotor Wi
10. 977517 Rod end 3 8 female 2 Rear master cylinder 5 8 Steel line 76 5 L Washer 3 8 ID 177003 3 Clutch master cylinder 3 4 16 Steel line 59 5 L 32 Junction 3 16 IF x 1 8 WH 4 Hose 13 3AN 3AN 61010112 17 Steel line 53 5 L 652 x3 5 Bulkhead fitting 3AN x 3 16 18 Banjo 7 16 977640 33 Switch stop light 6 5 16 barb x 4AN mod d from 19 Banjo 10mm 997641 34 Banjo bolt 3 8 24 997503 961504 20 Hose 4AN 64191914 35 Steel line 1 4 5 16 hose 21 Bulkhead fitting 4AN x 90d 36 Flare nut 3 16 7B 5 16 hose 983304 37 Clip clutch hose 7 5 16 hose 22 Tube sleeve 4 561904 38 Reservoir clutch and brake 8 3 Bulkhead T 983403 23 Tube nut 4 561804 39 Banjo bolt 7 16 20 977504 9 3 Bulkhead nut 561803 24 Steel line 1 4 diam 40 Adapter swivel to 1 8 npt 10 3 Tube sleeve 561803 25 Flare nut 1 4 included w 24 41 RPV 2 psi Wil 20 1874 11 3 16 Steel line 26 Bulkhead fitting 4AN 983204 42 Elbow 3 8 x 3AN 962203 12 3AN Bulkhead fitting 27 Washer 7 16 ID 177004 43 Banjo 3 8 x 3AN 997603 94191913 28 Slave cylinder clutch BMW 44 Adapter 3AN x 1 8 npt 13 18 Hose assbly 3AN Banjo 2152 1104 269 610618 29 Clutch actuating rod CALIPERS ROTORS Part numbers are listed on page 14 48 SUSPENSION AND BRAKES FRONT Calipers 1984 through 1987 Chevy Corvette calipers cand be used at the front and rear wh
11. As you can see from the diagram above the water pump extends into the rear bulkhead and has a fi berglass cover All engines must use a short wa ter pump either Snow White or a Ford Motorsport shorty pump or an electric pump from Davies Craig http www daviescraig com au If you use the electric pump also we also recommend that you use the control unit so that you can eliminate the thermostat ERA can supply a water neck with the proper fitting for the temperature pickup The clutch flywheel and bell housing must fit and work together Because of the low drive train height you cannot use just any pieces The original GT40 used a twin disk clutch Fortu nately there are now standard single disc clutches that work very well within the restricted space Your choice of parts depends on your power requirements budget and reliability desired PARTS PREPARATION Alternator Ford 1965 78 w single V groove pulley and external regulator Fits most Mustangs w o AC A heavy duty unit 100 Amp is recommended with air conditioning Delco Remy rebuilt 321 159 Fits 1978 1984 Ford with HD alterna tor option Some single wire alternators can also be substituted Call for special wiring hints Carburetor Cold Air Box A cold air box for Weber carbs duplicating the original one is avail able from E R A Others can be custom fabri cated Distributor Because of space limitations your distributor must be of approxima
12. EMERGENCY shim thickness Rear geometry may be changed by BRAKE ASSEMBLY varying the castor angle of the hub carrier For serious competition the spring rates should be increased by 50 to 100 for optimum high speed handling Customers have used 50016 and OVERVIEW AND RESTRICTIONS 651b in R with success Spring length must be shorter if the rate is increased When the damper is fully extended the spring may be loose with the standard dampers Shorter dampers may be fit For With certain restrictions you may use 11 5 or 12 Corvette brakes Also at the time of this writing special racing pieces are being developed instance the front damper may be used at the rear FRONT a the E R A 289FIA damper may be used at the 12 front rotors will NOT fit into 15 wheels The ront pin drive kit includes rotor that are already sized correctly 11 5 Front uprights drilled for the 12 brakes are available on special order for those with 16 or 17 wheels For bolt on wheels in 15 wheels the standard Corvette 11 5 rotors must have their OD reduced to 11 5 and the anchor plates must be slightly modified by E R A You also must use spacers be tween the anchor plate and the upright mounting ears 12 PARTS PREPARATION REAR 1988 94 Corvettes with 12 rotors have their emergency brake built into the caliper The 12 rear rotors are very tight with 15 pin drive wheels Normal wheel weights t
13. REAR DAMPER STANDARD SPRING RATES Max length 17 5 Compressed length 12 0 with any rubber bumper fully compressed If you are using springs with rates greater than 350 Ib inch reduce the maximum extended length of the dampers by 1 Otherwise the spring will come off the seat in rebound Obviously the listed preloads for stock springs are not accurate for non standard length dampers If the extended length differs from the specifications listed on page 11 the preload length will have to modi fied accordingly If you are thinking of using very stiff damper set tings and springs for the street consider that low speed handling especially over less than perfect roads will be adversely effected Long term chas sis fatigue may also be a problem with extremely stiff springs and dampers Don t do it if you don t have to 11 PARTS PREPARATION COMPETITION STEERING GEAR Properly set up with good street tires at normal 1965 1975 MGB The early unit pre 1969 has pressures the street suspension should generate ets ie ous more than 1 and is very well balanced Handling evden Mabresults 10 2 turns poe to lock and Is recognized by a bulge in the pinion end cap The should be adequate for occasional high speed work a if tire pressures are increased by approximately post 1969 unit is 2 9 turns to S flat pinion end cap See the illustrations on page 32 10 psi Also
14. Washer 14055941 10052216 562247 562249 PARTS PREPARATION Retainer 562248 Cotter pin Rotor 12 from GM 10097655 Pin Drive Hub Drive pins Hub left and right hand thread Wing nut left and right hand thread 4 Washer cal mt 4 Bolt caliper plate DN 12mm lock M12 x 30 WHEELS AND TIRES BOLT ON With the standard fender openings we recommend bolt on wheels that follow the following specifica tions Front 8 x 15 4 7 backspacing 5 x 4 3 4 bolt circle Rear 10 x 15 4 7 backspacing 5 x 4 3 4 bolt circle With the 1075 option wheels up to 10 wide front and 12 5 wide rear may be fit Inquire as to the rec ommended offset for your rim and tire width PIN DRIVE Several Pin Drive wheels designs in 15 16 and 17 diameter are available or in development See the sources list on page 18 and or call us for the latest in formation TIRES The suspension is designed to maintain street ground clearance 5 0 with tire diameter of 25 front 26 5 rear You must keep your front tire diameter under 25 5 rear under 27 0 to avoid interference with the bodywork Small diameter tires will reduce ground clearance and change suspension geometry Wheel width is contingent on the wheel offset The 15 wheels that we supply both bolt on and pin drive will allow maximum sections of 245 in front and 295 in back with standard fende
15. damper stiffness can be temporarily dth dif increased for crisper response ort e early and late steering gear and the mo L 1 cations necessary for each You must tell us which For the most precise handling get a wheel load unit you are using because of a choice of tie rod measuring device and balance the chassis from adapters supplied with the kit The steering gear side to side This will compensate for variations in for a right hand drive car must be from a RHD MG spring stiffness and other factors You may also donor See M C Griffiths in the source listings at increase the negative camber in the front and rear the end of this section for RHD steering gears For suspensions up to 1 5 degrees and reduce toe in at those in a hurry E R A has bolt in steering gears the front to zero This will severely shorten tire life assemblies in stock and make the car hunt a bit while going straight and is not recommended for street driving Final ANTI ROLL BARS camber and tire pressures are best set by an expert with tire pyrometer Anti Roll Bars are not required but strongly rec ommended See the option list For track tuning keep the standard size bars but use an adjustable rear bar Increase only the spring rates The front and rear suspension may be bump steered by a shop specializing in road racing sus pension The steering gear may be raised or low ered on its mounts by increasing or decreasing the BRAKES CALIPERS
16. note on page Error Bookmark not defined As the kit is delivered the fuel tanks are already installed in the chassis secured in their aluminum cradles with high strength tape The following procedure duplicates the factory installation proc ess PREPARATION Secure the plastic tank into the cradle with rein forced tape Note that the front end plate of the cradle has two tapped holes Slide the tank cradle into the rocker gently guid ing it past rocker ribs way If you are using a fuel return line the fitting must be installed on the tank cover before the tank is fully in Remove the top access plate A in back of the front wheel and remove the access plug below When reinstalling use a thin coat of silicone In stall the lower flange onto the tank with the rubber gasket supplied using aviation gasket cement to coat both sides of the gasket and the bolt threads You can pre assemble the tank breather tube C onto the flange too The fuel filler well drain tube D is pre installed onto the filler flange Assemble the intermediate connector assembly E lower hose and aluminum connector tube outside Secure the line s going to the fuel pump and the the car and then install the assembly leaving the lower clamp slightly loose return line if you are using one along the crease of the inside corner of the fuel tank before you slide it into the pontoon Also tape the vent line to the fill
17. pump pulley s is typically removed from the center of the rear face of the pulley Install the reinforcing strap between the water pump and the outside of the alternator and secure with a lock nut The belt is installed directly from the crank pulley to the alternator without looping over the water pump 24 PARTS PREPARATION The adjusting bracket is mounted on the lower left bolt on the front cover and the slotted end 15 offset toward the front of the car If you are using a 351 engine you may have to increase the offset of the adjusting bracket to line up on the backside of the alternator boss Just make each bend slightly more acute Use a 3 g x 1 bolt into the alternator boss Belt length Try a Gates 7320 or 7325 or equiva lent to start OIL FILTER Don t forget that the oil filter must be changed to one of a smaller diameter or a remote unit See page 7 for details See page 64 for details if you are using an oil cooler TRANSMISSION DESCRIPTION AND SELECTION OPTIONS Pantera 4 bolt see below Pantera 7 bolt see next column BMW see page 29 Also see the bell housing notes on page 30 EARLY TRANSAXLE 5 DS 25 1 AND 4 BOLT PANTERA BELL HOUSING This transaxle can be recognized by the 4 bolts se curing the bell housing to the transmission While the torque capacity 15 slightly less than the 505 25 2 this is essentially the same transaxle as used in the original GT40 The Pantera
18. rod is going through a spherical bearing so you rear without rotating it Slide the short clamping may have to fiddle a bit to insert it If the rod is end onto the transmission rod and tighten the tight do not force Use a fine abrasive paper to clamp slightly clearance the rod Lightly grease the front rod and Place the transmission in neutral by finding the slide the rod through the chassis bearing midpoint in the front to rear travel The internal Bolt the tab on the front rod onto the shift lever springing will automatically rotate the rod to the with the shoulder bolt supplied The offset of the 2nd 3rd plane Have hold the shift lever tab should be toward the right side of the lever straight up and down Tighten both clamps on the rear coupling Install the rear rod by inserting it from the rear next to the transaxle through the hole in the engine bay right side Pass it forward through the holes in the inner panels so that it slides over the front shaft about 1 Access for this operation is from pling underneath the car through the rear trailing arm access hole From the drivers seat check that all gears are available and appropriately placed Small changes can be made at the front clamp on the rear cou SHIFT LINKAGE REAR AXLES REAR AXLES OVERVIEW We re working on an adapter that will fit the BMW transaxle Inquire Each drive axle assembly consists of a Hooks type joint on each end a
19. 27 Snow White water pump unten 22 solenoid Star er ed 16 oeieo RO 95 SOE I 17 VP Gre MOUM ed 76 SE LE JR 21 Speedometer ED 96 Speed 9 Splash panels Front compartment 76 Springs 11 SPANN 10 Starter Te 30 See RR SEE 30 e 16 74 TO 3 Steering column Replacement 109 Steering COMMI SUPP Ol 97 Steering gear TNS PANT GR RE NE 37 Mode 30 er 12 SKO Ea 88 SY KOL NU eh ase EN ET 111 GOO EE 76 81 VP ee 90 UOT AIS FRO AL EE JO 84 Suspension 35 ALIN ee 38 Replaceme t sad 108 36 Merv 40 Replacement Parto seede 108 Ts 38 Rieber 11 Suspension parts INDEX Societe int ochre A 14 LE EE RE EN EN 12 Tank Coolie system Cx PansiOn 16 Feed 70 Tank Fl ae 63 Thermostat vater vadestedet 69 Tol eee 21 46 Throttle pedal 96 TRO 8 29 Tie Rods SA red 31 Tire IRECSS URC 44 T NS KE E A 16 Trene
20. After feeding the drain tube through the grommet See the instructions and diagram on page 67 In install the access plate A with a small amount of sert the fuel filler fitting into the hole at the top of silicone sealer the cowl with the intermediate hose and bottom hose clamped and tightened Check that the bot tom of the hose lines up properly with the fitting on the tank Adjust if necessary Tighten the screws securing the flange to the cowl From access hole in front of the sill in back of the front wheel connect the breather hose to the fitting on the top of the tank Connect the large hose to the large tank fitting Install and tighten clamps RECOMMENDED DUAL FUEL PUMP AC EP12S or equivalent 5 25 O A L x 2 5 O D Minimum flow should exceed 30 G P H Install the front access plate to the tank cradle You may use both pumps simultaneously for very 20 bolts and use screws around the plate perime high long term fuel demand ter to hold the assembly firm in the chassis pon toon Use the clamps provided to secure the drain tube as shown Note If you are using a fuel pump different from the one above it must be equipped with a check valve preventing reverse flow or you must add From the hole in the battery box and the one in line between the tank and the junction corresponding box in the other side of the chassis block to the carburetor s Otherwise excess fuel install th
21. Classic Auto Insurance Div Steeves Smith amp Assoc Monroe CT Tel 203 261 8474 ext 20 Parrish Insurance Nashville TN Tel 800 274 1804 State Farm Insurance has been known to insure replicas as a Classic Car The Specialty Constructed Vehicle Association 310 422 1967 offers insurance through Condon and Skelly TransNational General Insurance Dallas TX Dave Gobel Tel 214 980 8941 Tri State Insurance Co Luverne MN Tel 800 533 0303 MN 800 722 9365 Mid west only Also see the article on insurance in Peterson s Kit Car SHIPPING COMPANIES Typically companies charge about 50 mile with a minimum charge to ship of about 400 Bats Motorsports Road Show Phone 541 739 2597 Phone 415 861 3111 Horseless Carriage Intercity Lines Phone 800 631 7796 Phone 800 343 0802 116 OG eiet 83 AT conditioni T 100 Chare ino With 103 COMPPESSOP 22 NN NE EE EN 102 IV MIT 104 Alignment BOO ENN RE 85 SPES ed 43 Ted 43 Alternator Mo seven 23 SCLC CHOI NR ET E 7 EEE 69 PRTC OAS reniras E en 69 ESSEN EN 12 stallati OU vvs 41 PNSSEMID IV seguente aan S 3 4 Reed 57 Backlash 1002 21 Balance Bar Brake uses EA 45 4
22. Cooling system header tank E R A offers a reproduction of the original tank that is mounted on the rear bulkhead Fuel pump s One fuel pump on each side or you may use a single pump and a tank crossover valve ac tuated by the power line from the other tank Mini mum capacity for each 15 30 gallons per hour more if your engine is modified If your fuel pump does not have an integral check valve you must add one in each line between the pump and the fuel junction to prevent flow from one tank to the other See section E for more details Handbrake lever Pontiac Fiero 10046473 GM A special modified lever is supplied with the RHD op tion See page for necessary modifications Hoses water See page Error Bookmark not defined for details Starter solenoid SX 581X Blue Streak or equivalent Voltage regulator VR 118 Standard or equivalent Wiper motor cable hardware and one wheelbox from 1971 1978 Triumph Spitfire Preferred wheelbox numbers 72859 72861 72902 or 72906 The motor linkage must be modified See page 34 PARTS PREPARATION Wiper arm 15 pivot to end Wiper blade 18 Assemblies are available from E R A 17 PARTS PREPARATION SOURCES SOO Tel Nos do not apply in State being called Aviad Metal Products 7570 Woodman Place Van Nuys CA 91405 Tel 818 786 Oil pan 4025 CFI Motorsports 5 B Hamilton Bus Pk Dover NJ 07801 Tel 973 9260 AVO Dampers Clark Bros Instruments Shelby
23. and lap joints PREPARE AND PRIME THE CHASSIS Thoroughly degrease the chassis and all attach ments to be painted rollbar subframe brackets Glundcoat etc Use a metal conditioner to chemically etch Rust proofing and undercoating are different proc the metal to ensure good primer adhesion follow esses using dissimilar materials which are applied to ing the manufacturers instructions Spray the unique areas of the chassis primer carefully into all areas including as much When rust proofing a thin waxy material is applied to as possible the areas inside Epoxy and other the hidden areas of the chassis allowing it to seep into primers and paints are toxic Be sure to follow the the narrow seams and joints formed at the junction of necessary health and safety precautions indicated panels Rust proofing material should be non on the labels while using these materials hardening to eliminate the possibility of cracking and After the primer has cured caulk all the welds and subsequent moisture invasion Access holes have seams with a paintable autobody seam sealer Use been provided in the chassis see the diagram on the a squeegee or heavy rubber gloves if applying next page along with push in plastic plugs to seal the caulk with your fingers The gloves are used to areas afterward Under avoid being cut by any burrs that may have been coating The underside of the chassis may be coated missed with one of the rubberized undercoatings
24. and clamp or tie wrap the inner end over the housing Install a Jam nut 20 LH on the stud The thread is left hand ERA STEERING GEAR This gear includes the inner tie rods as integral with the rack General installation is the same as the two steering gears described above Tie rods are screwed directly into the inner tie rod sleeve WIPER MOTOR When purchasing the wiper motor and linkage be sure the following items are included Motor with cable and intermediate tube one good wheelbox the chrome retaining nut plastic spacer on the wheelbox threaded section and the short cable guide tube on the furthest wheelbox The latter may be cut from the old intermediate tube because a new tube is supplied with the kit For testing and trouble shooting the wiper see the Electrical testing and troubleshooting supplement 33 The chrome bezel must be modified by machining so that it is no longer beveled on one side The bezel is also available from ERA on an exchange basis Chrome Bezel The connecting rod and crankshaft inside the wiper motor gearbox must be modified to yield the proper sweep of the wiper on the windshield If you are sure that the wiper motor functions cor rectly and do not wish to disassemble the wiper motor for inspection at this time skip steps 4 through 8 Conversion wiper crankshaft and con necting rod are also available from ERA on an ex change basis Remove the 4 screws holding the cover to
25. bell housing transmission end must be redrilled to permit rotating it 180 relative to the transaxle The transaxle itself already has pas sages for proper internal lubrication but must be drilled for drain and level indicator holes This bell housing transaxle combination uses a full size 164 tooth starter ring gear Consequently the bell housing hangs about 1 5 below the chassis and is also about deeper than the E R A bellhousing For extra ground clearance it is possible to ma chine a flat section on the bell housing bottom edge Unfortunately the starter ring gear will now be exposed and will fall slightly below the chassis The depth of the bell housing as measured from engine side to transmission side must be reduced a total of 4 by machining about 25 from the en gine end and 15 from the transmission side 2 As with the later transaxle ring gear must flipped to the other side of the pinion gear so that you don t end up with 5 speeds in reverse LATE TRANSMISSION 5 DS 25 2 Check this distance when you buy Some rare transaxles use a much longer input shaft Many transaxles must have the end trimmed 1 mately 4 anyway Final finish is not critical so the operation can safely be done by hand gt man b transin The late ZF transmission uses 7 bolts to secure the stock Pantera bell housing to the transmission rather than the early version s 4 Unfortunately re dr
26. below the chassis the maximum oil pan depth is 7 There must also be clearance for the starter when using the ERA bell housing Be cause of this limited depth proper baffling in the sump 15 mandatory Call us about special pans and pumps The best bet is the Road race GT40 55360 Aviaid pan which can be used with the starters listed below The capacity is 7 qts plus whatever is used in the oil cooling sys tem If you have a LHD car the dip stick should be mounted on the front cover or the left side of the pan A dipstick tube on the right will interfere with the shift linkage Oil Filter Because of clearance necessary for the alternator it is necessary to use a remote filter or a small diameter filter such as Fram PH966B 3 7 long PH2825 5 6 long PH2870A 5 long or equivalent When using an oil cooler care must be taken to select the proper fittings on the engine adapter It 15 best to have the major components installed in the chassis before buying parts Starter We recommend using a Ford Motorsport Mini starter M11000 A50 or the heavy duty equivalent M11000 A60 as used in post 87 cars although most other starters will fit if they are matched to the ring gear depth of the flywheel and the oil pan configuration LHD cars Because of the nearness of the shift link age limit the length from mounting face to starter end to 7 Some aftermarket gear drive starters may require that you rota
27. by supporting the gear edge and tapping the shaft with a soft hammer Be careful not to damage the circlip groove Note the position of the crankpin relative to the raised section on the backside of the plastic gear The position of the crankpin must be changed in order to increase the stroke of the cable See page 34 Punch the underside of the crank plate exactly opposite the center of the crankpin Use a Blair spotweld cutter to cut the pin from the plate drilling from the back side at the punch mark Ei Wiper crankpin diagram Drill a hole in the opposite side of the crank plate at the position indicated in the illustration Countersink from the crankpin side just enough that the crankpin will be flat on the plate after in sertion into the hole Weld or braze the pin in the new hole from the back 34 Ei wipgear Install the plastic gear onto the crankshaft engag ing the tangs of the gear into the crankshaft notches Keep the same relative orientation be tween the new crankpin and the gear as before dis assembly The raised section on the plastic gear is about 150 degrees offset from the new crankpin position b Wiper cowl Clean and deburr the crankshaft Grease the shaft lightly install the conical thrust washer and insert it into the housing Install the outer thrust washer and circlip b wiper Connecting Rod Modify the connecting rod shape by removing the shaded area Cut the
28. c rsusp REAR UPPER AND LOWER CONTROL ARM INSTALLATION Install the rod ends on the upper radius rod the same way described for the trailing arms Install the upper radius arms right hand threaded end on the rear hub carrier as illustrated Use a flat washer between the rod end and the hub carrier Note that both the upper and lower fulcrum pin brackets are offset Orient the offset of the upper pin bracket 45 degrees down and in This will keep the line of force as close as possible to the junction of the end of the pin and the U bracket welded to it Install the 5 rod end and jam nut onto the outer end of the lower control arm See the illustration for the correct fitting dimensions If you are also installing the front bearing press it into the arm and secure with the snap rings on both sides Lu bricate the ball with a small amount of chassis grease 43 Install the rear lower control arm onto the hub car rier Slide the lower fulcrum pin through the front bearing 282 spacer and the hub carrier There are shims provided to fit between the hub carrier and the rod end Install a washer and lock nut and tighten to 35 Ib ft Orient the offset of the fulcrum pin bracket toward the inside of the car and up 45 deg As with the upper bracket the line of force from the trailing arm should pass through the base of the bracket where U section is welded to the shaft Install a 5 g x 5 bolt into the outer sleeve
29. can be permanently bolted in place without the subframe BODY LIGHTS INSTALLATION All the lights are pre fit Fit them to the body us ing your notes from section A WIRING Connections are detailed in the wiring connec tions supplement PAINTING DETAILS After carefull fitting and matching the panel con tours with the body sections mounted also head light covers page 95 all panels front and rear body sections doors should be removed for final preparation and painting of the edges Metallic colors should be painted with all the panels in place to avoid metallic mis matches STRIPES See below for the original competition stripe di mensions Gistripe GLAZING You may wish to have a glass specialist install the windshield and rear window You can do it at home but it is delicate operation The following directions apply to home or professional installa tion WINDSHIELD When bonded in place the windshield is a stress bearing part of the roof When the car is driven the glass will probably crack if it comes in direct contact with the body anywhere Be very careful when centering the glass Glue the rubber windshield molding in place on the edge of the windshield G fwindow2 Use rubber spacer blocks high and no wider than the width of the body flange to hold the glass away from the body and smaller ones placed around the perifery of the glass to center the windshield in t
30. car bounces from bump to bump or control is maintained adequately Increase the damping until side hopping begins then decrease the setting until control is regained Read the instructions given above for Koni re bound damping adjustments for transition under steer oversteer adjustment SUSPENSION AND BRAKES WHEEL ALIGNMENT Camber is the vertical tilt of the tire to ward the outside Camber controls the All alignment operations should be done with the contact patch of the tire Negative ride height set to your preference See the section on camber tends to give higher cornering springs page 10 for further information force limits but wears the inside of the tire rapidly Excess negative camber can traction especially during braking and acceleration Fuel tanks should be full or the car ballasted appro priately and the car on a level surface Tire pres sures should be set to Front 22 PSI Rear 25 PSI King pin inclination is the position of the front upright axis inward at the top toward the center of the car Its primary purpose is to decrease the offset of the center of the tire patch from where the front upright axis meets the ground This lessens steering effort and unwanted gy roscopic reactions from the spinning tire as it travels up and down It is not ad justable FRONT ALIGNMENT SPECIFICATIONS Caster 6 degrees 1 deg The right side caster should always exceed the left if there is a varia
31. earlier all inside releases are con latching the door with the other Move the door nected to the latch by cable in until it is lined up with the outer body While holding the striker in place carefully un LIMIT STRAP latch the door and pull it open Tighten the Install with 4 screws striker retaining screws While holding the door handle in the open posi x tion close and open the door several times Listen for metal to metal contact Not just the light sound of the latch fork contacting the striker pin as it moves to the closed position The door should not be pulled up or down when it contacts the striker but go straight into its closed position With the door held in the closed position and the handle released it should latch without having to move the door If door readjustment is necessary repeat the proc ess Remember the striker will not be perpen dicular to the chassis when properly adjusted The striker is oriented 90 degrees to the swing of the door When adjusted properly and with the weather stripping in place the door should close with a solid thunk when given a moderate push Hard noise indicates contact between fiberglass GVstrap and fiberglass or fiberglass and metal Soft resis tance indicates that there is binding because of the weather stripping INSIDE DOOR LATCH RELEASE Three types of inside releases are available for the GT 1 Standard pull cable release 85 BODY
32. firewall tunnel and check the vertical clearance between the bottom end of the shift lever and the bottom of the Front universal joint clamp J slot in the shift box The clearance should be about Rear rod If the height needs adjusting remove Connecting universal joint clamp to transmission shift lever and shaft and screw the the rod end up Caution If you decide to plate any rod components one clearances through the bearings may become too 7 ROD small Remove the shift box temporarily A spherical INSTALLATION bearing is taped onto Z link Remove the bearing and remove any burrs from the short end of the link The bearing can only be installed after The shift box comes preassembled and plated and the lockout 7 har d chr omed for wear already Note the link is fed through the hole in the engine bulk the configuration including washers screw direc tions etc for assembly 56 SHIFT LINKAGE REAR AXLES Feed Z rod through slot above the tun nel snaking the end through the support bearing housing on the rear firewall The fit is tight so a little encouragement may be necessary Grease the support bearing and install over the shaft and into the bearing sleeve while lining up the dimple in the bearing with the set screw Secure in the sleeve by tightening the 10 32 x setscrew Do not overtighten Install the shift box onto the tunnel while sliding the front s
33. for ZF specialists The Pantera used two variations Early cars used the SDS 25 1 with a 4 bolt bell housing Later Panteras used the 5DS 25 2 with a 7 bolt bell hous ing The 2 models are somewhat stronger and must be used with the special ERA bell housing Both transaxles are nominally rated at about 325 lb ft capacity The rating is probable conservative there are twin turbo d Panteras with more than 450 Ib ft out there presumably not trashing their trans axles at every stoplight The Pantera transaxle must be converted to run in an inverted position See page 26 for modifica tions The Mangusta and BMW ran with the correct GT40 orientation In addition top cover must be changed to one with mounting bosses like the Mangusta Covers are available from ERA or RBT Transmissions f topmount The Pantera bell housing for the 25 1 can be re drilled to enable transaxle inversion Unfortu nately the bell housing depth must also be reduced and the bottom edge must removed for ground clearance Even with the bottom edge modified ground clearance is limited by the ring gear diameter which must be kept compatible with the starter location on the bell housing An original GT40 bell housing might fit on a 25 1 transaxle Unfortunately it may impossible to actually find one The later transaxle 25 2 must be used with the E R A bell housing Our custom bell housing solves the ground clearance problem it us
34. in place drill through the holes in the aluminum into the subframe tubes with a s bit Use 4 grip range alumi num countersunk rivets along the upper subframe tubes so that when the weather seals are put on later they will be flat against the panel Apply silicone or similar sealant adhesive caulking between the areas to be riveted together to prevent buzzing later on Rivet the panels in place Check that there are two drain holes in the floor panel under the radiator and if you have air conditioning the case drain hole has been drilled in the panel ATTACHMENTS Use the illustrations below to install the following brackets floor reinforcement spare tire mount horn bracket and if ordered the jack mounting bracket and A C drier bracket Note Install the water pipes through the chassis be fore the removable spare tire stop and radiator Frntbay2 BODY Gl rntbay1 FRONT COMPARTMENT WEATHERSTRIPPING Install the aluminum weather strip rails onto the cowl These units were fitted at the factory and held in place by 2 or 3 screws for shipping Re place them to their original locations and screw them in place with 6 screws Use a sealant caulk under the rails COWL TO FRONT BODY Fit the weather seals to the rails Also install the small dams between the w s rails and the pinch weld flange at the front of the cowl 80 G TOPCOWL COWL TO NACA DUCT To minimize water seepage into the cowl area
35. of the rear hoop from the engine bay side Slide the lower control arm inner pivot onto the bolt The 375 spacer goes between the inner bearing and the rear subframe tie bar Finish with a flat washer and lock nut torqued to 80 Ib ft Slide the upper radius rod over the stud in the up per hoop Install the tie bar between the outside of the rod end and the stud on the top cross member The tie bar end with the slot goes over the stud in the crossmember See the diagram of the rear sub frame on page 87 Secure each end with a flat washer and locknut Install the upper and lower trailing arms onto the hub carrier pins with x 1 3 4 bolts flat wash ers and locknuts Do not tighten the lower bolts SUSPENSION AND BRAKES FRONT ANTI SWAY BAR COIL OVER INSTALLATION For specifications see page 11 The bar is fit in the channel under the front floor FRONT mounted in the special plastic bushing sandwiched by a steel strap The bar extends forward to the front side of the damper bolt Use the 7 16 x 1 bolts with lock washers to secure the bushing and brackets to the chassis Install the rod end links to the anti sway bar with the x I screws stover nuts The long 3 8 bolt slides in from the front through the rod end the lower control arm sleeve and then through the reduced diameter bushings in the lower damper mount REAR See page 43 Place the rubber bushings and metal clamps over th
36. of the GT40 which contained only the heater ACLAYOUT2 The compressor is engine driven with the lines running the full length of the car to the condenser core mounted in the front of the radiator See the schematics for airflow and coolant at the end of this section for layout details Fresh air is drawn from the NACA ducts on the front fenders and at the base of the windshield into common plenum in the box At your option you may use this fresh air or air that is recirculated by the fan from the footwell for cooling or heating Air can then be directed to the face level vents at the left and right of the dash and or to the vents at knee level under the dash and or to the vent 1 rected at the feet The defroster vent at the top of the dashboard is continually open but air flow may be maximized by closing one or more of the other sources Flow through ventilation is controlled by the roof vent and the side windows A complete air flow schematic is on page 106 Interior Ventilation COMPONENT INSTALLATION EVAPORATOR HEATER BLOWER BOX See the diagram below FUNCTION AND CONTROLS The AC control panel consists of a three speed fan switch AC temperature control rheostat three sliding controls controlling the source of the air x direction of forced air and the temperature of the heated air At either side of the dashboard face level vents at the may be opened or closed by rotating the cen tral kno
37. of the engine CARBURETORS INTAKE MANIFOLD The water temperature sender requires a hole in the water section of the intake manifold tapped about 7 to the outside of the threads or a fitting in the water outlet Check the thread in your manifold You may want to drill and retap before the engine s final assembly If you are using an Inglese Induction Weber mani fold you must remove the spacers underneath the carburetors or replace them with thinner ones The replica cold air box Weber Carburetor only available from E R A must mount just below the carburetor mounting flange This air box prevents use of the tapped hole in the intake manifold for the water temperature sender You must make or purchase from us a special thermostat housing manifold incorporating a fit ting for the temperature sender WATER PUMP Changing to a shorter water pump 15 highly rec ommended Note that the alternator and AC ad justing brackets etc are mounted on the flange of the pump and the lower right water pump bolt must be exchanged for a longer one included in the AC kit Measure from the front of the block face to the front face of the crankshaft damper Do not measure from the front cover The early damper will measure about 4 When using any engine with the long crankshaft damper the crankshaft damper must be replaced with an earlier one or the Snow White pulley must be machined on the rear surface so that it line
38. right on LHD cars on the ers with gasket in place into the body Remove left on cars the covers and enlarge the holes for the screws as described above Alternately you can black out the edge of the cover by painting with flat black paint rather than using gaskets REAR WINDOW Use similar techniques to drill and secure the win dow Wiper Assembly the drive through the cowl after modi fying the bezel as indicated on page 33 Note that the motor is always mounted on the passenger s 96 Interior Ventilation INTERIOR VENTILATION 97 Interior Ventilation WIRING THE DASH AND FRONT THROTTLE LINKAGE AND CABLE FIREWALL OVERVIEW See the wiring supplement for details LEFT HAND DRIVE SOUND DEADENING AND HEAT The throttle pedal acts on a bellcrank mounted on the forward end of the tunnel which in turn pulls INSULATION the cable that attaches on to the carburetor s The Before the carpets are installed you may want to bellcrank translates the linear motion of the pedal place sound deadening material on the floor and into a progressive action at the carburetor so that the footbox sides Material is available from most low speed control is enhanced The progressivity body shop supply stores Apply the pieces on the may be changed by altering the various linkage re flat areas of the floor alonge the sides of the foot lationships boxes and rocker panels and on the diagonal panel behind the seats
39. rods provided in the kit Which one you use will depend on the forward and aft location of the brake box Determine where you want the brake box first and then find the most appropriate rod length The stop on the bell crank should rest on the tun nel The welded nut on the throttle pedal is threaded 20 Use the hex cap screw 1 long to go through rod end and into this nut RHD See the illustration of the brake box on page 49 for an assembly breakdown of the front linkage The bellcrank on the tunnel is not used The cable is connected directly to the transverse link mounted on the brake box 99 SPEEDOMETER CABLE Note Because of the variations in speedometer and transmission drive gearing there is a gear re duction unit in the cable about two feet from the transmission end It should be correct for your application but if you find that your speedometer is highly inaccurate the reduction unit may be ex changed for a more appropriate one Installation Pass the cable forward through the engine firewall see Illustration on page 66 for the correct hole and through the hole above the rear end of the tunnel Fasten or tape the cable to the passenger s side of the tunnel allowing enough length about 56 on the transmission end to reach the speedometer drive If you have air con ditioning the cable may be routed with the hoses alongside the tunnel Loop the cable behind the passenger s footrest and alon
40. sleeve and engage the unit onto the transmission throwout guide sleeve PARTS PREPARATION Rotate the transmission throwout arm forward so that the fingers engage the retaining springs on the adapter It may be necessary to remove the out side arm to rotate the throwout fork forward enough Cltch ht With the throwout bearing assembly in its rear most position measure the distance from the throwout bearing face to the face of the bell hous ing This dimension should be between s and 14 more than the height of the fingers If not in stall one or both of the spacers behind the bearing When properly set up the throwout bearing should be capable of depressing the clutch fingers at least without rocking on the guide sleeve When the proper fit is confirmed use Locktite Bearing Mount to secure the bearing to the adapter 31 Throwbr Use a light grease when installing the bearing adapter assembly onto the transmission guide tube STARTER If you are using the ZF 5DS 25 1 with the stock ZF bell housing inverted you may use the Ford or Tilton starter listed without modification If you are using the ERA bell housing on the ZF 5SDS 25 2 and using the recommended Tilton starter you must rotate the motor of the starter clockwise about 45 degrees If you are using the Ford starter with the ERA bell housing you may use it without modification pro vided you have an oil pan that is notched f
41. time the clutch seems to be too high or starts to slip check this clearance and ad just 1f necessary WITH A RETURN SPRING BUILT IN After installing the pushrod as described above ad just the length so that there is 6 amp to s clearance at the slave cylinder You will have to push the lever arm forward against the internal springs to measure the clearance Note The rod will have to be adjusted every 3000 miles to maintain this clearance Install the starter using two x 1 bolts ENGINE AND TRANSAXLE Install the water manifold on the intake manifold See page 70 INSTALLATION INTO CHASSIS The engine and transmission must be installed as a unit sliding in from the rear of the car Because of tight front clearances a direct approach from the top is impossible Don t install the engine mounts onto the block un til the engine is approximately in place WITH AN ADUSTABLE ENGINE HANGER AND CARBURETOR PLATE Attach one end to a carburetor plate and the other end to a sling around the transaxle Lift the assem bly so that it tilts down at the front slightly Slide forward with the engine pan just above the bottom of the rear hoop WITH A SLING OR CHAIN Hang the engine from the front of the left cylinder head and a loop around the right transmission axle flange so that the assembly tilts slightly forward If you have Weber carburetors use a straight spreader between each end Keep the spreader dista
42. 008 interference fit If you replace the flywheel note that some crankshafts are externally balanced and require an out of balance flywheel to match The ring gear must then be heated in an oil bath to about 160 deg above ambient temperature and quickly slipped onto the flywheel If the clutch bolt pattern is different from what you have now is the time for the machine shop to modify the fly wheel 30 Bellpro1 Assemble the flywheel pressure plate and driven disk onto the engine Bolt the bell housing only onto the engine and rotate the crankshaft a full 360 degrees checking the clearance between pressure plate and bell housing through the transmission flange hole If there is minor interference you may grind the bell housing If there are major in terferences replacement of the pressure plate with one of different manufacturer may be necessary THROWOUT BEARING ADJUSTMENT Install the special pilot bearing supplied with the ERA bell housing into the crankshaft A throwout bearing and adapter sleeve is supplied with the ERA bell housing Because of different clutch finger heights the adapter sleeve is supplied with spacers to adjust the height of the throwout bearing relative to the bell housing face With the clutch installed use a straight edge across the pressure plate to measure the height of the fingers relative to the engine plate See page 31 Temporarily install the throwout bearing onto the adapter
43. 20 cup can be purchased from most bearing supply stores You will proba bly also need different shims to set the ring gear backlash These are available from the Pantera specialists mentioned in the sources list in incre ments of 004 Imm Do not use standard gasket sealant like Permatex 300 or silicone Use only aircraft type non hardening stuff Many critical transmission clear ances are based on the use of this material MODEL 25 1 Have a machine shop redrill the bell housing so that the unit can be inverted See the 25 2 instruc tions for reversing the ring gear installing a new filler and new drain hole MODEL 25 2 EX PANTERA DISASSEMBLY Clean the exterior case before disassembly Drain the oil It may be helpful to make a rig to support the transaxle from the bell housing side for the follow ing operations Invert the transmission so that the differential ac cess cover 15 at the top This is the way the trans axle will be installed in the car so from now on any reference to top and bottom will refer to this position Remove the long cross bolts going from side cover to side cover Save the shims between the side plates and the top cover Note their location and number for assembly later Remove the differential top access plate bolts Remove the nuts securing the side cover plates Carefully and evenly pry the plates straight out from the main case If there is resistance check that all the bolts h
44. 351 manual transmission Ford all models ZF TRANSAXLE INVERSION PROCESS PANTERA GENERAL HINTS We strongly recommend that you purchase a ZF factory service manual for overhauling the trans mission see page 18 for information Those companies can also do servicing and have parts for the ZF You will need the normal complement of metric wrenches and sockets plus 5 and 6mm allen wrenches Special attention should be given to synchronizer rings bearings and the speedometer driving and driven gear Itis also recommended that the bolts securing the ring gear to the differential unit be drilled and safety wired If you are going to do any major service the spe cial tools or equivalents listed in the manual are very important to some operations especially re moving the ring gear from the case and disassem bling and assembling the gear clusters onto the back plate While it is possible to remove the ring gear bearings without the factory tool or its equivalent it 15 a difficult and time consuming process Not recommended When disassembling the transaxle keep multiple containers for each sub assembly and its associ ated parts Label them with notes for assembly Buy a full gasket set for the transaxle Get a new locking nut for the shift rod cross shaft 26 The ring gear bearings may be damaged during disassembly and it is good practice to replace them anyway Replacement bearings SKF 25590 cone and SKF 255
45. 4 ID x 3 1 4 approx long from straight material are needed See above for material Hose longitudinal tube to 5 connector Snow White Pump Gates 20837 cut to specifications in diagram Ford Motorsport Gates 20887 cut to spec s Hose bottom longitudinal tube to L 20594 Gates cut to specifications in diagram Hose S connector to water pump 2 ID x 2 long straight Hose L connector to 1 1 4 ID x 2 1 4 long Hose to intake manifold 1 ID x 10 long flex type Hose connector to header tank 1 1 4 ID x 2 Water pump Snow White shortie Expansion tank with 12psi cap capacity 2 quarts minimum available from E R A Water manifold for Weber intake manifold or 90 degree gooseneck see page 72 for 4 bbl manifold Weber water manifold also needs 2 1 1 4 x 2 hose connectors WITH HEATER Hose heater to left longitudinal tube 3 g ID Hose heater to right longitudinal tube 5 SEE THE COOLING SCHEMATIC ON THE FOLLOWING PAGE FOR THE GENERAL LAYOUT OF COMPONENTS FUEL AND COOLING SYSTEMS MODIFYING THE SNOW WHITE WATER PUMP Plug the heater outlet This can be done by tapping the casting and installing a NTP pipe plug or using a short length of hose and a plug Use teflon or thread sealing compound on the threass If you are using a Weber carburetor manifold with dual water outlets the upper 3 4 of the water pump base plate must be removed to clear th
46. 7 Bo 16 Bearne 36 Bell housing PASSED ad 29 all 59 B S De 16 Body MEN 85 re EEE ER 86 87 Pi 90 Removal Toe 20 IE RE 20 Bolts Application 18 110 OSS NE 22 Brake box sad 47 Brikke 12 Balance nd 47 15 5 50 Caliper SAR ee 48 Fs 46 ds 46 Erie ms va 46 VENN 45 PE Cal ASS CMa 46 EEE 12 Breather ET 61 INDEX 117 61 Varen 7 Bulkhead panels 76 Bulkhead 99 Cable 16 Speedometer 9 16 ata 96 EEE EE EE 21 95 Caliper Brake 46 Came 43 Capacity Msn ene 7 WAN SAK easter 21 Carburetor AM DOR 21 Cold air bok ass 7 Webe 21 nen 97 GE RR ER E 43 Chassis uer 73 ee 24 Adapter sleve 29 ING spss
47. 714 744 1398 PS Engineering 2675 Skypark Dr 112 Torrance CA 90505 Tel 3110 Wheels 534 4477 18 PARTS PREPARATION TOOLS REQUIRED Standard combination wrenches from You may need two of each Socket sets in and with extensions and universal joints Torque wrench Screwdrivers in various sizes Small jack Jack stands 4 Patience YOU MAY NOT HAVE 8 mm Allen wrench for use with a socket driver rear brake calipers 10 mm Allen wrench for front brake calipers rear hub bearings Allen wrench drive pin drive only Allen wrench drive for Upper Control Arm 31 flex socket drive Frt damper top mt Crowfoot drive Trailing arm jam nuts Servicing the transaxle requires metric wrenches from 10mm to 32mm and several allen wrenches YOU WILL ALSO NEED A GREASE GUN SILICONE SEALANT THREAD LOCKING COMPOUND AND SAFETY WIRE 19 PARTS PREPARATION PARTS PREPARATION 20 PARTS PREPARATION KIT DISASSEMBLY Unless E R A has already painted and or un dercoated your chassis it for you it 15 neces sary to partially disassemble the kit to pare some pieces for final assembly This section will give you the best sequence and or hints for removal of the more difficult parts BODY REMOVAL INSTALLATION FRONT DeDzus and remove front hood by rotating the wing on each fastener 90 degrees Counter Clockwise Note tha
48. A Note F Retain the stock pressure plate and disc Use the throw out bearing and pilot bearing sup plied with the ERA bell housing See below and page 62 for other details See also note G Note G Temporarily install the bell housing and starter onto the engine When using the 157 160T ring gear there may be interference be tween the nosepiece of the starter and the ring gear teeth A small amount of material may be removed from the starter nosepiece at the appro priate point SPRINGS AND DAMPERS OVERVIEW Several combinations of springs and dampers are available depending on your driving intentions and your pocketbook For economical street and lim ited competition work we have worked with Spax UK to develop custom units For greater adjust ability and performance Koni units are available with steel or aluminum bodies Springs may come from many sources but we have found that only certain brands are reliable for long term use Inquire PARTS PREPARATION Dimensions given below are subject to final ad COIL OVER DAMPERS SHOCK justment for your preferred ride height We rec ommend 5 inches front 5 25 back for street ABSORBERS ground clearance tub to ground The original The following dampers fit the chassis well and have GT40 s had 4 8 street 4 1 track clearance At 5 adjustable height and adjustable damping Koni there will be approximately 39 travel 3 dampers are quite expensive excep
49. ASSEMBLY and SERVICE MANUAL FOR THE ERA GT 2 REPLICA AUTOMOBILES 608 612 E MAIN ST NEW BRITAIN CT 06051 TEL 860 224 0253 FAX 860 827 1055 E MAIL eracars sbcglobal net WEB SITE www erareplicas com 2005 ERA REPLICA AUTOMOBILES Revision 4A 1 05 CONTENTS PARTS NEEDED ASSEMBLY SEQUENCE 1 PARTS PREPARATION 20 SUSPENSION AND BRAKES 36 SHIFT LINKAGE AND REAR AXLES 55 ENGINE AND TRANSAXLE 61 FUEL AND COOLING SYSTEMS 65 BODY 75 INTERIOR VENTILATION 97 UPKEEP REFERENCE REGISTRATION 109 INDEX 117 PARTS NEEDED ASSEMBLY SEQUENCE PARTS NEEDED ASSEMBLY SEQUENCE Parts Needed Assembly Sequence WELCOME Congratulations on your purchase of the ERA GT kit Our goal when we started on the design and construction of this kit was to cre ate an accurate and buildable Ford GT 40 replica with minimum compromises You are free to make your own improvements but be aware that the ERA GT is a complex and integrated design Changes that you make in one place will proba bly effect several other systems If you wish to retain the essence of a true rep lica it s best to be conservative Also it is usually the case that the more com plex things get the less reliable is the result While this is certainly not a small project it can be one that is straightforward and very rewarding Read the manual well We have tried to include all the informa tion necessary for yo
50. Borgeson U10 HS Alinabal NBA 10A MOOG 9170 or TRW 12336 192 INDEX FASTENERS INCLUDED IN KIT OR WITH OPTIONS T top F front R rear U upper L lower HC Hex cap screw SCS Socket cap screw TR Threaded rod Quant Size Type Application s 8 ae Xs HC Shift box to tunnel col mt 8 la KL HC Fuel tanks 1 x 1 HC Steering col front 1 x 1 HC Ground bolt right engine mt 4 F Sway bar bracket 10 F Pin Dr hat to rotor 1 fis x 14 HC Clutch master link 2 h x 1 4 HC Steering column dash support 4 fis x 214 HC Steering gear mount 1 2 Column support column 1 x 3 16 HC Balance bar 1 fis x 4 HC AC tensioner to water pump 4 Alt bracket Alt adjuster 2 AC mounting bracket 4 HC sway bar top link 8 SCS FLCA Ball Joint boss to hub carrier 3 Starter bellhousing 8 SCS Front Steering Arm to Hub carrier 1 he RE HC AC tensioner 2 HC Front sway bar L link 2 Te HC Crossmember to R hoop 1 3h x 4 1 HC AC compressor to bracket 2 VEKS A R subframe to R hoop 2 2 x 10 TR Trans to trans mt 1 x 1 HC AC bracket 8 he x 14 HC F axle bearing to hub carrier 4 he x 2 1 HC FL control arm inner pivot 4 SCS FU control arm inner pivot 4 susp trailing arms to hub inner tie rods 2 UK HC R damper L end 2 ee Se HC R damper U end 2 HC F damper U end 2 Hy Gon R L trailing arm forward end 2 fy 4
51. HC R U trailing arm forward end 2 Wy KD HC R subframe L tie bar 2 Y RO HC F damper L end 2 fo x 234 HC Engine mounts 2 fis x 4 HC Transmission mount to chassis 2 x5 1 4 R L control arm inner 4 M10 x 30 SCS DIN 912 12 R cal ps early 5 M10 x 40 SCS DIN 912 Bell housing 2 M10 x 30 SCS DIN 912 Bell housing to trans 4 M12 x 30 SCS DIN 912 12 R cal ps late 113 INDEX 4 M14 x 40 SCS DIN 912 12 F caliper anchor plate two piston w 11 5 rotor M14 x 50 F caliper anchor plate two piston w 12 rotor M12 x 40 F caliper anchor plate single piston 6 M14 x 70 SCS DIN 912 12 R hub carrier bearing housing 3 M10 x 40 Stud DIN 935 Slave cyl bracket to trans SPECIAL WASHERS 6 M12 Star R Hub carrier bearing 2 DIN 9021 M12 Flat U ball joint 1 2 x 1 9 16 2 085 Flat L ball joint 1 2 x 1 3 8 2 088 Flat Trans mt 11 16 x 1 3 4 Bowman 36771 7 M10 rib Bell housing to trans 12 fi int l star F U C A inner 4 SAE flat L C A inner pivots 16 flat R trailing arms damper mts etc 2 tee int l star F U damper 4 wave U and L ball joint 6 SAE flat Rear subframe trans mt 2 M24 DIN 463 Lock tab Rack end clevis FRONT SUSPENSION CASTER SHIMS Quant Thickness Style 20 070 slotted 8 035 slotted 8 060 hole TORQUE SPECIFICATIONS FOR FASTENERS Use figures below only if unspecified in appropriate instructions Torques are for lubricated threads or threads with liquid t
52. OINING THE ENGINE AND TRANSAXLE Before you attempt to install the engine and transmission check the preparation outlined on page 9 and 28 INSTALL THE BELL HOUSING ONTO THE TRANSMISSION See the clutch installation notes on page 30 DS 25 1 EARLY TRANSAXLE PANTERA BELL HOUSING The modified Pantera bell housing is held to the transaxle with the 4 special fasteners that were originally used in the Pantera DS 25 2 LATE TRANSAXLE ERA BELL HOUSING The bell housing 15 held to ZF transaxle with the 7 allen screws supplied 5 M10 x 40 on the upper section and 2 M10 x 30 the lower sec tion with a low head for clearance Remove the external clutch linkage arm from the cross shaft splines Rotate the shaft so that the throwout bearing is in its fully retracted position and reinstall the arm in the position indicated in the drawing of the slave cylinder in section E Bolt the engine to the transmission with the en gine plate flywheel clutch and throwout bearing installed You should have already checked for clearance between the bell housing and the clutch see page 31 but rotate the engine one revolution to check again 62 Rotate the external throwout arm forward until the throwout bearing hits the fingers of the clutch If your transaxle has the clutch shaft return springs this takes a fair amount of pressure If there is not room between the arm and the trans axle case for 1 travel remov
53. Orange Black Yellow Separate There is also a probe from the expansion valve tie wrapped to the water tubes Because of the prox imity of the probe to the heater tubes it is impor tant that the heater valve be fully closed while the Connections for the other end of the harness and also the temperature probe L30 are made at the lower right corner of the housing The tempera rak ture probe 13 2214 goes through the hole in the AC 1 being used housing with the fluid lines and is inserted into the core from the back about an inch 107 INDEX Wire L21 connects to the pressure switch mounted between the condenser and the drier The other pressure switch wire L28 should be grounded to the chassis tube Ground L2 to the dash access panel screw Wire 3 I from the control box connects to the 32 from the control panel Remove C19 from the 6 way connector between harness C and harness D by inserting a pin or jewelers screwdriver into the small slot on the side of the connector Insert C19 into the two way connector supplied with L3 Once all the components are in place and the con nections made and tested use the supplied insula tion and tie wraps to wrap as much hose as 1 ble Engine compartment Include insulation around the fittings at the compressor Front bay All exposed hoses and fittings Tunnel run Separate and insulate the hoses In clude the short runs inside the panel behind the seats
54. RFLOWS AND BREATHERS OIL COOLER For continuous high speed driving an overflow ERA offers an oil cooler kit that mounts one or two system should be used The top cover plug can be coolers on either side of the transaxle A full size oil drilled for a fitting and connected to a 1 2 quart filter can be used on the remote filter mount capacity container E R A has an optional tank de signed specifically for the GT or you can use a Canton breather tank 23 030 By putting a nipple on the filler hole in the side of the transmission and a nipple on the drain of the tank you can automati cally return oil back to the transaxle sump Also desirable is a system for venting the engine valve covers Continuous high cornering loads will force oil out a normal breather Special breathers are available oilcool 64 FUEL AND COOLING SYSTEMS FUEL AND COOLING SYSTEMS 65 FUEL AND COOLING SYSTEMS FUEL SYSTEM GENERAL DESCRIPTION LEFT RIGHT FUEL BALANCE Two independent tanks of approximately 8 gallons capacity each are in the chassis pontoons Each impact resisting plastic tank 15 carried in an alumi num cradle and filled with anti slosh anti flame propagating foam Separate fuel level sender in each tank control in dependant gages placed on the left and right end of the instrument cluster Filling is done through separate caps one on each side of the front cowl There is an air bleed at the top of each tank to compens
55. Township MI 810 781 7000 Speedo cables gears Danhard Inc 3839 Dilido Rd Dallas TX 75228 Tel 214 328 8541 Air conditioning parts Davies Craig 3847 Exchange Avenue Aurora Illinois 60504 877 964 Electric water pump 6305 Fax 630 851 7744 Earls Performance 189 W Victoria St Long Beach CA 90805 Tel 310 609 Brake and oil cooler Products 1602 parts Eibach North America 17817 Gillette Ave Irvine CA 92714 Ford Motorsport Catalog available at the dealer Special technical assistance Ford engine parts Hot Line 313 337 1356 Hall Pantera 9210 Alondra Bellflower CA 90706 Tel 310 867 3319 ZF gearbox parts Tues through Sat only Jongbloed Modular C O Johnson Motorsports Tel 952 445 7276 Wheels Wheels Koni America Inc Div ITT Automotive Parts Supply Div 8085 Production Coil over damper Ave Florence KY 41042 Tel 606 586 4100 M C Griffiths LTD Grifco House Smeaton Rd West Portway Industrial Estate RHD steering gear Andover Hants England Tel Andover 0264 23650 Telex 477675 Grifco G McLeod Industries 1125 N Armand Anaheim CA 92806 Tel 714 630 2764 Clutches flywheels RBT Transmissions Tel 714 250 1798 Fax 714 660 0288 rbttransmissions com ZF transaxle parts Panteras East 7165 30th Ave North St Petersburg FL 33710 727 381 ZF transaxle 113 Pantera Performance 13749 A E Smith Dr Aurora CO 80011 Tel 303 360 9848 ZF transaxle parts Center PI Motorsports Orange CA Tel
56. UP Check engine oil and water EVERY 3000 MILES Change engine oil and filter Check engine drive belts for wear and tension Grease rear axle sliding splines EVERY 6000 MILES Inspect front and rear brake linings Spray Lubriplate or equiv on rear suspension rod ends and spherical joints EVERY 12 000 MILES Change transaxle oil Grease rear axle universal joints Grease front upper and lower ball joints and outer tie rod end EVERY YEAR Change antifreeze LUBRICATION ZF TRANSAXLE Initial fill 3 gts 2 7 qts after drain ing in the car Fill to the overflow level of the hole that was made in right side of the case Recommended Lubrication Mild EP Oil SAE 80 or 75 90 Synthetic Oil change intervals After first 500 miles Each 15 000 miles thereafter 110 INDEX MAINTENANCE PARTS All pieces listed below are included in the kit but are listed here for reference and long term service Part numbers listed are typical but equivalent brands may be substituted unless otherwise stated BRAKES MASTER CYLINDERS LINES FITTINGS Master cylinder front or or Master cylinder rear or Or Sizes noted are for standard Corvette calipers Pedal pivot shaft bushing Thrust washer Balance bar bearing Master cylinder rod ends Clutch slave cylinder Clutch throwout bearing for ERA bell housing SUSPENSION FRONT Ball joint lower Ball joint upper Tie rod end outer Tie rod end inner Sway bar link ends botto
57. WEATHER STRIPPING The door weather seals were initially fitted at the factory and should have been checked for proper fit earlier upon disassembly page 21 With final installation special concern should be given to the joint areas where the upper and lower seals meet Use sealing caulk or putty to prevent water seep age between the sill flange and the door opening flanges where they do not butt together TOP BUTTONS You may install plastic buttons to keep the top edge of the doors from raising at speed from air pressure One or two plastic screws may be in stalled so that they contact the aero fairing when the door is closed Mark the profile of the aero fairing on the top of the door for reference Drill and tap the fiberglass for the plastic screws Trim the bottom of the screws flush with the in side body File the top of the screw to the proper height 86 BODY REAR SUBFRAME The subframe serves as the rear body mounting frame and supports the lower rear suspension arm pick ups The splash panel is actually part of the structural strength of the system and must be se curely fastened to the subframe with steel mandrel pop rivets Ei RSUBFRM FRONT AND REAR BODY INSTALLATION The front and rear body sections are mounted to the chassis on aluminum mounting plates bolted to body flanges These plates fit onto plastic bush ings on studs on the front of the chassis subframe Ei
58. a light grease on the shaft Match the length of the link to the pedal with the position DISASSENDE you re going to mount the pedal assembly at The pedal box can be removed as an assembly with all master cylinders attached If you wish to avoid bleeding the brakes and or clutch the master cylinders can be detached from the box and left in place Remove the 2 side bolts securing the pedal box to the chassis Shift the box rearward to remove the master cylinders from the frame 49 SUSPENSION AND BRAKES Remove the set screw securing the pivot shaft lift the pedal box up and drive the shaft out Note the position of the shims and thrust washers When reassembling after paint or plating lightly grease the pivot shaft and the sideways thrust sur faces on the pedals washers and bushings The ID brake master cylinder is toward the right side of the pedal box the 5 cylinder in the center Take care on installation The bushings in the pedal sleeves are reamed to fit and cannot be replaced without reaming On the RHD unit the transverse link for the throttle linkage must also be removed The fittings are different on each cylinder so mark their position for proper installation Secure the assembly with the 5 6 x 3 4 bolts sup plied inserting any shims between the left side of the box and the chassis bracket 50 Generally for those over 5 11 tall the assembly will be most comfortable in the forw
59. acket bolts Relatch to recheck adjustment If the body fails to latch or latches too high it may be adjusted by loosening the jam nut metric and threading the pin in or out to achieve the desired height When the body is properly adjusted it will latch freely if dropped 6 to 8 inches It should also pop up freely when the release lever is pulled BODY Release FRONT BODY ATTACHMENTS RADIATOR STONE GUARD Paint the screen and frame semi gloss black Fit the screen to the frame by tightly wrapping the edges around the frame and secure with black plastic tie wraps through the holes provided Attach to the backside of the body radiator open ing with 4 screws as shown 91 BODY FGRILL MIRRORS If fitted to original cars mirrors were located anywhere from the front of the doors to mid way to the front on the fenders of the competition cars Road cars had mirrors fitted to the rear of the fenders by the doors If you are going to drive on the street the mirrors should be placed where they can give the best view to the rear REAR BODY ATTACHMENTS DRILLING ACRYLIC The headlight and driving light covers side win dows and rear window are made from coated acrylic plastic Plexiglas This material is quite brittle and requires special care when you drill it Drills are available from plastic supply houses or one can be modified as shown below REAR WINDOW The rear window is supplied with a plastic cover in
60. ard the rear of the engine On the right side of the engine cylinders 1 4 run the wires down along the front of the engine and under the air conditioning bracket to the rear On cylinders 5 8 run the wires under the coil and the alternator bracket and to the rear 351W Add to each of the dimensions above Boss 302 351C Spark plug wires can be run in a more conventional manner but because of the proximity of the exhaust they must be especially resistant to high temperatures 1 e silicone Use separators on all systems to prevent cross firing between wires 23 SPECIAL NOTES The Ford Motorsport 302 Windsor 351C and 351W engines use different mounting brackets so you must specify the engine before you pick up the alternator and AC mounting pieces If you use Dart II cylinder heads one of the holes in the cylinder head to mount the AC bracket 15 pre tapped to You must use an insert to re duce the hole to 7 USS thread Fit and spacers depend the crankshaft damper and other factors The following are general in structions which will work most of the time For other combinations some changes may be neces sary engfront Bolt the air conditioning bracket onto right inder head as illustrated The 351 engine requires spacers between the bracket and the cylinder head On the front face of the head two holes are tapped 16 and one 14 PARTS PREPARATION acm
61. ard most posi tion in the rearward most position for those under 5 6 somewhere in between for the rest of you Within limits you may adjust the links between the pedals and the master cylinders Be careful however that there is at least 1 of thread in the rod ends and clevis joints involved Check for binding and interference after adjusting the length of the rods Tighten the jam nuts when adjustment is finished BALANCE BAR ADJUSTMENT As shipped the standard balance bar has equal length shims on both sides of the central bearing Drive the car thoroughly breaking in the brake pads With the pads warm but not hot do several panic stops on good pavement Generally the preferred action 15 to have the front and rear lock simultaneously or to have the front slightly early The rear brakes should not lock first If the front to rear balance seems off it can be ad justed as follows Remove the bolt securing the balance bar assem bly together Do not lose the shims Note that there are narrow lock washers at each end of the bolt SUSPENSION AND BRAKES To decrease the braking at one end of the car use more spacers on the side of the balance bar going to that end s master cylinder Transfer a spacer from the opposite side of the bar Total spacer length must remain the same Each spacer changes the balance approximately 10 CALIPERS Front and rear calipers are illustrated on page 14 Hub carriers are shown on
62. are especially TRANSAXLE critical All are covered in detail in thelatter part of Both the ZF 505 25 1 and 505 25 2 will fit but each this section requires a different flywheel and bell housing The Block Don t use a pre 1965 model The bolt BMW 1 transaxle doesn t require inverting but the pattern won t match the bell housing shift linkage must be moved from the left to the right Front Cover only one is acceptable see parts side requiring some new parts list REAR BRAKES Front crankshaft and damper See page 6 for Standard brakes use a 12 rotor with emergency brake dimensional limitations built into the caliper Clearance for wheel balancing weights is severely restricted if 15 pin drive wheels are used about 180 You must use special weights that are very thin or that clip onto the edge of the wheel Remember The more exotic you get the more likely you are to have problems There is a maxim in engineering practice Keep It Simple Stupid Please Read the information that follows in its entirety before you purchase parts that you might be unable to use PARTS PREPARATION ENGINE AND ACCESSORIES E R A has developed our GT around parts and accessories from the 1965 on small Ford block The earlier 1961 1964 221 260 CID en gine bell housing bolt pattern 15 different from later models and fits neither Pantera nor ERA bell housing While many variations of the 289 CID throug
63. ate for expansion and allow for complete filling of the system It is vented to the filler neck just below the filler cap Each of the caps is also vented through a tube exit ing the bottom of the pontoon For prolonged street driving where there is low fuel flow in hot conditions you might want to in stall a return fuel line from the carburetors or fuel injection system to the tank There 15 a third hole in the top of each tank cover for the line It is nor mally closed with a g NPT plug When you have a fuel return line a solenoid valve must be put in the circuit to direct the overflow back to the correct tank It may be triggered by the same wire as one of the fuel pumps FIREWALL The level of the left and right tanks is dependent on their use There is no automatic balance For ideal suspension balance the driver can maintain the left to right weight in the tanks commensurate with the passenger payload i e With only the driver aboard empty the left tank first With the driver and a passenger empty the tanks alternately so that the left and right levels remain within about 4 gallons of each other FUEL FEED TO THE CARBURETOR S USING 2 FUEL PUMPS Each pump draws fuel from a fitting in the top ac cess plate of a tank The feed line runs along the top of each tank to the rear Each pump is con trolled by a separate switch on the dashboard The fuel pumps are most appropriately mounted on the left and right upr
64. ated on the upper rear part of the arm as installed in the car Install the control arm into the brackets as illustrated us ing x 2 3 bolts and stover lock nuts supplied Torque to 35 Ib ft See also page 37 for hub car rier details 40 SUSPENSION AND BRAKES Install the rod end links to the anti sway bar with LOWER TRAILING ARMS the x I screws and stover nuts The long 3 8 bolt slides in from the front through rod end the lower control arm sleeve and then through the reduced diameter bushings in the lower damper mount UPRIGHT Install the bottom hub carrier boss onto the lower control arm ball joint stud Use the ID x washer nut and cotter pin Torque to 50 lb ft See the exploded view on page 37 Bolt the hub carrier to the bottom boss assembly using the 1 long socket cap screws and ribbed washers Safety wire the 4 screws together so that the screws will be held in tightening tension Cross section through chassis Install a tapered nut onto the upper ball joint Install the bushings sleeves and lower trailing threads and insert through the upper control arm areas chown below laste the bolt n Install another tapered nut The tapers on the nuts side the threaded end ofthe point toward each other and allow camber adjust ment After final camber adjustment safety wire the nuts so that they are in constant tension shorter trailing arm into the brack
65. ave been removed Take your time Don t damage the gasket surfaces Save what is left of the gaskets They will be useful when you set the ring gear backlash PARTS PREPARATION Remove the differential side bearings from the CASE MODIFICATIONS differential This requires a special tool or a lot of cursing The ring gear assembly will not come out of the case with the bearings on it Remove the differential ring gear assembly noting the side of the pinion gear it was mounted on Don t install it on the same side unless you want 5 speeds re Check the internal clearance for running the ring gear on the opposite side of the case Later castings may have heavier walls adjacent to the ring gear Look for machining on the inside face of the case for clearance for the ring gear bolts Measure from each side plate mounting surface to the opposite inside face The measurements SHIFTER BOX should be within 06 of each other If not the in Remove the shifter cover and the rubber plugs at side surface will have to be relieved It can be the top of the shifter box carefully done with a simple hand grinder Note that the case tapers from top to bottom so only the Using a small chisel or punch release the locking bottom must be ground portion of the nut on the end of the shifter cross shaft Jam something between the arm and the See the diagram on the following page for dimen box to prevent rotation and remove the nut Rotate sion
66. b Under dash vents may be closed by rotating down 90 degrees The foot level vent is controlled by the slider If no air at all is needed set the controls to recirculate and defrost without the fan At speed the fan may not be needed be cause of the ram air effect with fresh air on For maximum cooling however set the controls to recirculate and fan speed on high Be sure that the heater temperature control is off when the air conditioning is on The radiator fan and compres sor clutch are automatically actuated only when necessary Glue the weatherseals onto the chassis opening as shown Fasten the unit with two bolts through the front of the foot box and two clamps at the rear edge of the foot box opening 104 Interior Ventilation CONTROL BOX AND CABLES 1 Compressor discharge to condenser top Length LHD 132 Length RHD 164 Install through the right hole see page 66 in the engine firewall leaving 17 of hose ex posed along the passenger side of the tunnel Pass through the right hole in the right hole in the footbox to the right diagonal subframe rail Go behind the aluminum radiator duct work and attach to the upper fitting on the condenser 2 Compressor suction to evaporator Total hose length including T fitting LHD 99 RHD 122 Install from the front Pass the end with the longer hose through the left hole in the foot box and back along the passenger side of the tunn
67. be a tight fit but if you wish use a little contact cement to secure it to the footwell SUSPENSION AND BRAKES FRONT CONTROL ARM AND HEPER CON TEE AE UPRIGHT INSTALLATION See the exploded view for proper orientation of the arm and related pieces Install the arms with a Fuel tanks should be installed before the up retaining tab on either side of each bushing or rights are installed onto the control arms See thrust washer then the retaining tab when using Section E the competition bushings Use the X 2 7 12 point cap screws and internally splined lock washers supplied Do not tighten the bolts at this time Slide an equal number of shims on either side of each inner pivot so that a single cotter pin can be slid through the shims and the retaining tabs They will be used to adjust caster and cam ber The cotter pin fits below the plane of the con trol arm This initial setting may be changed when the final alignment is done INCLUDED IN THE KIT ARE 8 2 shims 8 shims 14 shims This is more than enough to fill the gaps FRONT ANTI SWAY BAR The bar is fit in the channel under the front floor mounted in the special plastic bushing sandwiched by a Steel strap The bar extends forward to the front side of the damper bolt Use the 6 x 1 bolts with lock washers to secure the bushing and brackets to the chassis CIFCTRLARM LOWER CONTROL ARM The anti sway bar tabs are loc
68. ce by both Dzus fas teners and cast side body latches The Dzus fasteners are located at the factory but you must drill the rivet holes with bit before the body is painted Final riveting must wait until after the body is painted The Dzus plates should be aligned as shown Note that the cowl Dzus s are slightly longer than the hood s 89 BODY REAR BODY LATCHING TOP The rear body is held down with lever latches on either side of the engine compartment and pin latches released from inside the car at the top front Details of the side latches are covered in the Front Body section Access to the top bolt securing the rear latches is through the plugged hole on the inside of the rear body inner panel The top latch latch mount and release mechanism is factory mounted to the rollbar See the dia grams on page 91 and 91 To adjust the striker pins Leave the bolts loose enough so that the pins can be moved if light force 15 applied Lower the body and carefully push the body down to its closed position 90 Before closing the rear body make sure the latch releases are working properly If the rear body is closed and the windows are installed the engine compartment is the only way to access the latches The latch pins will self align while going into their receptacles Release the latches from inside the car and carefully raise the body without disturbing the pin positions Tighten the pin br
69. comes high because of a pres sure demand switch in the air conditioning system FUEL AND COOLING SYSTEMS 74 BODY BODY 75 BODY Follow the same preparation procedures for all the CHASSIS PAINTING chassis attachments that are to be painted the same If you have an early non stainless steel chassis color as the chassis rollbar door hinges door painting and rust proofing are the most important latch striker mounting plates rear body latch operations you will do to ensure the long term in mounts battery storage bin covers rear sub frame tegrity of the monocoque chassis We recommend spare tire mount etc that the chassis be painted with 2 part polyurethane semi gloss black or be powder RUST PROOFING amp UNDERCOATING coated When painting use an epoxy primer or one that is recommended by the paint manufac turer as appropriate for the paint used Rustproofing is not absolutely necessary with a stainless steel chassis but can be applied as a sound deadener and security for very long term PROCEDURE structural integrity No matter what some sealant Remove EE is desirable at the areas between the pinch welds Inspect the chassis for pin holes in the welds and for spot weld flashing and sheet metal burrs Fill all holes and grind off flashing and burrs Check all welded seams and lap joints Use body hammer or spoon to flatten puffed out or separated flanges to achieve tight fitting seams
70. d any adjust ments and notes of shims etc made at that time g roof3 Replace the NACA duct opening screen at the base of the windshield after the car is painted Glroof1 Use urethane windshield adhesive for bonding the roof to the cowl It creates a stronger bond than silicone and creates a more rigid structure G roof2 On the cowl use 1 1 sealing rivets with aluminum body and steel mandrel Countersink each one into the fiberglass and space them 2 to 3 apart On the rear edge of the roof where it fas tens to the roll bar use x L aluminum dome head rivets with aluminum body and steel man drel 78 BODY FRONT COMPARTMENT WHEELHOUSE PANELS ENGINE BULKHEAD PANELS Rivet and bond all the bulkhead panels in place except for the center access panel Use silicone or urethane sealant caulking material between the panel and the rollbar Locate the panels in place with the existing holes and screws Drill holes into the steel tube using the holes in the aluminum panel Add the bonding agent and attach the panels in place with aluminum rivits x grip range Don t attach the steel latch panels until the door latches are in place and adjusted Rearbulk 79 See illustration on page 80 The aluminum panels enclosing the front compartment and wheel housings are normally fastened in place with screws when you received the kit With the panels
71. ding to the side Such caps are available in the aftermarket from Echlin or Mallory etc Remember It is difficult to service or even to see the distributor without removing the panel behind the seats Make maintenance as easy as possible You must use 90 degree nipples on the wires as they enter the cap See Spark Plug Wires below SPARK PLUG WIRES 289 302W 351W If you are using a 180 exhaust system must be run along the front of the engine and down under neath the exhaust system 90 ends must be used at the distributor cap 45 or 90 ends must be used at each spark plug PARTS PREPARATION AC AND ALTERNATOR MOUNTING AIR CONDITIONING COMPRESSOR MOUNTING Standard wire sets for the small block are usually too short It may be necessary to use the longer wires from two sets or cut your wires from bulk rolls Universal sets that Fit everything may have the necessary lengths also but check that the ends are appropriate or can be changed to ones that are Standard Ford convention Number one cylinder is at the left front of the engine number 5 at the right front The following lengths will fit the 289 302 engine with stock heads measured from the corner of the angle connectors on both ends Cyl 1 2 3 4 length 23 5 26 5 31 35 Cyl 5 6 7 8 length 27 29 2 33 5 38 5 The above lengths are measured with 1 cylinder on the distributor pointed approximately tow
72. djust with each use of the emergency brake Remember If you don t use it you will slowly lose the adjustment BLEEDING THE HYDRAULIC BRAKES This dual master cylinder system requires no spe cial techniques just common sense USE DOT 3 OR DOT 4 FLUID ONLY Be sure to keep adequate fluid in the brake reser voirs when bleeding If you run out you must Start over again The brakes may be pressure bled with care to avoid so much pressure that the feed hoses are blown off the fittings Use a hose on each bleeder immersed in a con tainer of fluid This will prevent air from being drawn back into the caliper Start at the caliper furthest from the master cylin der Open the bleeder about turn and slowly pump the brake pedal until the fluid is clear Re peat the process at the opposite wheels in turn Lightly tap each caliper to dislodge any trapped air bubbles Wait for several minutes and repeat bleeding at each corner to remove the last of the air 53 SHIFT LINKAGE REAR AXLES SHIFT LINKAGE AND REAR AXLES 55 SHIFT LINKAGE REAR AXLES SHIFT LINKAGE AND SHIFTER BOX LEFT HAND DRIVE x THE SHIFT LINKAGE CONSISTS OF SHIFT BOX ADJUSTMENT Shift box with handle extension and reverse Temporarily secure the assembled shift box to the lockout mechanism tunnel with four 20 screws Z link with support bearing from handle ex Hold the slotted rod on the shift lever parallel to the tension through
73. dles before painting the car The illustration below shows the right door handle assembly The left side is similar except that the pivot pin goes in from the bottom HANDLE REMOVAL Remove the door trim panel The standard access panel has the inside latch release attached to it Remove the screws holding the panel in place and lift it away Loosen the wire clamp holding the latch pull cable and pull the panel free The release handle will fall free Remove the latch latch plate combination from the end of the door Remove the spring from the notch in handle tang Remove the screw securing the cover plate and slide it to the end of the tang Remove the clevis pin and pull pin and spring out of the handle 83 G Dorhandl Reposition the handle so that it may be slipped out through the opening inside the door Don t try to remove the handle through the outside open ing The handle is refit in the reverse order BODY HER DOOR LATCH The latch assembly is cable actuated either di rectly or through a lever mounted on the top of the door The latch body is fastened to an inter mediate aluminum latch plate that is attached to the end face of the door The door locks if ordered with kit were fitted at the factory and it is a simple matter to re install them as shown below Ei The striker is attached to the door jamb with an aluminum spacer block and possible shims on Install the lock bar car
74. drive cable to 21 inches measured from end to end with a grinder or other suitable tool PARTS PREPARATION wiperlay Partially fill the gear housing with grease and place the cable into the guide Some guides have cast in liners while others have separate plastic pieces Install the connecting rod with its thrust washers and the connecting rod circlip If possi ble test the clearance between the connecting rod and the lower part of the housing by rotating the crankshaft Install the cover plate with 4 screws 35 SUSPENSION AND BRAKES SUSPENSION AND BRAKES 36 SUSPENSION AND BRAKES FRONT UPRIGHT ASSEMBLY THE FOLLOWING PIECES ARE INCLUDED IN THE KIT 2 Hub carrier center casting I each left and right steering arms with top boss in stalled 2 Bottom boss 8 3 3 x 1 Socket cap screw stainless steel 8 3 3 x 1 Socket cap screw stainless steel 16 Washers ASSEMBLY Drill a gt hole for the Vs brake flex line clamp Drill carefully holes through the head of all socket head screws for safety wire The center of the hole must be within 120 of the top surface of the socket Install the upper ball joints into the left and right steering arms with steel boss installed using the special washer 9 6 ID x 1 5 OD and cas tle nut and cotter pin supplied Tighten the nut to AO lb ft Install the steering arm onto the hub carrier Note that the offset of t
75. e center part of the bar at the inside of the bends Hold the bar in place over the studs in the removable rear transmission crossmember with the ends toward the rear of the car Secure the assembly with the washers and locknuts pro vided Install a spacer and the vertical link on the bottom stud of each lower control arm Secure with a high collar lock washer and locknut Se cure the top of each link with x 1 screw and a high collar lock washer Adjust the lengths of the links so that there is no preload in either one Tighten all jam nuts 44 If you haven t installed the anti sway bar yet see the previous section Install the upper mount with a 2 Bolt and flat washer If you get the dampers from ERA spacers on either side of the bearing ends will be included Tightening of the upper bolt is easier with a 3 flex socket Install the lower end of the damper on the lower control arm using the spacers provided The bolt is x 6 REAR Install the upper end of the coil over into the bracket on the chassis using spacers on either side of the top bearing if necessary Face the top adjustment slot Koni double adjustable only out Insert the x 2 bolt through all the pieces from the rear The bottom damping adjustment faces either toward the inside Spax or the front Koni To mount the lower end of the damper in the con trol arm it may be necessary to disconnect the lower trailing arm fr
76. e fittings and fuel level sender into the top will flow to the fuel tank on the opposite side of plate the car possibly over filling it 68 FUEL AND COOLING SYSTEMS Carburetor s with fuel overflow plumbing must utilize an electrically operated fuel control valve that diverts the fuel to the same side as the fuel is being drawn from See the fuel flow schematic for the proper hook ups FUEL FILTER Recommendedfilter Wix 33033 or equivalent 3 5 O A L x 1 75 O D 69 FUEL AND COOLING SYSTEMS ENGINE COOLING AND HEATER PARTS INCLUDED IN KIT 2 Pipesfrom front to back installed in chassis 5 tube from water pump to firewall L tube from firewall to header tank tube between intake manifold header tank and L tube Radiator with fans and fan thermo switch Optional Front intermediate pipes from the radiator to the longitudinal pipes PARTS NEEDED Clamps No 24 clamps with Weber intake manifold and optional front tubes 21 clamps should be used on the 1 ID hose and No 32 clamps 3 on the 2 ID hose A straight length of hose Gates 24224 can be cut up for many of the short sections of I 1 4 ID hose listed below Hose Radiator to left top longitudinal tube I ID x 18 long flex type Hose Radiator to right bottom longitudinal tube 1 ID x 18 long flex type When using the optional aluminum front pipes the above flex hoses are not needed Instead 4 hoses each 1 1
77. e the arm from the spined shaft and rotate to correct the position Too much potential travel disturbs the geometry of the linkage too little risks improper clutch disengage ment Check that the snap rings securing the slave cylin der onto the bracket are secure and slightly tighten the 1 4 locating bolt into the slot of the slave cyl inder Bolt the bracket onto the side of the trans axle as shown in Section E Note that the studs are metric thread M10 x 1 5 Push the pushrod into the slave cylinder so that it is fully bottomed out Install the clevis pin through the throwout arm and the rod end and se cure the clevis with the retaining clip It may be necessary to shorten the length of the rod so that the clevis can be installed WITHOUT CLUTCH RETURN SPRING If you do not have a return spring built into the ZF clutch throwout shaft so that the throwout bearing doesn t automatically retract the internal spring in the slave cylinder will automatically take up the clearance between the throwout bearing and the clutch The initial position should be adjusted as follows Measure the approximate distance the pushrod can be pushed into the slave cylinder from the rest posi tion If it cannot be moved forward shorten the pushrod adjustment Adjust the length of the pushrod so that the play is 1 4 This distance will allow the slave cylin der to automatically compensate for wear in the clutch If at any
78. e water manifold See the cooling schematic diagram for details When installing the water pump on the engine the right most bolt must be re placed with the x 4 one supplied with the AC system SETTING UP THE SYSTEM P There are many connections in this system some of them relatively inaccessible so it is very impor tant that each one is leak free and secure Do it right the first time For backup use a system lu bricant and sealer such as Bars Leak Before you make any permanent connections assemble all the pieces of the system for fit 71 FUEL AND COOLING SYSTEMS FREEZING POINTS FOR SOLUTIONS OF ETHYLENE GLYCOL Make sure that the antifreeze you use is formu lated for aluminum components almost all are now We recommend that the coolant mixture be changed each year to maintain anti corrosion prop GLYCOL op oC BYVOLUME o O Ooo nrs z3 a a 10 2 5 0 ag 35 0 23 4 A D _ 4 0 4_ _ EE For optimum cooling it s best to use the smallest proportion of anti freeze commensurate with your local temperatures Pure water has the best heat transfer rate of all We ve had good results by adding Red Line Water Wetter too Follow the cooling system schematic for place ment of individual components 5 TUBE This piece is shaped to go outside of the shifting rod Snow White pump only the Ford pump is on the other side If the air conditioning com
79. eatest installation 105 Interior Ventilation AIR DUCT HOSES Because it s tight in the cowl section the configu SEE PAGE 24 FOR INSTALLATION OF THE ration must be followed carefully Install a 2 COMPRESSOR AND BRACKET ONTO ID hose onto the left side of the cowl manifold ENGINE BLOCK Install the cowl manifold through the access hole just forward of the dashboard fastening it to the CHARGING brackets at the bottom As you tighten the screws Charge with 29 33 ounces of Freon R134 with ap keep upward pressure upward to seal the manifold proximately 4 fl oz of compatible refrigerant oil to the cowl Install the drain hose to the manifold Charge through the T fitting at the front compart running it out through the hole in the left side of ment after removing the pressure switch the cowl 106 Interior Ventilation WIRING A C Also see the instruc tions in the wiring supplement for spe cific connections There is also an AC electrical schematic that will accompany the main wiring dia gram Mount the control box on the access panel in front of the dash panel The AC harness goes through the panel parallel to harness D Connec tions to the blower motor are made in side the box using the 4 wire harness with one end un marked the other L22 23 24 25 Use the terminals on the molded connec tor Harness wire Molded connector wire Yellow Yellow Blue Red Green
80. efully There is a 90 de the outside and a movable nut plate on the back gree swing to the lock barrel The lock bar must side of the door jam See page 79 be either horizontal pointing to the rear of the car unlocked or vertical pointing straight down x over the back of the handle locked Final installation of these pieces cannot be done until after the interior trim panels are in place INSTALLATION The actuator and cable must be attached before attaching the latch body to the latch plate Install the latch onto the latch plate 84 BODY Fit the body of the latch through the opening in 2 Window sill mounted release handle road car the end of the door making sure the plate on the option I actuator goes around the adjustable actuator rod on the outside door handle Screw the latch plate to the door Move the latch fork to the closed position and pull open the outer door handle The latch fork should snap to the open position does not adjust either the actuator rod by unscrewing it or by bending the striker plate of the actuator until the latch releases freely Bolt the striker to the door jamb Because there is added thickness from the door panel some shims may not have to be used Leave the screws loose enough that striker can be easily moved Reach through the window opening with one 3 Flush mounted release handle road car option hand and grasp the striker while closing and II As noted
81. el on top of hose 1 Go through the CONDENSER large inside hole in the bulkhead behind the seats and the left hole in the firewall leaving 16 of hose not including fittings exposed in the engine compartment Attach to the radiator with the brackets provided See page 103 RECEIVER DRIER 3 Condenser bottom to receiver drier with The receiver drier is mounted on the right side of fitting and pressure switch the front compartment in the bracket provided Length 26 See page 80 Attach to the right subframe tube parallel with FREON HOSES hose 1 The 90 deg fitting attaches to the l bottom of the condenser If air conditioning was delivered with the kit hoses are laid out in the chassis properly with their ends installed Once the hoses positions are rator 5 16 0 determined isolate and insulate each hose along Length 5 5 its entire length including the engine and front bay 4 Receiver drier to expansion valve evapo After installing and securing the lines we recom mend that all lines be insulated especially in the IF THE AIR CONDITIONING KIT IS BEING passenger compartment and engine bay E R A RETROFITTED uses water heater insulation with aluminum foil on Each hose assembly can be identified by its length one side adhesive on the other for wrapping and end fitting Loosely install the hoses in the car Before attach ing everything permanently adjust the layout for the n
82. en using the 11 5 rotors 1988 90 Corvette calipers are used with the 11 5 or 12 rotors in front 12 rotors in the rear Note the restrictions mentioned in Section C regarding wheel diameter and balance weight clearance Rotors Stock Corvette 11 5 or 12 rotors are used with bolt on wheels Front rotors used with pin drive wheels are made by Wilwood JFZ REAR PEDAL ASSEMBLY Corvette rotors are used at the rear hub carriers The rotors are furnished with the pin drive option and are redrilled for the pin drive hubs Emergency brake controls are modified from the Pontiac Fiero A custom E R A cable is supplied with the kit The 12 rotors 88 94 have the emergency brake integral with the caliper BRAKE LINES As delivered the ERA GT kit has all the steel lines fittings adapters flex hoses etc fitted to the chassis Do not assume that any connection is tight Tighten each fitting using proper wrenches on both sides of the junction Use DOT 3 or 4 brake fluid only During brake and clutch bleeding and after final assembly check for leaks at all junctions If there are any component questions refer to the diagram and parts list on page 48 Assemble com ponents exactly as shown THROTTLE LINKAGE The left hand drive throttle linkage uses a bell The pedal assembly consists of pedals pedal box crank mounted on the tunnel as shown When as linkage and master cylinders sembling use
83. er in the same way Leave just enough length to connect to the fittings on the tank cover 67 FUEL AND COOLING SYSTEMS Install the upper hose F onto the filler cap flange Both the filter and the pump must be run as low as with the lower clamp installed on the hose but not possible Use a 1 long hose from the filter to tight Lower the filler flange hose assembly onto the pump If you use the recommended pump AC the cowl checking how well the upper and lower EP12S you must cut off the mounting bracket as sections match up Make any changes and tighten illustrated The right pump can then be mounted the lower clamps on the same hole as the header tank Run each fuel line on top of the transverse tube Connect the front filler hose and the breather to the tank Use clamps at all connections Install the upper assembly onto the intermediate pipe and tighten the upper clamps Removal Note If you loosen the lower clamp B you can remove the entire filler as a unit Then re move the filler flange and the fittings installed If at all possible mount each fuel pump on rubber insulators to decrease the vibration transmitted to the chassis This is especially important with re ciprocating type pumps such as Stewart Warner Loosen the lower hose clamp B and one of the up per clamps Loosen the fuel filler cap from the cowl and raise the cap and filler pipe about an inch to FUEL FILLER clear the tank INSTALLATION
84. es afterward Apply a light coat of caulk ing sealant to the mating surfaces and fasten them in place Refit the seals to the rails At the joining of seals A and glue the bulb end of seal A to the top of seal B with urethane sealant adhesive contact cement or other compatible adhesive Seal any remaining gaps between the two with the ure thane or other caulking BODY DOORS INSTALLATION Bolt the mounting plate to the chassis with the shims that were installed on the chassis on deliv ery 82 gldrhinge 1 With the hinge pivot rod fitted to the door and the ball pivots screwed all the way on to the pivot rod lower the bottom hinge pivot of the door into the lower socket on the hinge g drhinge2 BODY Raise the door into place and screw the upper ball pivot up into the top receptacle on the hinge plate Unscrew each upper and lower ball pivot equally bottoming them out in their receptacles Unscrew each ball pivot another half turn to preload the sockets and ighten the jam nuts against the pivots This will prevent rattles and keep the door tight HEIGHT ADJUSTMENT Loosen both bevel nuts and turn equally to change the door height Remember There must be no play at any of the hinge points to achieve proper final fit DOOR HANDLES OUTSIDE While the pictures here will help when reassem bling the car it can t hurt to take some pictures while taking your car apart for paint prep Remove the han
85. es the smaller Ford flywheel and the depth is correct The bolt pattern will accept the inverted transaxle SPEEDOMETER GEAR The speedometer cable ratio is usually on a tag on the shift box listed together with the other gear ra tios If your box has been rebuilt etc it s a good idea to check your ratio by marking the output flanges and case with tape and counting the number of times the speedometer cable drive turns with each turn of the flanges in the same direction The ratio will be approximately 2 turns of the cable for each one of the flanges There is a gear reduc tion in the speedometer cable to compensate for the different requirements of the various speedometers PARTS PREPARATION TRANSAXLE CLUTCH FLYWHEEL SELECTION TABLE and this TRANSAXLE with this ENGINE Early 5 DS 25 1 Late 5DS 25 2 1965 1966 289 CID Note A Note B w 157 160T ring gear 1968 1981 289 302 CID Note C Note D w 164T ring gear 1982 on 302 CID w Note E Note F 157 160 ring gear The Ford ring gear 157 or 160 tooth is on most engines with 10 or 10 5 pressure plates The replacement Ford part number is C20Z 6384 Note A You must use an inverted and modified Pantera 4 bolt bell housing Use a Long type pressure plate with a 10 or 10 5 disk The lower starter mounting hole in the bell housing must be changed to move the starter centerline to 9 838 from the crankshaft center Change the engine plate to match the new s
86. et inside the chassis using the x 4 bolts Access for instal lation is through the hole in the bottom of the Insert the steering tie rod stud into the steering arm chassis Torque to 60 Ibft from the bottom and secure with a flat washer and castle nut It is best to check toe in before the final tightening in case the outer tie rod must be adjusted Torque to 20 Ib ft and secure with a cotter pin REAR TRAILING ARM INSTALLATION The upper and lower trailing arms and rear upper control arms are threaded left on one end and right on the other Preferred orientation 15 with the left hand thread at the outside end of each arm al though this is not critical Install the appropri ately threaded rod ends with their jam nuts onto the ends on each trailing arm Adjust the longer arms to 32 between rod end centerlines and the shorter ones to 30 between centerlines These dimensions are starting points and must be readjusted for exact wheel alignment Leave the jam nuts loose Lower trailing arm installation gt man c ftrarmmt Slide the boots over each trailing arm together with the emergency brake cables 4 SUSPENSION AND BRAKES gt mani c rltaboot UPPER TRAILING ARMS Attach the longer trailing arms to the upper chassis mounts using 1 2 x 4 bolts and stover nuts The bushings and sleeves are assembled in the same manner as the bottom mount Torque to 60 Ibft 42 SUSPENSION AND BRAKES Gt man
87. g for protection Leave the covering on until after trimming and drilling and the window is ready to install The acrylic may require trimming for an exact fit Leave minimum clearance between the win dow edge and the body contour for thermal ex pansion 92 We paint a strip of flat black on the perifery of the acrylic underside to hide the edge where it overlaps the body Tape the window in place and apply masking tape around the perifery to mark on Use a 3 drill to pilot all of the holes through the window and into the body The dimensions shown below are approximate and may have to be adjusted slightly LOUVERED VENT PANELS The rear body vent panels are factory located by two screws Use each panel as a template to care fully drill the rest of the holes with a bit Do not over torque the screws If they are tight go ing in wiggle the drill a bit when redrilling LICENSE PLATE BRACKET The bracket mounts to the lower panel on the body and is held in place by 4 screws Connect the license plate lights wiring to the rear harness through the grommet hole ROCKER PANELS Fasten the fiberglass to the rocker panels with the supplied screws A weather seal may be added to the front rocker access panels and at the rear of the rocker panel if desired The subframe is directly connected to the installa tion of the rear cross member and the lower rear control arms Neither
88. g the top of the foot box taping or clamping where necessary Interior Ventilation CARPETS Follow the diagram below for the proper placement of each piece 15 is glued to the removable passenger floorboard mounted on the three chassis brackets The rocker sill carpets are fastened with snaps at the top for access to the fuel senders Do not glue on the top Ei STEERING COLUMN SUPPORT x Install the transverse member between the chassis brackets replacing any shims that were installed at the factory The column housing and column with out the steering wheel can be installed as shown 100 Interior Ventilation DASHBOARD Competition Layout Competition Car RHD REMOVAL PREPARATION AND the defroster vents Open up both doors and slide INSTALL ATION the dashboard rearward and out The dashboard may be covered in cloth or vinyl If necessary remove the steering wheel and hub or painted flat black by loosening the clamp under the hub shield and pulling the steering wheel rearward Remove the Installation is done in the reverse order screws at the base of the windshield and above each rocker sill Remove the screws securing the dashboard to the steering column cross brace Disconnect any hoses to the face level vents and or 101 Interior Ventilation REAR ACCESS PANEL TUNNEL COVER Thecenter access panel behind the seats may be The tunnel cover is secured on either side at the rem
89. ght will increase the rebound damping With rebound control set on full soft and the bump control set from your previous testing drive the paying attention to how the car rolls when en tering a turn 45 Increase the rebound damping three sweeps on all four dampers and test drive the car Continue in creasing the damper setting until the car enters the turns smoothly with no drastic attitude changes and without leaning excessively Any increase beyond this point is may be detrimental to good control Final adjustments can be made to effect the turn in of the car That is whether the car has initial understeer pushes or oversteer loose in the back By increasing the rebound control at one end it will decrease the initial adhesion at that end Conversely decreasing the rebound control in creases the initial adhesion In general neutral or slight initial understeer is most desirable There shouldn t be a large difference between tran sient and final balance although slightly less ini tial understeer will increase responsiveness SPAX While the Spax damper does not have separate bump and rebound control a reasonable compro mise can be made using patience and common sense The bump rebound ratio is designed for the ERA GT and only detail changes need be made for optimum handling Initially set all four dampers 4 clockwise clicks from dead soft Drive the car over uneven sur faces to determine whether the
90. gin of your parts Be sure that you have bills of sale for your engine transmission wheels etc You will get a Certificate of Origin for the kit from E R A at the time of delivery 115 INDEX INSURANCE Many insurance companies will allow you to add the E R A GT to your present policy If not there are num ber of insurance agencies specializing in composite cars Look in issues of Kit Car Illustrated Specialty Cars and related magazines and Cobracountry com for the latest offerings Below is a short but not necessarily cur rent list If you use a specialty insurer there may be some restrictions to your use and the yearly mileage al lowed The cost however is usually quite reasonable Aidukas Insurance Agency Palm Springs CA Tel 619 327 3889 California Only American Collectors Insurance Cherry Hill NJ Tel 800 360 2277 Apollo Insurance Sonoma CA Tel 800 624 5829 Cardiff Insurance Rich Dunham Tel 818 980 8941 Classic Automobile Insurance Div Modern Home Ins Tel 800 397 0765 44 states limited mileage CollectorGuard Heacock Ins Grp Lakeland FL Tel 800 678 5173 Condon and Skelly Maple Shade NJ Tel 800 257 9496 in NJ 800 624 4688 Only some mid west States Grundy Insurance Horsham PA Tel 800 338 4005 grundy com Insurance Alternatives Agency Bridget Scherb Forked River NJ 609 693 3943 John Young 310 254 7355 K amp K Insurance Fort Wayne IN Tel 800 540 0858 Northeast
91. h 351 engines have been used in the E R A GT some are more difficult to adapt than others With the help of its customers E R A will try to accommodate all reasonable engine alternatives As can be seen above the length of the engine is limited by the engine bay The 26 3 length is typi cal of a 302 with a stock front crankshaft damper Since changing the alternator belt requires a mini mum of 34 clearance your total length measured from the rear face of the block to the face of the front pulley must be less than 27 If you must use the maximum length we recommend using an elec tric water pump so that the hump between the seats can be kept reasonable Also note clearance above the carburetors As a general rule 302 engines with stock deck height can use standard velocity stacks but the 351 may require shorter ones Flywheel Considerations The flywheel is the first engine part that merits attention If the flywheel must be changed remember that the crankshaft and flywheel and sometimes clutch are normally bal anced as a unit If you have the late ZF transaxle 5 DS 25 2 you must use a small diameter Ford flywheel and ring gear that fit the ERA bell housing s starter place ment Certain series engines have flywheels that may not have to be modified for a new ring gear Look for an engine with a flywheel that is ap proximately 13 3 in diameter measured on the outside of the teeth 157 or 160 teeth
92. haft into the Z link clamp sleeve Don t tighten the clamp yet REAR ROD UNIVERSAL JOINT If there is still a spline adapter on the end of the transmission shifter input shaft remove it and de burr the shaft if necessary Install the long end of the universal joint double clamp onto the rear end of the rear rod The short end will extend forward to meet the Z bar Install the rear rod by passing the rod through the rear hoop surrounding the transmission from underneath the car The air conditioning belt goes around the shift linkage If this is the final installation of the link age you may want to install the belt before con necting the clamp onto Z rod When replac ing the belt this clamp must be disconnected For ease of fitting a new AC belt you may want to pin this connection so that this adjustment won t have do be done every time Engage the front clamp fully onto Z shaft and slightly tighten the clamping screw Adjust the transmission shift rod into one of the rearmost positions By pushing the front rods for ward the sleeve connection at the transmission can be engaged Slide the rear universal joint onto the transmission rod about 1 and tighten the clamp with the slot oriented up ADJUSTMENT LHD See the illustration on page 56 Proper adjustment of the linkage is critical to the function of the shift linkage Take your time Find the neutral position of the transmission gear selecto
93. hat stick to the in side of the wheel will not clear the caliper Balanc ing weights must be very thin or clip onto the rim edge 13 PARTS PREPARATION SUSPENSION AND BRAKE PARTS BOLT ON WHEELS REQUIRED PARTS optional or supplied by the customer FRONT BOLT ON x Because of tight clearance between the caliper and the wheel very thin wheel weights must be used Com plete caliper assemblies are available from ERA or Baer Racing Hub bearings and caliper bridges are illustrated on page 38 Qt Description GM Part ALL BOLT ON APPLICATIONS 2 Hub bearing 7466902 Two piston floating caliper 11 5 rotor 12 on special order 2 11 5 Rotor or 14084142 special order 12 4 Spacers anchor plate E R A for 12 rotors alrcalip2 gif 23 1 Caliper housing and 10104471 Qt Description GM part piston LH 1 Mounting plate LH 10052211 25 1 Caliper housing and 10104472 1 Mounting plate RH 10052212 2 Rotor 10097655 3 1 Anchor plate LH 10181205 2 Spindle w o ABS 14055941 31 1 Anchor plate RH 10181206 2 Nut spindle 562247 2 Rotor 10097654 9 Washer 562249 24 1 Pad kit 10104485 2 562248 28 2 Pin caliper guide 10140586 4 U joint clamp 14046907 29 4 caliper damping 10104481 Q Clamp bolt 14046904 1 1 Caliper LH 10132839 1 Caliper RH 10132840 Each caliper also in cludes the following 2 Nut lever arm 22521550 4 Lever arm 10132841 7 Cap lever pin 10112647 6 Pin lever pivot 10132833
94. have any reason to remove the primaries do it Remove the mufflers and transaxle bracket as a unit if possible Remove the collectors from the primary pipes Support the engine and transaxle with an adustable engine sling Remove the bolts securing the engine mounts to the engine block Remove the 4 upper bolts of the hoop crossmember and the bolts holding the transmission bracket to it If the primary pipes are in place raise the en gine transmission a couple of inches while tapping the crossmember up Remove the crossmember one end at a time snak ing it out from under the primary pipes Tilt the engine transaxle forward and support the engine at its rear edge with a small jack Release the transaxle support gently The transaxle must be high enough to clear the subframe and its sheet metal Remove the bolts securing the bellhousing to the engine and slide the transmission to the rear Installation is done in the reverse order ENGINE AND TRANSAXLE SPECIFICATIONS ZF TYPICAL GEAR RATIOS Differential 4 22 1 LUBRICATION Capacity Initial fill 2 7 qts 2 5 qts after drain ing in the car Fill to the overflow level of Speedo 2 0 1 hole that was made in right side of case Gear Ratios Recommended Lubrication Mild EP Oil SAE First 223 80 Second 1 47 1 Oil change intervals After first 500 miles Each Third 1 04 1 15 000 miles thereafter Fourth 846 1 Fifth 705 1 Rev 2 86 1 OVE
95. he opening A rubber squeegee available from auto body supply stores can be cut up to make spacer blocks G fwindow Once the windshield is laid in place trace the in side body edge onto the glass with a grease pen cil Remove the glass and spacers and lay flat con vex side up Sand the body flange with 80 grit paper Mask the body about 4 from the edge to prevent the sealant from adhering to the visible paint Lay a bead of urethane auto glass sealant along the edge of the glass using the pencil marks to demarcate the inside edge Lay another bead on corresponding the body flange With a friend carefully lay the windshield in place Press down so that the molding is level and even all around It may be helpful to use masking tape to hold the windshield in place while it cures Excess urethane can be cleaned up while still uncured with kerosene or special cleaners sold by auto glass supply stores CAUTION This operation should be completed before the car is painted The urethane adhesive may stain lighter colored finishes Urethane windshield sealant comes in a cartridge for use in a caulking gun A special primer is sometimes required Inquire when purchasing Be sure to follow manufacturers instructions Cure time is usually between 6 to 24 hours COCKPIT INSIDE REAR WINDOW Starting at the top middle fit the rubber gasket to the opening in the bulkhead panel The side of the gasket with the locking f
96. he reg istration with only an out of state vehicle inspection Titles Unlimited Tel 1 800 325 8136 Int l Title Service Tel 1 800 543 8626 PO Box 590136 Joe Holmes Birmingham AL 35259 Las Vegas NV 89121 World Title Services Tel 1 800 325 2050 US Auto and Title Serv Tel 1 716 342 5769 P O Box 9816 P O Box 17325 Birmingham AL 35220 Rochester NY 14617 EZ Auto Registration 1 562 982 1342 California specialists Martinia POSSIBLE PROBLEM AREAS Glazing Some states require that all windows be laminated or tempered glass This would make the optical quality Plexiglas side windows out of compliance The solution Take the side windows out Headlight covers In some states there are restrictions as to material or even whether they are allowed at all Take them off Headlight height It may be necessary to raise the car on the suspension to get the minimum headlight height required in your state BE PREPARED Don t go to an inspection station ignorant of the laws Don t expect special favors from motor vehicle inspectors and treat them with respect They are just doing their job If you have a problem ask the inspector how it might be fixed They can be very helpful If you have to return for a follow up try to get the same inspector Do have everything working properly adjusted neat and clean The better your car looks the easier it is to pass inspection Most states require thorough documentation of the ori
97. he steering arm is toward the outside of the car That is toward the flange of the carrier Use ribbed washers under each 1 1 4 long socket cap screw Safety wire the 4 screws together so that the screws will be held in tighten ing tension ot C fupasbbo The bottom boss will be installed onto the lower ball joint before installing onto the hub carrier See Control Arm Installation PIN DRIVE WHEEL NOTES FRONT HUBS ROTORS Note If the rotor hat and rotor have not been in stalled on the front hub already please do so now Note the orientation of the screws on the diagram Torque 5 6 x 1 1 4 screws to 18 Ib ft and the drive pins to 24 Ib ft Mark the rotor hat and hub so that if they are disassembled they may be reas sembled with the same orientation Install the stub axle onto the hub carrier with 4 Tlig 1 5 hex cap screws Torque to 50 Ib ft Clean the inside of the bearing hub and remove any machining burrs Closely inspect the area where the bearing races are installed SUSPENSION AND BRAKES Install bearing races in hub Inner LM12710 Outer L68110 At this point we recommend that the hub rotor combination be sent out to an automotive machine shop to have the rotor resurfaced This will insure that the rotor rotates with a maximum runout of 003 When assembly is returned be sure grind ing effluent is thoroughly cleaned out of the bear ing cavity Fill the about 50 of the
98. hread locker All stover nut threads should be lubricated with a light oil Bolt size Grade 5 Grade 8 Vg 9 13 Ib ft he 18 28 e 31 46 Te 50 75 75 115 he 150 225 Metric Grade 10 9 Grade 12 9 M8 25 Ib ft 29 Ib ft M10 47 58 M12 83 100 M14 100 120 114 INDEX INSPECTION AND REGISTRATION Without researching and writing an entire book on the subject it is impossible to give up to date information on the process of inspection and registration in every state You must call your state Department of Motor Vehicles or its equivalent to get local procedures and restrictions Most states have a pamphlet outlining the requirements for composite cars GENERALLY STATES FALL INTO 4 INSPECTION CATEGORIES 1 Inspections are done only by central or regional motor vehicle inspection stations 2 Inspections may be done by a local state inspection station That is a branch of the state Motor Vehicle De partment 3 Inspections may be done by authorized private inspection stations 4 No direct inspection is necessary Study your local laws carefully Because the GT40 was originally a race car some of its equipment may not be in compliance You must use your ingenuity to meet the letter of the law It is also possible to register your car in Alabama by mail This registration is only valid for 3 months but it may allow you to drive and sort out your car before your state inspection Some states may allow you to transfer t
99. ical and centered fore and aft and tighten the clamp between Z bar and the front rod At this point the spring detents in the shift lever should be in retracted positions and not rubbing against anything Lower the reverse lockout lever Adjust the rear spring detent so that it just contacts the lower part of the lockout lever Adjust the front spring detent to just touch left inside of the shift box SHIFT LINKAGE REAR AXLES At this point you should be able to select 1St through 5th gears and the lever should return natu rally to the neutral position 1 the second third 58 plane Readjust if necessary Raise the reverse lockout lever to check selection of reverse Grease the rubbing areas of the shift box gener ously SHIFT LINKAGE REAR AXLES RIGHT HAND DRIVE SHIFT LINKAGE x The RHD shift linkage consists of a rear rod with With the shift lever oriented vertically twist the offset double coupling sleeve front rod with a flat rear rod so that the offset gives maximum clear plate shift lever pivot box and shift lever ance through the hole in the chassis Tighten the ASSEMBLY front clamp Assemble the shift box onto the right rocker with Slide the long end of the double clamp onto the the shift lever already attached Check the fit of rear rod as far as it will go with the clamp slot ori the rod in the chassis bearing behind the seat The ented up Push the transmission rod toward the
100. ight section of the roll bar just above fuel filter fitting then joins the out put of each fuel pump and directs the fuel to the carburetor Some fuel pumps require a check valve between the and each fuel pump so that fuel will not simply be pumped from one tank to another Check valves are available from Earls or Russell FUEL AND COOLING SYSTEMS SINGLE PUMP DESIGN The fittings on the top of the tank cover must be The pump draws fuel from a crossover valve actu installed or removed through the door sill access ated by the power line from the uninstalled fuel hole at either side of the dash after the tank is in pump If you wish you may use a manual cross place over valve in place of the electric one leaving the INSTALLATION dashboard switch inoperative The fuel pump and filter may be located in the rocker panel storage If the front suspension is in place the upper and area on the car side opposite the battery This lower control arm and tie rod must be separated setup has the advantage of being quieter and less from the upright and the upright swung out of the heat sensitive than the exposed fuel pumps al way See page Error Bookmark not defined though we recommend that the fuel crossover line be insulated INSULATION For street use insulate all the engine compartment fuel lines This will prevent heat soak induced vapor lock TANK INSTALLATION REMOVAL 2 For fuel injection see
101. illing this bell housing is impractical The E R A bell housing is designed for a smaller starter ring gear eliminating ground clearance problems and is less deep allowing easier use of the air conditioning components The transmission must be partially disassembled to drill new internal oil drainback holes and to drill new drain and oil level holes As with the early transmission the ring gear must be transposed to the other side of the pinion gear You must use a standard Ford flywheel with 164 teeth This was used on some earlier engines and most post 1980 ones You must specify your flywheel when ordering the bell housing The location of the starter is differ ent for each See the diagram for specific machin ing dimensions McLeod Industries of Anaheim California can produce a flywheel to our specifica tions for about 300 PARTS PREPARATION A 10 5 Long type clutch from various 260 289 302 and 35 Ford engines must be used so it is sometimes necessary to redrill the flywheel for the new pressure plate The recommended clutch parts are listed in Section A The bell housing to pressure plate clearance 15 lim ited so check it as early as possible The 9 5 clutch set from the late 81 gt Mustang may fit but 15 not recommended because of its small torque capacity If you wish to use a special clutch see the diagram on page 8 for clearance considerations The starter necessary is from a 1967 74 289 302
102. imits the steering motion The spacer for the early rack has an internal indentation that fits over the retain ing ring extension The spacer for the late steering box has no groove Fit the inner retaining ring locktab Type 2 only and the aluminum clevis for the inner heim joint PARTS PREPARATION With the flat in the pinion shaft straight up adjust the outer clevises so that they are 26 5 see page 32 from the clevis hole center line to hole center line and equally spaced from the rack housing Rotate the slots about 20 degrees back from vertical relative to the mounting stands so that they will be approximately vertical when in stalled in the car Tighten the retaining ring against the clevis Secure the Type retaining ring by using a punch to indent the ring into the grooves in the rack and the clevis Secure the Type 2 retaining ring by folding the lock tab over the flats in the retaining ring and the clevis I also recommend that a hole be drilled through each clevis into the rack and a s Diame ter x Long roll pin be inserted as illustrated preventing rotation on the rack Install the left hand thread rod end joint HMRL 8 in clevis using 055 x 1 HC Bolt with a star washer Torque the bolt to 50 ft Ibs Grease the joint and the outside of the steering gear gen erously working the gear back and forth to dis tribute the lubricant Reinstall the boot over the rod end stud
103. is com pleted tighten the inner nut to approximately 60 lb ft and safety wire the inner and outer nuts to gether so that they are always in tension Each full turn of the adjusting nutschange the camber by approximately 3 degrees REAR rcastadj ALIGNMENT SPECIFICATIONS Inclination of the hub carrier toward the rear 7 deg 1 deg Camber 1 deg _ deg Toe in 3 35 0 4 deg 0 1 deg TO SET REAR ALIGNMENT Set the caster inclination of the rear hub carrier to 7 degrees deg This can meas ured by the angle of the outside horizontal tube of the lower control arm Only the upper trailing arm need be adjusted if the specification can be met If not adjust the lower trailing arm also 47 Set the camber by adjusting the upper radius rod Set the toe in by lengthening or shortening the upper and lower trailing arms equally Check and reset the inclination if necessary Reset the camber if necessary Reset the toe in if necessary TIRE PRESSURES Try initial settings cold of 22psi front 25psi rear Depending upon tire brand and size these pres sures will be a reasonable compromise between ride and responsiveness Remember this a a light car with very large tires High tire pressures are neither necessary or desirable Track tire pres sures should be determined with a tire pyrometer Over inflation will actually decrease the amount of rubber on the
104. l on the brake handle comes with the kit handle It connects at each rear wheel with a screw on clevis that engages each actuating lever The lever then acts on the bottom of the emer gency brake shoes or at each caliper Feed both clevis ends of the cable through the slot on the left bottom side of the diagonal panel behind the seats The loop remains at the handle The longer cable half is fed over the water hoses but under the throttle cable and goes through the grommet on the right side of the inner bulkhead The cable runs inside the chassis structure Tightly tie wrap the cable housing to the top side ebhandle of the trailing arm about 1 foot back from the front Install the handle on the chassis bracket at the left pivot and again about 8 inches from the rear end side of the drivers footwell with a 516 USS x 1 The short cable half passes through the left grom screw at the rear and a 5 3 4 screw at the met in the intermediate bulkhead and is attached to front Bolts longer than those will drill into the the trailing arm in the same manner as the other fuel tank half Feed the cable ends through the lower trail ing arm boots 52 SUSPENSION AND BRAKES CALIPER TYPE EMERGENCY BRAKE Install the special cable clamp bracket onto each caliper with a single bolt See below ADJUSTMENT Adjust the nuts on the cable housing at the front chassis bracket The lever arms must be free to fully return The caliper will self a
105. lap goes to the rear engine side Carefully work the gasket onto the edge of the bulkhead panel Push it tightly into the corners Don t stretch the gasket during installation the gasket will shrink slightly with age Instead push the gasket back onto itself as you fit it BODY 94 When the gasket has been almost completely in stalled trim the end leaving about more than you think necessary Refit the gasket again forc ing it back on itself trying to get the ends to butt one another Trim if necessary cockpitwind Lubricate the glass channel using waterless hand cleaner Fit the bottom of the window into the rubber using a windshield setting tool bone Work the lip of the gasket over the glass from the bottom up the sides and across the top to the middle Work the locking flap into its channel to secure the window in place BODY SIDE WINDOWS Each door window is made from a special hard surfaced acrylic material and is held in place by Refer to the illustrations when assembling the 21 stainless steel screws hinges and adjusting bracket Note the small O ring which acts as a rattle eliminator A little x grease makes assembly of the pieces easier You may wish to paint the outer of the win dow border with semi gloss black paint before fi nal installation HEADLIGHT COVERS REAR WINDOW The main window along with the smaller vent H FG windows pre drilled
106. lation See page 82 for door details Remove the limit strap from the door Remove the 4 bolts securing each door hinge as sembly from the chassis Remove the hinge assembly irom the door Loosen the jam nuts adjascent to the sockets each end of the threaded shaft and screw each ball pivot as far onto the thread as possible This will allow the ball pivots to be disengaged from the sockets on the hinge frame Installation is done in the reverse order ROOF Remove steering wheel and dashboard page 101 Remove the rear bulkhead interior panels The roof is secured to the cowl with screws along its front lip and to the roll bar at the rain gutter flange ROLL BAR REMOVAL Measure and record the dimensions shown on page 77 ENGINE PREPARATION Because the engine ts the equivalent of a quart in a pint pot clearance in the engine compart ment ts limited Many engine accessories must follow the guidelines in Section A OIL PAN SPECIFICATIONS AND NOTES bloilpan e Because of interference with the shift linkage LHD cars require that the oil dipstick be in the front cover not in the right front corner of the oil pan PARTS PREPARATION e Maximum pan depth without hanging be low chassis 7 3 e Maximum width at widest point ahead of starter 14 The Smiths and Stewart Warner oil temperature gages require NPT female fitting welded into the pan preferably on the left side toward the front
107. ll the engine transaxle page 63 Install the rear axles page 60 Install the rear shift linkage page 56 Install the front body Section page 87 Install the front body sealing hardware and gas kets page 81 Install the rear body page Install sound deadening panels if required page 98 Install the dashboard page 101 Install the steering column housing page 100 Install interior page 97 PARTS PREPARATION PARTS REQUIRED AN OVERVIEW WITH SPECIAL NOTES The ERA GT chassis and body follow the dimensions Water Pump A Ford Motorsport shorty pump of the original GT40 very closely Therefore your or Snow White pump is highly recommended mechanical components must conform to similar Alternately you can use an externally mounted space limitations as the original car Some configura electric pump made by Davies Craig of Australia tions will fit together better than others and some are Inquire simply not possible Flywheel must match the bell housing clutch Be careful when selecting and building your compo and crankshaft nents The information on the following pages shows Clutch must fit the transaxle flywheel and bell the recommended parts for many possible drivetrain housing combinations As of 1 99 the several exhaust systems are avail ENGINE able for 289 302 engines with various head de Because of space considerations and transaxle com signs Please inquire patibility the following engine parts
108. lwood 160 0790 cut to 11 5 or 12 diam 2 Nut Castle 3 4 16 2 D Washer 2 Cotter pin 7 64 x 1 1 4 Bearings Seals fits both Calipers above 2 Wheel bearing inner A 12 Bower BCA 2 Wheel bearing outer A 13 Bower BCA 2 Seal inner 19753 CR 15 REAR PIN DRIVE Uses 1989 92 Corvette pieces with the emergency brake built into the caliper Except for the pin drive hub parts are the same as the Bolt on See caliper parts diagram on page 47 YOU MUST SUPPLY ua Description GM Part 1 Mounting plate LH 10052211 1 Mounting plate RH 10052212 1 Caliper LH 10132839 1 Caliper 10132840 Each caliper includes Nut lever arm 22521550 Lever arm 10132841 Clip lever arm 10112646 Pin lever pivot 10132833 1 Cap lever pivot pin 10112647 2 Repair kit includes 10112656 Pushrod Retainer Boot Actuating Collar Boot Bushing Clamp rod 2 Bracket parking brake spe L and R cial 4 Spring EB collar retainer 10112650 2 Bolt anchor plate 10112649 2 Anchor plate caliper mount 10112652 ing 4 Guide pin 14067560 4 Boot guide pin 14067552 I Pad set includes 4 guide pins 10132836 bolts Bolt guide pin 14067559 2 Spring lever return 10112651 ERA SUPPLIED PARTS WITH KIT ua Description 2 Hub bearing Federal Mogul 513020 or GM 7466920 or 7466924 is modified for use with Type and pin drive adapters and is supplied with pin drivekit Spindle w o ABS used or NOS only Spindle w ABS Nut spindle
109. m top Sway bar bushings Bearing hub for bolt on wheel Bearing hub pin drive inner Outer Seal inner pin drive Inner pivot bushing sleeve Inner pivot thrust washer SUSPENSION REAR Inner pivot bearing lower wishbone Outer front bearing lower wishbone Outer rear pivot rod end lower wishbone Girling 3 4 bore Tilton 260 0412 Neal NP 141 NR Girling 5 8 bore Tilton 260 0426 Neal NP 140 NR NF810 5 Boston 18824 Boston LSS 8 Heim HF 5 BMW 2152 1104 269 Nissan 30502 21000 fits 81 84 Maxima Pickups Republic BJ 10324 MOOG K6273 Republic Moog ES 383R Alternate ES314R Republic Moog ES 381R Heim HMRL 8 Heim HMR 6 HFR 6 Nissan 54617 21002 GM 7466902 A 13 Bower BCA Cup L88110 cone L88149 A 12 Bower BCA Cup LM12710 cone LM12749 19753 CR Heim NRR 10 Heim NRR 10 Heim HMR 10 111 Trailing arm ends upper lower forward end rearward end Bushing isolator upper and lower Upper radius arm ends inner outer Sway bar link ends bushings Drive axles see Section D STEERING COLUMN Bushing upper column housing Joint universal Joint may be rebuilt using cross kit SHIFTER Shift rod support front Universal joint front and rear Shift rod support firewall ENGINE MOUNTS Bushing only INDEX Heim HMRL 8 Heim HMR 8 Energy Suspension 2191G Heim HMRL 8 Heim HMR 8 Heim HMR 6 Nissan 54617 21002 Boston NS1012 6 Borgeson UISN 5 8 x 5 8 Heim HM 10
110. n screw the inner socket from the rack Discard all the old tie rod parts except for the inner locking ring jam nut 32 Center the rack by equalizing the distance each end extends from the housing 1 6 With the steering gear assembly oriented with the mounting faces down mark the pinion shaft on its uppermost surface Be as accurate as possible This is to indicate where a flat surface is to be ground The shaft is hardened It is not easily marked with a punch Use a stone grinding wheel or permanent marker Remove the flat preload cap spring and sleeve from the top of the housing Do not lose the inner spring etc Note the shims if any Remove the pinion end cap and retaining pieces Note the shims if any between the cap and the housing Remove the pinion shaft with the bear ing from the housing by driving from the splined end b pinion The shaft must be machined ground to the di mensions shown After the machining is completed install the pin shaft back into the housing as it was when it was marked With the rack centered the flat on the pinion shaft should be at the top as it was be fore disassembly The pinion shaft may rotate as the teeth are engaged so compensate for this ef fect Use an EP grease to lubricate the gears and bear ings Fit the pinion retaining pieces and the end cap Reassemble the rack ends Install the spacer pro vided next to the rack housing This spacer l
111. nce above the carburetors to a minimum Remove the transmission support crossmember from between the rear damper brackets on the rear chassis hoop Raise the engine so that the oil pan will clear the bottom of the rear hoop Either move the car back ward or the engine forward until the engine mounts line up Loosely install the mounts on the block The E R A mounts are stamped L and R on the top Lower the engine until the mounts are slightly above the chassis pedestals Install a bolt through each upper plate and through the mount bushing Engage the bolt into the threaded boss in the chas sis while carefully lowering the engine into the chassis Snug the bolts slightly then install the bolts securing the upper plates While lowering the engine into place tighten the bolts on the block then all the bolts on the chassis brackets Install the crossmember onto the rear hoop using only the 2 upper bolts Insert each 9 6 x 4 bolt from the back of the car while holding the lighter washer against the transmission bracket The heavy washer is used against the bushing at the front Tighten the nut to 45 Ib ft REMOVING THE TRANSAXLE LEAVING ENGINE IN PLACE Possible but difficult Remove rear body anti sway bar slave cylinder bracket from the transaxle side plate Remove the distributor cap and starter The primary pipes of the exhaust system may be left in place but it does make things pretty difficult If you
112. nd a sliding spline between them to take up length variations occuring as the suspension moves up and down The inner end has a flange to mate with the ZF transaxle output flange The outer end mates to the stub axle cross assembly The axle assemblies can be made by most drive shaft fabricating facilities or purchased from E R A Dimensions and part numbers are included in the drawings provided There is some variation in equivalent parts Critical dimensions are open and closed length and minimum angle of the flange HSHAFT3 Check that there is clearance in the appropriate ar eas to allow 23 degrees rotation of the flange from perpendicular especially at the outside end of the shaft where it mates with the hub carrier Inade quate clearance will result in binding of the shaft at full suspension droop followed by strange noises INSTALLATION Use grade 8 x 1 4 Hex cap screws flat washers and stover lock nuts to secure the inner ends to the gearbox flanges The outer cross is held in place by the U bolts of the GM stub axle Do not overgrease the sliding splines but grease sparingly every 2000 miles If you separate the sliding spline sections mark the male and female so that they are assembled with the same orientation Otherwise the balance and phase will be disturbed Always line up the inner and outer on each axle ENGINE AND TRANSAXLE ENGINE AND TRANSAXLE ENGINE AND TRANSAXLE J
113. ne of the outer tie rod end to 9 as a preliminary adjustment Since there is limited adjustment on the inner end of the tie rod assembly any major ad justment must occur on the outer end When ad justing toe in it might be necessary to remove the tapered end from the steering pitman arm of the front upright to make major changes You may check that there are adequate rod end threads in the tie rod by running the jam nuts lightly against the tie rod then unscrewing the tie rod to expose the threads There should be minimum thread in the inner tie rod and mini mum in the outer INSTALLATION Remove the side splash access panels Turn the pinion all the way to the right With the left side of the rack assembly pointing 45 degrees forward place the right side tie rod through the open section on the right Rotate the left tie rod toward the rear and rotate the entire rack to the rear simultaneously inserting the pinion shaft through the hole in the footbox 39 Using the four x 2 hex cap screws pro vided bolt the steering gear to the chassis brackets with a shim under each mount The shims allow exact bump steer adjustment for those who de mand competition tolerances Adjusting the bump steer of your street car is not necessary Standard factory settings are very accurate Slide the foam gasket provided onto the pinion housing to seal against the front footwell panel It will normally
114. om the bracket Use a I bolt and appropriate spacers Reconnect the trail ing arm SUSPENSION AND BRAKES DAMPER ADJUSTMENT For optimum ride and safe handling there are spe cific characteristics that can be adjusted into the suspension by way of the damping Control over rough surfaces is important as 1s transitional be havior i e the way a car reacts when it suddenly changes direction Within limits you may cus tomize those characteristics to your preference KONI Bump control The control knob 15 located at the bottom of the damper Turning the wheel clockwise increases the bump control damping Set all four dampers on minimum bump and re bound settings Drive the car to get the feel of the car Over uneven surfaces Disregard body roll just notice the behavior over bumps Notice if the car walks or side hops in a rough turn Increase bump adjustment 3 clicks at a time on all four dampers until the car starts to feel hard over bumps Back off each adjustment 2 clicks The back off point will probably be reached sooner on one end of the vehicle than the other If this oc curs keep increasing the bump adjustment on the soft end until it too feels too hard Then back it off Final micro adjustments can be made after you get used to the feel of the car Rebound control The adjustment is made by in serting a 1 pin in the wheel at the top of the damper Turning the toothed control wheel from left to ri
115. on If you are install sucessfully tested a Davies Craig electric pump ing an aluminum flywheel have it drilled to the 82 It eliminates the engine driven pump and thermo on Ford clutch pattern and use the 157 Tooth Ford stat and offer full water flow at any speed Call ring gear This is a good combination for clear or e mail us for the installation details ance reliability and compatibility Snow White LTD shortie pump The front cover on pre 1968 engines must be changed to the later cover See the information below The 3 or 4 bolt pattern on the crankshaft damper must be specified when ordering the Snow White water pump Some modifications to the Snow White unit are necessary when using a Weber carburetor manifold with dual water out let Most aftermarket manifolds use only a single outlet See section L for details Ford Motorsport M 8509 E351 Short pump Buy the 3 piece 2 groove pulley kit M 8509 N from Ford Motorsport The front groove on the water pump pulley must be machined off for ade quate firewall clearance Final pulley details are being worked out Inquire CLUTCH AND FLYWHEEL Ford has used several combinations with 289 Ford Motorsport makes a 10 5 combination that 302 Engine The clutch must be properly matched is rated for 750 BHP and is still streetable The to your engine s flywheel and also to the transaxle disc is a combination metallic one side organic you use If you haven t selected y
116. or gravel chip guard materials available to prevent chip ping of the paint and also to act as a sound deadener Depending upon your local weather conditions it is recommended that you inspect your undercoating and rust proofing at regular intervals and retouch if neces sary Paint the chassis being careful to get into the hid den areas as much as possible 76 BODY ROLL BAR Fit the painted bar to the chassis in it exactly the same position as it was when shipped replacing any shims to their former location Use the flat bar washers under the nuts and lock washers see figure below Assemble the upper rear body latches and release levers to their mounting brackets and attach these units to the bar Fit the latch release actuating rod onto the bar between the latches Use 47 minimum grip range pop rivets and bonding material to attach the roll bar to the roof section Make special note of how the rear roof flange is riveted to the flange on the rollbar also shown in the view of the rear bulkhead Install the ID plate and voltage regulator as shown Note the location of the starter solenoid G ROLLBAR 77 BODY ROOF BULKHEAD ASSEMBLY x The roof assembly is bolted riveted and bonded to the chassis This multiple attachment achieves a unitized type construction that adds some stiffness to the chassis tub The roof door relationship should have been veri fied before initial disassembly an
117. or clear ance PARTS PREPARATION STEERING GEAR There are two original MGB steering gears avail able Type 1 and 2 shown below that require some tie rod modifications and one new ERA re placement see page 33 that does not To deter mine which MGB one you have remove the in ner boot clamp nearest the pinion end of the hous ing and pull back the boot to reveal the rack 8 mgsteer The earlier Type 1 steering box has the gear teeth cut at 90 degrees to the rack centerline The Type 2 steering box has the teeth cut at about 60 to the rack centerline In order for us to supply you with the correct tie rod end adapters you must tell us which one you have The differ ence in adapters is subtle but significant All the information below can be applied to RHD steering gears which are the mirror image of LHD steering gears REMOVING THE TIE ROD ENDS AND BOOTS 1 gear assembly Use a suitable tool such as a punch to uncrimp the retaining ring indents of the inner joint 2 gear assembly Locate an indentation on the edge of the inner jam nut near the original tie rod socket This spot is actually the top of a lock ing pin Use a bit to drill through the pin to depth of the rack itself Use a large wrench and a vise or pipe wrench to loosen the retaining ring from the inner pivot socket nut Be careful not to scratch the round surface of the rack or damage the gear teeth U
118. ount altmt Install the brace from the water pump right most 289 302 Engine Use the 7 5 bolt with the bolt to the compressor bracket The rod end of shorter spacer through the outer hole in the the compressor tensioner goes on top of the brace bracket using the x 4 bolt in the ERA AC kit The er tensioner has one left hand thread and one right 351 Engine Use the x 6 bolt with the longer hand thread so it may be adjusted without disas spacer through the inner hole in the bracket sembly BELT ALIGNMENT Attach the lower end of the link to the front of the Check alignment with a straight edge across the boss on the AC compressor using a 5 6 x 1 5 crankshaft pulley The rear crankshaft pulley screw groove will usually line up with the alternator and Depending on the crankshaft damper the front water pump grooves groove of the crankshaft pulley may drive the al ternator or the AC compressor With a standard Ford alternator we usually start with a 8448 or 8455 Gates belt or equivalent ALTERNATOR MOUNTING See the diagram below for the bracket to head at tachment points All three bolts are NC x 1 You may also wish to mount the coil on one of the bolts engtop 289 302 Engine Use one or more of the washers provided to correct any misalignment 351 Engine We recommend that you machine the backside of the crankshaft pulley 1f there is misalignment of the rear groove with the water
119. our engine yet other side design read the information that follows with the purpose Clutch dise M 7550 X302 of keeping your special machine work to a mini Pressure Plate M 7563 A302 or M 7563 mum Take note that some crankshafts are exter B302 with centrifugal assist nally balanced with the flywheel Your crankshaft THROW OUT BEARING must be balanced in unit with it The ERA bell housing is supplied with the engine plate throw out bearing Nissan 30502 21000 adapter sleeve and pilot bushing Spacer rings in cluded will adapt the mechanism to most configura tions If you use the inverted Pantera bell housing and Pantera clutch use the standard Pantera throw out bearing PARTS PREPARATION TRANSAXLE BELL HOUSING OVERVIEW The original GT40 used the German ZF 5DS 25 transaxle Fortunately the basic design is good for both competition and street use having constant mesh helical gears with excellent synchromesh Successors to the original transaxle unit were com monly used in the Pantera upside down and less commonly in the DeTomasso Mangusta right side up A third variation on the transaxle is used on the BMW M1 This unit is similar to the Man gusta but the gear change is on the left side rather than the correct right Consequently conversions for the ERA must include moving the transaxle shift mechanism to the other side something that is best done by a professional See page 18
120. oved to allow engine servicing by sliding the front and rear If you have seat tracks sliding the seats forward and unscrewing the trim screws seat forward makes it easier to remove the rear around the periphery See the diagram on page 79 screws Otherwise an extra long screwdriver is for placement on the rear bulkhead best SEAT BELTS SEATS There are standard threaded inserts 1s 20 thread Note The drivers seat may be wider than the pas for the lap and shoulder harnesses welded into the senger s chassis Each seat is secured with bolts and large flat wash The lap belt inserts are in the diagonal bulkhead ers from underneath the floor into the seat frame behind the seats just above the floor and to the left or seat adjusting track Because the seat is a very and right of each seat tight fit it is recommended that the tunnel cover Shoulder harnesses are secured to brackets on the be removed first bottom of the roll bar cross brace Two inserts for each shoulder harness are provided You may use either a single diagonal belt or competition belts with separate left and right belts 102 Interior Ventilation AIR CONDITIONING HEATER GENERAL CONFIGURATION The ERA Air Conditioning System 15 an integrated heater air conditioning system utilizing a combination core with blower valves and thermostat mounted in a single box over the footwell This housing is very similar to the one originally found in the street version
121. ow bottom of the differential section INPUT SHAFT of the case They are a press fit into the case You must drive the internal tube out through the outside hole with a punch Tap the case 39 16 18 from the outside and use a cap screw to plug the hole Use gasket sealer or silicone on the threads to prevent leakage See the diagram on page 25 for input shaft dimen sions 2 PARTS PREPARATION Drill and tap an oil level hole in the right side of the case in the position shown The hole should be drilled to 1 and tapped NPT and a pipe plug installed When filling the transmission from the top the oil level should reach the bottom of the hole transide Drill and tap two NPT drain holes in the bottom of case as illustrated If the transfer holes between the differential and the gearcase are low enough the oil can be drained exclusively from the rear hole transbot Install a baffle and vent fitting in the now top access plate The baffle will prevent oil from be ing thrown out of the fitting by the rotating ring gear E R A makes a plate for this purpose that must be welded or screwed to the inside of the cover If you make your own The baffle plate must allow clearance for the ring gear on the left Therefore the plate must be biased toward the right side of the gearbox access plate 28 man b trnsbafl Stuff brass wool from a scouring pad through the vent hole into the baffle area Even so a dump
122. page 37 and 38 FRONT CALIPER Attach the caliper bridge with the M14 x 40 mm bolts The flex hose to each caliper is secured to the top of the upright with a nylon clamp See page 37 The cable should be positioned so that there is no binding and no interference with any suspension or steering piece through the full range of wheel travel REAR CALIPER Mount the bracket ears toward the front of the car as shown on page 38 and bearing assembly to the hub GM bracket 10052211 is used on the left side 10052212 on the right Secure with M12 x 70 Allen screws and lock washers Torque to 80 Ib ft An exploded view of the caliper parts is on page 14 Note that the emergency brake cable bracket is a special E R A piece Installation is shown on page 53 After assembly of the parts orient the caliper so that the cable enters from the bottom Use the M12 x 30 screws and lock washers to secure the calipers to the bracket Torque the screws to 55 Ib ft Secure the brake hose with the clamp on the upper inside of the hub carrier tie wrap the emergency brake cable so that there is no binding or interfer ence with any suspension piece through the full range of wheel travel 51 SUSPENSION AND BRAKES EMERGENCY BRAKE HANDLE AND CABLE 2 clebillust Trim the LHD emergency brake handle part num The emergency brake system is a single continu ber is on page as shown on page 16 The RHD ous cable pulled by a balance whee
123. part 3 Follow the same procedures in temporarily fitting this part Arrange rail 5 and weather seal to seal the vertical space between the cowl and the inner face of the body panel Attach the weather seal to the rail and place them in position bending the rail to fit if necessary Overlap the front upper portion of the rail 5 with rail 4 so that they can be attached to one another If the rail 15 too long trim it back even with rail 4 To enable the two weather seals to fit together ef fectively the end of rail 5 must also have a por tion removed See the illustration With the seal refitted to the rail move the rail to the outside un til the seal lightly contacts the body Drill holes and use sheet metal screws to hold rail 5 in place Trim back weather seal B even with the longest end of rail and remove 1 2 of the clip on portion Peel back the bulb from the clip on portion and cut off the desired amount See the illustration Trim seal A similarly The clip on portion of A must be shortened so it butts against the sealing bulb of B with the seal ing bulb of A overlapping bulb B After the pieces have been fit together open and close the hood to make sure the weather seals have not dis turbed its fit and there is no binding Re adjust the seals if necessary Once the placement of all the rails have been de termined drill the balance of the rivet and or screw holes Remove the rails and deburr the hol
124. pressor is installed on the engine the tube will come very close to it with the tube outlet pointing forward and to the inside about 45 degrees TUBE Insert this into the hole on the lower right of the engine firewall with a grommet insu lator It should extend only about 3 4 in side just enough to get the inside 20594 Gates hose on If you use the ERA header tank the other end of the tube will fall about 1 below the connection on the header tank Use a short length of hose 3 x I ID to make the connection 2 CONNECTOR This tube is an intermediate between the header tank L tube and the intake mani fold hose It should be installed so that the L tube is very close to the chassis panel Longitudinal tubes The lower tube can be recognized by having a 45 degree bend with a boss on the front end and a 90 de gree bend on the back Install the lower tube into the tunnel corridor first Slide the tube in until there is only the angled section visible and then rotate the tube so that the welded boss is up Install the upper tube the same way rotating the boss up The lower tube should point toward the right side of the radiator the upper toward the left THERMOSTAT DETAILS Use a thermostat of about 170 deg F to maintain reasonable engine temperature Running without some type of restriction in the system will result in high speed cavitation and the resulting overheat ing Do follow the ste
125. ps in the Snow White in structions to drill a hole in the thermostat for air bleeding and smoother transition opening Some thermostats already come through with a small bleed hole An optional intake manifold water outlet with a boss for the water temperature sender 15 available from us for use with the Weber intake manifold or a normal 4bbl manifold FUEL AND COOLING SYSTEMS FILLING THE SYSTEM Once you are sure that all the connections are tight and secure check that the engine drain cock is closed Open the bleeder on the radiator top It may be helpful to raise the front only of the car so that air will not be trapped in the longitudinal tubes Fill the header tank with antifreeze water mix ture and allow to drain down refilling when nec essary This is a somewhat slow process so have patience Monitor the vent on the radiator and when only liquid comes out close the valve Find a water fitting on the engine intake manifold at the highest point This can be either a plug or the temperature sender Vacuum fittings look similar so take care that the fitting is in the cool ing system When the header tank seems to main tain its liquid level loosen the fitting to vent any remaining air from the system If you have a heater loosen the upper hose and al low air to bleed from the heater Reinstall the hose when only water is expelled Run the engine at fast idle for several minutes monitoring the tempera
126. r rod by locating the central position of the forward and aft available travel The input shaft is spring loaded in the 20d 3rd plane 57 With the shift lever vertical rotate Z bar so that it is centered in the slot in back of the seats ad just so that there is potential equal travel up and down and front to rear as the shift lever 15 moved The fore and aft travel of 7 bar is very critical The rod will tend to jam in the support bearing if it 15 too far back or will hit the diagonal panel if it is too far forward Tighten the clamp on the front rod only after checking for interference D zpro Rotate the rear rod to about the 1 30 position with a Ford starter the starter cable bolt will point di rectly at it With the rod engaged about 1 tighten the clamp connecting the rear end of Z bar with the forward end of the rear rod Tighten the clamp at the transaxle input but leave the clamp to the rear end of the rear rod a little loose Check to see that there is no interference when the rear rod is rotated and extended fore and aft to select all the gears Adjust the long connection at the rear rod so that all gears are available and the shift lever is oriented correctly If necessary re adust any other connec tions to perfect the fit Check to see that the transmission is still in the neu tral 2nd 3rd plane position Loosen the front clamp Hold the shift lever about 5 degrees to the right of vert
127. rake shoes drum EB only prevent smooth installation check that the shoes are centered and the adjustment screw is fully home It may be necessary to file any high spots on the shoes Install the pin drive hub holding the assembly to gether with the pins The left hub 15 threaded right hand and the right hub threaded left hand Use high strength thread locker on the threads and torque each pin to 65 Ib ft in several stages Disassembly can be accomplished only by heating the pins enough to weaken the thread locker Rear control arm and hub installation is shown on page 43 SUSPENSION AND BRAKES BOLT ON WHEEL HUB CARRIERS FRONT HUBS Install the hub bearing GM 14084142 to the aluminum hub carrier with 1 5 bolts and star washers Torque to 50 Ib ft Install front rotor over studs REAR HUBS See the diagram of page 38 Follow the steps described for pin drive rear hubs except the rotors will be installed directly over the 5 wheel studs of the bearing flange There is no pin drive hub obviously STEERING GEAR AND TIE ROD INSTALLATION The ERA gear needs no preparation MGB gear only Prepare the steering gear as de scribed on page 32 Install the tie rods with the tie rod ends onto the threaded ends of the rod ends with jam nuts extending from the rack boots They are left hand thread Screw the tie rods on about 3 Set the distance between the inner end of the tie rod sleeve and the centerli
128. re 112 Tool 18 Tools DE 18 Torge values Tiberen 111 Transaxle BAW MT 26 Bre athe 61 Dran 26 TAOS 61 DS Ca 60 MIO CII CATIONS 26 Pantera Pla 23 PAN 24 Prepatation NE EE NET 24 Al 60 Rue 26 PE 5 SPIN 61 107 SPENN eee 61 107 NA 26 Ts NL 69 Tunnel Ge ER AAS REE EN 99 120 VidrbeN 73 vent Reven 89 WENGE Role 105 Trade cents se 26 re UA Oanes 74 Voltage ReSUlatOr 16 Washers Application 111 Water DINES yinni 76 A 21 22 68 Water Pump 8 Water temperature sensor urene andet 21 W ater DE 69 Weatherstripping PRONE DOO ass 77 Weatherstripping Adora 83 Weber Laden 21 Wheelhouses panels Fron sisest lest 76 Wheels FAD 16 Window eee 91 Dr 92 Rue 89 Windshield installation 90 Wiper DIVE pos sureste cee ease dase een 93 Modne 31 Parts 16 PIUS 21 Z at 53
129. road by crowning normally flat tires and tire noise and harshness become serious above 25 PSL Steady state under oversteer may be adjusted sig nificantly by working with the tire pressures If your balance is incorrect raise the pressures on the axle your want to stick better by about 2 PSI and road test the car You may alternately reduce the pressures on the opposite axle for a better ride Generally it is the tire pressure differential that determines handling balance If the steady state behavior of the car is not the same cornering right and left check that the anti sway bar links are not preloaded and that the spring preload is equal from side to side SUSPENSION AND BRAKES BRAKES TECHNICAL OVERVIEW Hydraulic pressure is created by two Girling Lockheed Master Cylinders actuated by an ad justable balance bar The brake and clutch cylin ders are mounted on a adjustable pedal frame which also carries the throttle pedal The clutch master cylinder is identical to the front brake master cylinder From chassis 2055 2 psi residual pressure valves were added to the system to alleviate some soft pedal problems associated with the 88 on Cor vette calipers All Fittings Lines and Hoses for input and out put are factory installed The front cylinder 15 bore the rear cylinder is 5 bore unless other than the standard Corvette calipers are used 1 Front master cylinder 3 4 Banjo Bolt w washers
130. rs Using 8 5 and 10 wheels there is enough clearance for 225 60 15 or 245 50 15 in the front and 255 60 15 or 295 50 15 in the rear Optional 1075 flares with 16 x 9 5 and 12 5 wheels allow 245 50 16 tires in front 315 40 16 in back 12 brake rotors will also fit easily in the 16 wheels Some increase in the maximum sizes listed above may be effected by increasing the wheel backspacing mov 16 ing the wheel toward the centerline of the car Re member Suspension harshness increases with very large tires and since the car is very light smaller sizes are more than adequate for spirited driving Racing tires are not recommended for street use and are illegal in most states AUXILIARY SYSTEMS Axle half shafts Available from ERA or can be made to the specifications in section on page 60 Battery Group 42 or equivalent HD Douglas Omni 7000 Belt alternator 7320 7325 or 7330 Gates or equivalent depending on application Belt AC compressor 8448 or 8455 Gates or equiva lent depending on application Cable battery to starter solenoid 18 long w clamp eye Cable LHD starter solenoid to starter 20 w 2 eyes Cable RHD starter solenoid to starter 72 x 2 gage w 2 eyes This must be fabricated from pieces See an automotive electrical shop if necessary Cable battery to bracket 18 w clamp eye Cable bracket to cylinder head 12 w 2 eyes Cable speedometer Custom unit See us
131. s for the following modifications the cross shaft back to the neutral position Drill 2 holes between the differential section and Use a 5mm allen wrench through the small holes the gearbox as indicated In my experience this is in the top of the shifter box to remove the set only necessary on the 25 2 gearboxes The 25 1 screws securing the socket arm to the longitudinal series already has the holes Try to have the holes shifter shaft Remove the shaft as close to the bottom of the case as possible They allow oil to flow freely between the two sec Pull the ball lever arm out and disengage t ions socket arm Remove the arm from the cross shaft using a x puller if necessary Remove the half moon key from the cross shaft Remove the 3 hex cap screws and 1 socket screw securing the shift box to the case Note that there is a thick shim between the box and the case at the front socket screw position Don t lose it and don t forget it on assembly Remove the shift box by gently tapping and rotat ing it GEARSET Remove the speedometer drive adapter from the side of the case by removing the securing screw Gently pry the adapter out Remove the end cover and intermediate gear plate by removing all the outside nuts and 4 allen screws at the top and bottom ibtrans view At this point you may want to inspect the gears Remove the vent tubes from the inside and out and synchronizer rings for wear side of the n
132. s up with the water pump pul ley CARBURETOR LINKAGE The kit is supplied with cable and linkage for a single 4BBL carburetor Bolt the bracket sup plied to the front bolts on the carburetor mounting plate The cable passes through the hole at the front to the carburetor bell crank on the throttle shaft You must remove the ball joint that some carbure tors come with replacing it with a HM 3 Heim rod end and 10 screw Weber conversion manifolds generally have link age systems that are adaptable to our cable without problems You may connect the throttle cable di rectly to the left front carburetor and use the rod end that is normally supplied with the carburetor setup BLOCK OIL PRESSURE FITTING Use a short 45 degree street elbow Weatherhead 3350x4 and a reducer WH 3220x4x2 to attach the flexible pipe to the block If you have air conditioning this should be done when you are mounting the alternator bracket and before you linstall the alternator on the left side of the engine DISTRIBUTOR Because of limited room at the front of the engine late model Ford electronic distributors will not fit The earlier point type Ford distributor or Mallory Unilite type distributors are your best bet for fit and tachometer compatibility Later model en gines must be converted to these distributors The distributor cap used with the taller en gines 351C and 351W must have a short profile with the wires exten
133. seals of closed cell foam should be placed as shown FRONT BODY TO CHASSIS SEALS There are 5 rail pieces and 2 weather seal sections per side The front body must be adjusted closed and latched before fitting the seals Remove the front wheels and raise the car high enough to al low working in the wheel wells Install rail 2 with support bracket 3 Temporarily install one end of the style A weather seal to part 2 Hold 3 against the vertical chassis reinforce ment and place 2 on top fitting around the rein forcing channel make sure 2 is facing in the right direction Slide both parts up until the seal ing bulb makes contact with the flange on the in ner panel crushing the bulb slightly Clamp 3 in place on the reinforcing channel with vise grips Mark the chassis where the bracket 15 positioned BODY 81 Temporarily fasten part 2 to 3 with two screws or Cleco fasteners Remove the weather seal from 2 and fit onto rail 1 with its end flush with the end of the rail Ei GIFSEALS The upper end of 1 is attached to 2 as shown Temporarily fit this part fitting the weather seal back onto part 2 at the same time Again slightly crush the rubber seal up against the flange It s important that the seal is not too tight especially at the front The fit and alignment of the body maybe effected Again use 2 or 3 screws to hold it in place Attach part 4 to the front of the cowl with its in ner end overlapping
134. site side by 010 The BMW transaxle doesn t require inverting like the Pantera derived ZF However the gearchange position must be changed from the left side to the right This requires new or used parts and some degree of experience We recommend that you go to one of the Pantera or ZF specialists listed on page 18 Also check the input shaft length as shown on page 25 There is very little clearance Install the top access plate with the baffle in for a shaft that is longer than illustrated stalled Torque the bolts to 15 Ib ft After the shims have been changed and the bear ings re installed install the side plates If the clearance change was small you might want to for it and use the new side gaskets now Oth erwise check the clearance again with the old gas kets Torque the side plate bolts nuts to 45 Ib ft in two steps using a criss cross pattern Install the transmission mounting bracket on the top cover using the 10 USS threaded rod supplied Don t forget to replace the shims be tween the top cover and the side covers The face bar with the holes faces forward toward engine Torque cross shaft nuts to 45 Ib ft Slide the E R A supplied adapter on the nose of the original throw out bearing mounting sleeve Rotate the cross shaft forward and engage the re taining clips onto the adapter The correct shims behind the throw out bearing will have to be de termined See the Flywheel and Cl
135. st 7 95 TSUEAN CEs sand 112 113 14114010 UI CU EE 2 J 76 Kine pin a 43 ITC CHS ASSEN y 20 Kiuckle SEN 35 sau 17 41 _ Latch Door 81 Lever Hand Drak 16 INDEX Lic nse plate br kvae 89 Lights 90 Limit Strap COOK 82 Linkage role 21 56 Boek DOO 81 Mimer Pati 108 Mine 9 Master Cylinder Part Numbers 108 Master Cylinder Bik jura 45 MINTO 89 eee 7 R placement p saa 109 Mounts rer 60 Oil cooler TSCA AION 61 MMM 1 23 GRE ENE E EN 7 20 Qil pressure N 21 Ovetflow Transaxle 61 PACKING LISS aisre 3 Pie 90 Painting the Chassis 73 Parts 5 Pedal DOK
136. t for the 827 rebound travel available in the suspension Be and are more race oriented The Spax pieces listed cause of component interference limitations do not are made especially for E R A and are available try to increase the available travel beyond stock only from us If you wish to experiment with other RECOMMENDED SPRING RATES AND brands dimensions are given below LENGTHS FRONT STREET TRACK USE Koni 8211 1121 Double external adjustable Spax Front 300x 10 Koni 8212 1422 Alum body as above Rear 350 x 12 Koni 8216 1906 disassemble to adjust Koni Front 300x12 Spax 297 PAS200 Special externl adjustable Rear 350x14 REAR Koni 8211 1123 double external adjustable Approximate spring preload Koni 8212 1430 Alum body as above Front 75 Koni 8216 1907 disassemble to adjust Spax G135 PAS200 externally adjustable FITTING DIMENSIONS FOR DAMPERS NOT Preload is the amount of spring compression when LISTED ABOVE installed on a fully extended damper of standard ex EIE tended length To calculate the installed spring length Rear 1 0 All ends have eyes that are 1 ID on damper in its extended position subtract the pre FRONT DAMPER STANDARD SPRING load from the free spring length Always measure the RATES uninstalled spring length Frequently the actual meas Max length 16 0 ured length of the spring will differ from the nominal Compressed length 11 5 length with any rubber bumper fully compressed x
137. t the facia plates are not fas tened to the body yet Don t lose them They won t be permantly attached until after paint Loosen the 2 Dzus s in front of the windshield and unlatch the sides of the front body by pushing in at the top of the latch From underneath the car remove the retaining screws in front body pivot retaining block See page 87 for details Disconnect the body limiting cable from the left side of the subframe to the body Disconnect the electrical connection at the right front if the wiring harness has already been in stalled Disconnect the fresh air vent hoses at the left and right side of the front trunk With a helper tilt the nose up about 30 degrees and slide forward disengaging the brackets from the pivot bushing Note the position of the brack ets on the body and the position of the pivot bush ings Installation is accomplished in the reverse order REAR Release the side latches p 89 and from inside the car release the top latches p 90 with the lever high on the engine firewall in back of the seats Disconnect the electrical plug at the right rear cor ner of the rear subframe Remove the tilt limiting strap where it attaches to the rear body With a helper tilt the body up 90 degrees and lift up out of the pivot bushings 21 DOOR REMOVAL Record the number and placement of shims dur ing the removal of the door so that the alignment can be restored upon instal
138. tank may be necessary to prevent excessive oil loss at race speed ERA offers an optional breather conversion kit with dump tank that can be installed by the customer Do not overfill the gearbox The initial fill should be 2 7 415 Refill ing after draining will be 2 5 qts You may want to check the accuracy of the fill level hole the first time you fill the gearbox ASSEMBLY Clean the case of drilling chips Install 3 longer studs 10mm diameter x 40mm into the left side plate for the slave cylinder bracket See the diagram Insert the ring gear differential spool assembly into transaxle case so that it is on the left side of the pinion as the transaxle will be mounted in the car without the side bearings installed Remem ber the breather tube that was removed from the inside bottom of the case That s the side that the ring gear goes on Install the ring gear bearings onto the spool Make sure that they are fully seated on the spool Assemble gear cluster plate into case Use non hardening aircraft gasket sealer between the cases Torque all bolts to 16 Ib ft Rotate the axles in the side plates feeling for ir regularities If the bearings feel worn now is the time to install new ones FAG 6207 C2 is OEM we replace with a slot filled bearing Fafnir 207W and also the seals Install new bearing cups in the side plates noting the shims underneath the cups on each side Don t mix them up Install the side plates with
139. tarter location The disk must have splines that are I 10 Not of Ford origin so you will have to check flywheel and pressure plate clearance Use a Pantera throw out bearing and pilot bushing For proper ground clearance the bottom of the bell housing can be machined Note B ERA bell housing with an ERA inter mediate plate Use a Long type pressure plate with a 10 or 10 5 disk or redrill for the recom mended Ford Motorsports combination See be low for recommended part numbers The throw out bearing and sleeve come with the bell housing See also Note G below Note C Inverted Pantera bell housing Use stock Pantera pressure plate driven disc pilot bushing and throwout bearing The bottom of the bell housing can be trimmed but the large ring gear is the limiting ground clearance factor Note D ERA bell housing with an ERA interme diate plate The flywheel must be machined to the small Chevy or Ford ring gear or changed to a new unit similar to the 157 tooth Ford flywheel described above New holes for mounting the pressure plate may have to be drilled and tapped also Preferred clutch is from a 1987 on Ford Mustang and is 10 5 in diameter See below for special Ford Motorsport parts 10 Note E Retain the stock pressure plate and disc but use the Pantera or Era throwout bearing A Pantera pilot bushing must be used The bell housing must be redrilled for a new starter loca tion See note
140. te the starter clockwise on the starter housing See page 31 Valve Covers if you intend to do track work standard breathers may not be adequate Oil will be pushed out the vent during continuous high speed cornering Covers with more sofisticated venting systems are available Water manifold for Weber carburetor manifold with dual water outlets Call us Water manifold for standard intake 4 bbl mani fold and Weber single outlet manifold It is nec essary for the water to take an immediate right turn after leaving the thermostat housing This adapter 15 available from E R A PARTS PREPARATION Water pump A shorty water pump is recom When examining your potential or existing engine mended for all cars and mandatory with air condi measure the flywheel ring gear diameter to the out tioning The Snow White unit is shorter than side of the gear teeth The 157 and 160 tooth fly the Ford Motorsport but some have had high wheel will measure approximately 13 3 The 164 speed track cooling problems with it The Ford tooth flywheel will measure approximately 14 2 unit works well but requires custom made pul Also measure the pressure plate bolt circle shown leys You must tell us which pump you are going below and the diameter of the driven disk if you to use so that we can supply the correct connect have one This information can be used to find ing tube and rear bulkhead bulge We also have your stock clutch configurati
141. tely the same di ameter and height as the original points type ford distributor You may use a Mallory Unilite or other pointless distributors within those space pa rameters If you choose to use a MSD system a tachometer adapter is necessary The car is wired for a 12 volt ignition system If your system re quires less voltage a ballast resistor must be in stalled in the ignition circuit Exhaust system The bundle of snakes exhaust system for standard 289 302 heads is in produc tion with others for Boss and 351 Windsor and Cleveland in development These 180 degree systems are functionally and visually the same as the original and make a wonderful sound For street use you may also wish to insulate your exhaust pipes Insulating kits and materials are available from major catalogs or from manufac turers such as Thermo Tec Engine Front Cover When using the Snow White water pump Ford front cover DOOZ 8508 A or the equivalent must be used The casting number on the cover may not correspond to the Ford part number The cover is 2 1 thick meas ured from engine face to water pump mounting See the instructions with the Snow White water pump on page 71 for other particulars Crankshaft damper See the length notes on the previous page Engine Mounts E R A has special reproductions of the original GT40 design to fit our chassis Specify chassis number when order ing Oil pan and pump To prevent the sump from hanging
142. the gearbox and remove the cover Remove the circlip and washer from the connect ing rod big end and remove the connecting rod Note the bottom washer Remove the circlip and washer from the back side of the crankshaft and push out the crankshaft from the housing Retain all the parts Note the thrust washer on the inside of the crankpin Mark the relative position of the round motor housing to the aluminum gear reduction housing Remove the two long screws holding the motor housing to the frame Separate the two with gen tle soft hammer taps if necessary Do not lose the felt washer and thrust washer in the bearing cup at the bottom of the housing Inspect the brushes for wear or sticking the com mutator for excess wear and arcing and the lower bearing Clean the parts with a solvent if neces sary Work the brushes in and out to insure free motion Install the armature carefully into the gear hous ing until it contacts the sides of the brushes Using a hook shaped wire or other appropriate tool re tract each brush in turn so that the commutator can slide past the edges of both brushes and continue into the gear case PARTS PREPARATION Put I or 2 drops of oil in the lower bearing of the armature housing Excess oil will contaminate the brushes later on Install the armature housing aligning the marks on the housing and the frame Reinstall the long retaining screws Remove the plastic gear from the crankshaft
143. the old gaskets onto the case temporarily torqueing the 6 inner fasteners to about 25 lb ft Measure the backlash between the pinion and ring gear It 15 easier to do this on the edge of pin ion gear The ring gear bearings are preloaded and prevent the gear from rotating freely PARTS PREPARATION The proper backlash is etched on the outside edge of the ring gear with some other numbers Look for 0 20 or 0 25 or a similar number This is the backlash in millimeters Multiply by 0394 for the inch equivalent Adjust the ring gear backlash by changing the shims behind the cups of the differential bearings in each side plate Removing the bearings requires a puller See the transmission service manual for details If the ring gear bearing preload was cor rect before disassembly the total thickness of shims behind the right plus the left bearings should remain the same It will only be necessary to re Transid2 distribute the total thickness of the shims Install the speedometer drive and shift box Don t The lash will change about 90 of the amount of forget the shim washer at the front between the change of the shim thickness underneath the bear box and the case Coat the shifter parts with ing cup 1 If you need to reduce the lash by grease before closing it up 009 increase the thickness of the shim pack the ring gear side by 010 and decrease the shim MODEL 25 2 EX BMW M1 thickness on the oppo
144. to position by raising and or shimming each stand to achieve the proper line along the door and rocker panel for the front body and the rear of the roof section and rocker panel for the rear body Final adjustment should be done with the latches installed Ei Bodaline 88 BODY BODY LATCHING AND FASTENING x The side latches were fit at the factory and should have been left in place when doing the bodywork When refitting be sure to replace any original shims Adjust the latch by lengthening or shortening adjustable pivot link If the latch is too loose but one turn of the adjuster makes releasing the latch too hard add a shim under the base plate to halve the difference HOOD2 Note when attaching the plates to the body use only aluminum rivets with aluminum mandrels Steel rivets and mandrels may cause stress cracks in the paint or fiberglass The rivets should be long enough to allow to use of back up washers HOOD PANEL The hood panel front compartment access panel is held in place by Dzus fasteners Because there is a gap between the outer surface of the hood panel and the body when they are latched together the spring tension of the Dzus tends to pull down the panel We have provided closed cell foam cushions to counteract this Glue the cushions to underside of hood panel as shown on page FRONT TILT SECTION 89 after the body has been painted The front body is held in pla
145. ture As the temperature rises check that there is flow in the system by feeling the tubes and hoses in the front of the car Until the thermostat opens there will only be a small temperature rise but it should be noticeable if you have drilled hole bleed hole as recom mended Open the bleeder in the radiator to expel any remaining air Allow the system to rise to operating temperature As the temperature continues to rise pressure will rise also so it is now a good time to shut down the engine and check the hose connections Tighten as necessary Restart the engine and continue to run until an indicated 200 deg F If the fans have not auto matically started at this time use the manual fan switch to start the fans The fan thermostat is set for about 165 deg F but because of the distance from the engine the fans will not start until the engine temperature gage reads over 200 deg F 73 Remember with 50 50 antifreeze and a 12 psi cap the system will not boil until 230 deg If the fan functions automatically in a satisfactory man ner do not use the manual override to keep the fans on constantly It is a waste of alternator power and reduces the life of the fans If you have air conditioning the fans will come on whenever the compressor cycles The fan warning light on the dashboard allows you to monitor the fan functioning If you have the air conditioning on the fans may start before the wa ter temperature be
146. u to complete this project The manual is arranged according to subject not the direct order that the kit should be put together This was done to enable the manual to be a reference manual and to give you some flexibility in your work sequence But Sometimes things should have a definite order The recommended plan of attack is on the next page Please use Good luck and above all have fun Parts Needed Assembly Sequence ASSEMBLY SEQUENCE OVERVIEW If there is an addendum with this manual please make notes or changes to the manual as soon as possible Preparation of many parts can be done before the kit arrives by following the instructions beginning on page If you wish to paint your chassis you must remove body and some components from the chassis for paint preparation and undercoating This is detailed on page 21 On the basic kit all the bodywork is located in its proper position secured by temporary fasteners unless we have been asked to take some optional actions When you remove the body from the chassis make note of the positions of hinge latches and shims by marking and tagging If any bodywork must be done it may be best to complete the rough work before dis assembly The parts that are not included in the kit but are necessary for the car s completion are listed in the latter part of this section Also provided is a list of sources where quality components can be found If you cannot o
147. ut source an item listed Sometimes the part numbers listed here have been superseded or de leted Call us before you panic We usually have new information or we can find out for you E R A also stocks many parts for our turnkey projects We may be able to supply you what you want When your kit arrives check it for completeness of parts You will find packing lists for each Check each box carefully for accuracy If you think there is a mistake please call us immediately FOLLOW THE SEQUENCE OF ASSEMBLY ON THE NEXT PAGE IT WILL SAVE YOU TIME AND PREVENT HEADACHES Parts Needed Assembly Sequence GENERAL SEQUENCE OF ASSEMBLY FOR COMPLETE INFORMATION ON INDIVIDUAL SYSTEMS CHECK THE INDEX ON PAGE 117 The sequence below is not cast in stone There are however some things on the list where order is critical They are marked with an asterisk If at all possible use the priorities below It will reduce your effort save time and result in a better finished product Disassemble the kit as necessary using the in structions on page 21 Clean and paint the chassis and suspension components Section 76 If your chassis is not stainless steel rust proof the inside the rockers and through the access holes provided See page 76 Install the front inner and bottom splash pan els and the rear subframe splach panel Page 87 Install the brake lines page 14 Install the internal aluminum water lines
148. utch section for details Install the slave cylinder bracket onto the left side plate See below for slave cylinder installation 29 PARTS PREPARATION FLYWHEEL AND CLUTCH PANTERA BELL HOUSING Clutch You must use a 10 5 clutch as listed on l page 8 for a guaranteed fit For other clutches we While the clutch and flywheel components can have also included an illustration page 30 show stock Pantera 104 tooth flywheel the bell ing the approximate clearance available within the housing must be redrilled so that the transmission i bell housing You must always check the fit be may be inverted This operation must be done by a machine shop Remember if you choose to use the Pantera bell housing ground clearance will be reduced fore permanent installation Throw at the clutch fingers is limited to about 65 We cannot be re sponsible for compatibility of your parts CHECKING BELL HOUSING TO CLUTCH CLEARANCE The standard Pantera throwout bearing and pilot bushing should be used with this combination ERA BELL HOUSING x No matter which flywheel you use the hole pattern must match the clutch you are going to use See the clutch section below Belloro2 Flywheel You must use a small Ford flywheel with a 157 or 160 tooth ring gear 13 3 OD If you have the 164 tooth flywheel the small Ford ring gear may be installed on the flywheel after machining the O D of the flywheel for an
149. volume between the bearings with high temperature wheel bearing grease Force grease into each bearing cone as sembly so that it is well lubricated Install inner bearing LM12749 and inner seal 19753 CR into hub Install hub onto axle with the outer bearing L68149 Note that the left side hub has right hand threads and vice versa Install and nut onto axle Torque to 150 Ib in 12 Ib ft Back off the nut to allow for a maximum of 002 end play Secure with a cotter pin s x1 5 through the hole in the side of the hub c fupasbpod 38 REAR HUB CARRIER ASSEMBLY Set the hub carrier outside face up and place the appropriate caliper mounting plate Left GM 10052211 Right GM 10052212 on top lining up the holes so that the caliper will be mounted to ward the front of the car Note that the small in side diameter 15 toward the outside of the car and the vent hole is down Install the hub bearing onto the mounting plate us ing allen screws M12x70 and star washers Torque to 75 Ib ft through the access hole in the bearing flange Install the stub axle GM 14055941 from the back Install the washer GM 562249 and nut GM 562247 Torque the nut to 125 Ib ft Install the retainer GM 562248 over the nut so that a slot lines up with the cotter pin hole and install the cot ter pin GM 11509457 Install rotor onto hub lining up the 6 pin drive stud holes If the emergency b
150. with rear hoses page 70 Install the brake pedal assembly page 49 Install the throttle cable and front linkage page 98 Install the speedometer cable page 99 Install the emergency brake cable and handle page 53 Install the radiator AC condenser with fans page 70 Install the air conditioning lines Section H Install the roof Check the fit of the front and rear body and doors Section G Paint all sections of the body See stripe info Install the wiper motor and linkage See the separate wiring instructions Install the fuel tanks fillers and lines page 66 Install the dash access panel passenger com partment electrical accessories See separate wiring instructions Install the voltage regulator and starter solenoin See the separate wiring instructions Install battery cables See the separate wiring in structions Install wiring harnesses D and L if applica ble See the separate wiring instructions Install the suspension front and rear Pages Error Bookmark not defined and 43 Install the air conditioning main box and or heater and the cowl hoses for the fresh air vents page 104 Install the air conditioning hoses from main box to rear bulkhead page 103 Install the shift linkage on the tunnel with Z Bar page 56 Fit the air conditioning compressor and alterna tor onto the engine page 24 Wire the engine See the separate wiring 1 structions Insta

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