Ford RS200 - Upper Wishbone, Outer Joint; To Change a Rose Joint

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Contents2
Introduction6
Technical Data14
Technical Summary15
General Layout15
Specification Details16
Engine16
Dimensions16
Compression Ratio16
Transmission17
Clutch and Transfer Gears17
Gearbox17
Gear Ratios17
Front Suspension18
Steering18
Rear Suspension18
Brakes18
Fuel Consumption Data21
Fuel Consumption21
Ignition Timing Data21
Index Sheet Listing27
Know Your Car36
Keys37
Starter Switch/Steering Lock37
Key Position37
Vehicle Identification Plate38
Engine Identification Number38
Main Transmission Identification Number38
Rear Final Drive Identification Number38
Interior Equipment and Controls39
Inertia Reel Seat Belts39
Seat Slide Lever39
Glove/Oddment Recess39
Rear Body Section Release Lever40
Sun Vizors40
Dipping Rear View Mirror40
Front Body Section Release Lever40
Transmission Mode Changes41
Gear Changing41
Interior Lights42
Reading Lamps/Map Lamps42
Instrument Panel43
Panel Switches45
Water Temperature Gauge45
Ignition Warning Light45
Oil Pressure Gauge45
Handbrake/Brake Fluid Level Warning Light46
Speedometer46
Fuel Contents Gauge46
Fuel Pressure Gauge46
Transfer Box Temperature Warning Light47
Instrument Illumination Control47
Speedometer Trip Reset Button47
Spare Switches, for Extra Circuits47
Switches on Steering Column48
Multi-Function Switch48
Lighting Switch48
Windscreen Wash/Wipe Switch48
Radio Installation49
Space for Fitting Audio Equipment49
Multi-Function Digital Clock50
To Set Time and Date50
Quick Time Set51
Timer Operation51
Ignition off Recall51
To Start and Stop Timer51
Heating and Ventilation52
Temperature Control Lever53
Air Distribution Lever53
Blower Control53
Side Vents53
Typical Control Positions54
Heating in Extreme Cold Conditions54
Windscreen Defrosting/Demisting54
Ventilation in Warm Climates54
Door Locks55
Filling Station Information56
Filling Station Data57
In the Engine Bay57
Rear Bodywork Completely Removed57
Under the Lift-Up Rear Body Section58
Cooling System58
Air Cleaner58
Air Cleaner Element Housing58
Alternator Drive Belt59
Engine Oil System and Tank59
Brake Pads59
Fuel Filter Cap59
Under the Lift-Up Front Bodywork60
Windscreen Washer Reservoir60
Brake and Clutch Fluid Reservoir Levels61
Brake Fluid Reservoir61
Clutch Fluid Reservoir Level61
Battery62
Battery Identification62
Terminal Connections63
Battery Charging63
Maintenance Free Battery Charging63
Tyre Care64
Tyre Tread64
Tyre Depth64
Winter Tyres64
Roadside Emergencies65
Towing the Vehicle66
Tow/Push Starting66
Towing Eye Position66
Jacking up the Vehicle67
Spare Wheel, and Wheel Changing68
Punctures, and Alternative Tyre Equipment69
Snow Chains69
Starting the Car Using 'Jumper' Cables70
Bulb Replacements71
Headlamps/Sidelights71
Headlamp Bulb71
Sidelamp Bulb71
Front Fog Lamps72
Adjustment72
Front Direction Indicators73
Bulb Changing73
Rear Lights73
Number Plate Lights74
Electrical Bulbs Fitted to the RS20075
Fuses and Relays76
Central Fusebox77
Fuse Colours, with Ratings77
Layout of Fuses and Relays78
Relays in Central Fusebox79
Relays Associated with Engine Management System Computer79
Drive Belt Adjustment80
Adjusting the Alternator Drive Belt80
Wiper Blades81
Checking Condition of Wiper Blades81
Wiper Blades/Arm Replacement81
Windscreen Washer Jet Adjustment82
Fault Finding and Diagnosis83
How Do You Find a Fault?83
Driving the Car89
Guidelines on Starting the Engine90
Starting the Engine from Cold90
Starting with a Hot Engine90
Starting a 'Flooded' Engine90
Stopping the Engine, after a Fast Run91
Running-In - from New91
Braking, and the Dual Hydraulic System92
Dual Circuit Operation92
Handbrake92
Footbrake Adjustment92
Use of Brakes93
Brake Pad Replacement93
Brake Fluid Replacement93
Tyre Pressures93
Driving Methods94
Cornering96
Braking and Stopping96
Winter Motoring97
Towing a Trailer97
Roof Racks97
Pre-Delivery Inspection100
Service Intervals100
Extended Period Maintenance100
Regular Maintenance, and Car E110
Recommended Driver Maintenance111
Check to be Made Daily111
Oils, Fluids and Greases111
Engine Oil Level112
Transmission, and Rear Final Drive, Oil Levels113
Brakes and Clutch Fluid Levels114
Antifreeze114
Checking Spark Plugs and Leads116
Checking for Leakage and Corrosion117
Under the Vehicle117
Exhaust System117
Tyres and Chains118
New Tyres118
Seat Belts119
Car Care: Locks, Hinges and Catches121
Winter Operation of Door Locks121
Corrosion Protection122
Car Cleaning122
Automatic Car Wash122
Paint Chip Repair122
Cleaning123
Exterior Rear View Mirrors123
Tar Spots123
Car Polishing123
Recommended Lubricants and Fluids124
Rear Drive Shaft Joints124
Hub Greases124
Specification, Equipment and Component Changes126
Engine Unit128
Rear Sub-Frame129
Underside of Chassis129
Rear of Car with Body Cover Removed129
Cylinder Head/Camshaft Cover130
Valve Clearance Adjustment130
Engine on a Stand131
Camshaft Drive Belt132
Cylinder Head Layout132
Bucket Retaining Clips132
After Removal of Cam Carrier132
To Adjust the Drive Belt Tension133
Removal of Belt133
Engine Camshaft134
Camshaft Removal134
Updating for Serious Motorsport135
Camshaft Drive Belt Details135
Bucket Retaining Clips in Place135
Camshaft Installation135
Cylinder Head Gasket136
Gasket Change136
Intercooler138
Uprating for Serious Motor Sport138
Inlet Manifold, and O-Rings139
Changing the O-Rings139
Exhaust Manifold139
Inlet Manifold Installation140
Inlet Manifold Removal140
Turbocharger141
Turbocharger Installed141
Turbocharger and Manifolding141
Engine Oil Tank143
Oil/Water Heat Exchanger144
Oil Filter145
Radiator and Electric Fan Installation147
Header Tank Installation147
Radiator148
Thermostat148
Water Pump149
Transmission Mode Control151
Unlocking the Transmission Mode Lever151
Clutch Assembly152
Clutch Master Cylinder153
Clutch Slave Cylinder153
Clutch Master Cylinder Position154
Transfer Gearbox155
Lubrication156
Primary Propeller Shaft156
Transmission Assembly157
Partial Strip down of Transmission Assembly158
To Strip the Centre Differential Casing from the Main Gearbox Casing158
To Remove the Centre Differential's Viscous Coupling Unit159
To Remove the Gear Lever Linkage from the Gearbox Casing160
To Change Oil Seals Surrounding the Propeller Shaft Entry Points160
Transmission Oil Cooler161
To Remove the Cooler161
Oil Cooler/Radiator Installation161
Propeller Shaft - Transmission Casing to Rear Final Drive162
Rear Axle Assembly163
Front Wheel Drive Shafts164
Rear Wheel Drive Shaft165
Adjusting the Castor167
Wheel Camber167
Castor167
Front Suspension Ride Height Adjustment168
Suspension169
Front Suspension Adjustments169
Front Suspension Coil Spring/Damper Units172
Removal of a Spring/Damper Unit172
Separating a Spring from the Damper Unit172
Removal/Changing a Bump Rubber173
Adjusting the Spring Platform Height173
Wishbone Bushes in the Front Suspension174
Removal of Bush at Inner End of Lower Track Control Arm174
Removal of Bush at Inner End of Forward Member175
Front Suspension, Top Ball Joint175
Front Suspension Bottom Ball Joint176
Front Hub Bearing177
Front Anti-Roll Bar179
Adjusting the Steering Toe-In/Toe-Out Dimension180
Steering Wheel180
Steering Column Assembly181
Steering Rack182
Fitting a Replacement Steering Rack183
Uprating for Serious Motorsport183
Track Rod End Removal and Replacement183
Steering Rack Change183
Steering Arm184
Rear Suspension Ride Height Adjustment186
Rear Suspension Pivot Positions187
Rear Suspension Coil Spring/Damper Units188
Lower Wishbone, Inner Bushes189
Upper Wishbone, Inner Bushes189
Upper Wishbone, Outer Joint190
To Change a Rose Joint190
Adjustable Toe-In/Toe-Out Control Rod191
To Adjust the Toe-In/Toe-Out191
To Change a Toe Control Arm Rose Joint192
Rear Anti-Roll Bar193
Lower Rear Wishbone, Outer Joint194
Braking System196
Brake Bleeding Procedure197
Handbrake Calipers at the Rear Wheels199
Brake Master Cylinder200
Brake Discs - Front and Rear201
Handbrake Lever202
Primary Handbrake Cable203
Secondary Handbrake Cable204
Fuel System206
Fuel Tanks207
To Remove Either Tank207
Fuel Pumps and Filters208
To Remove Filters208
Filter in the Low-Pressure Pump208
Separate Filter208
Body Shell and Panels209
Front Body Section210
Front Body Apron211
Rear Body Section212
Passenger Door213
Door Mechanism and Fittings214
To Remove the Door Trim Panel214
Removal of Door Locks and Latches214
Removal of Door Window Glass214
Windscreen215
Seats216
Safety Belts217
Instrument and Facia Panels218
Driver's Instrument Console218
Stowage Compartment218
Instrument Panel, Centre Console218
Paint Repairs219
Electrical Equipment220
Windscreen Wiper Motor and Linkage221
To Remove the Wiper Motor221
Removing the Wiper Linkage221
Windscreen Washer Installation222
To Remove the Reservoir222
To Remove the Nozzle from the Windscreen Surround222
Front Headlamp/Sidelamp Units225
Fog Lamps226
Indicator Assembly226
Indicator Repeater Lamp, Side227
Rear Lamp/ Turn Indicator Cluster228
Steering Column Switchgear229
Instruments, Gauges and Switches on Facia230
To Remove the Driver's Instrument Console230
To Remove the Instrument Panel, Centre Console230
Interior Lamps231
To Remove the Lamps, to Gain Access to the Bulb231
To Remove a Map Reading Lamp231
Electronic Engine Management System Computer232
Starter Motor233
Engine Alternator Assembly234
Distributor235
Radio Installation, Receiver and Aerial and Aerial236
Your Personal Contact at Ford243
Parts List247
Model Identification249

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Ford RS200 - Upper Wishbone, Outer Joint; To Change a Rose Joint

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