Era Replica Automobiles 427 ROADSTER Assembly And Service Manual Download Page 79 | Manualshive

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SECTION E -BODY PREPARATION-

79

HOOD GASKET

Permanently install the gaskets to the underside of the
hood as described on page 68.

Door gasket

installation is described on page 86.

FRESH AIR HOSES

After putting edge protector on the aluminum, carefully
feed the fresh air duct hoses through the hole in the back
panel of the front inner wheelhouse panels. Drape over
the upper control arm. Final fitting will be completed
later.

TONNEAU SNAPS

Chase the holes with a #25 drill (.150”). Install the
tonneau snaps with the fiber washers. Don't force! The
snap screws may twist off, leaving you with a broken
screw in the body. For extra safety and ease, you can use
a #10 steel screw to “chase” the threads into the fiberglass
before you install the snaps.

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Summary of Contents for 427 ROADSTER

Page 1: ...1 ASSEMBLY AND SERVICE MANUAL FOR THE Era Replica Automobiles 427 ROADSTER Chassis 758 on Revision 10m 06 2012 Copyright 2012 Era Replica Automobiles...

Page 2: ...posted on the web Use the e mail below for the location Thanks Bob Putnam ERA e mail eracars sbcglobal net Please direct your parts inquiries to eraparts sbcglobal net The Manual The text and layout o...

Page 3: ...HOOD GASKET 79 FRESH AIR HOSES 79 TONNEAU SNAPS 79 WIRING AND ELECTRICAL 80 WIRING AND ELECTRICAL 80 REAR HARNESS 82 INTERIOR PANELS 83 ENGINE AND TRANSMISSION INSTALLATION 83 DRIVE SHAFT 84 DOORS 85...

Page 4: ...SECTION A PARTS NEEDED 4...

Page 5: ...to make improvements to the design but be aware Changes from the original Cobra concept may not increase the value of your car and may even decrease it E R A has spent many years perfecting the detai...

Page 6: ...cessary to complete your E R A 427 SC together with part numbers and sources Normal wearing parts that may need replacement after use are also listed on page 154 Read this section thoroughly before pu...

Page 7: ...ave to be lifted on and off the trailer manually Have 3 strong friends to unload If you re coming on a weekend to pick up your kit please warn us if you aren t coming with extra people too Don t tie d...

Page 8: ...are listed in this section Any special component preparations are detailed in Section B Engine Engine accessories Oil cooler system optional Transmission Ford 4 speed or automatic Richmond Gear 5 spe...

Page 9: ...0 4 05 3 78 320up 427 427 4 23 3 78 410 up 480 428 4 13 3 98 325 475 The original Cobra used the 427 CID Side Oiler engine in the first cars intended for competition The remaining cars were equipped w...

Page 10: ...AKE MANIFOLD Low and medium riser intake manifolds including the Edlebrock Performer can be used on the E R A 427SC without modification The manifold may have to be tapped for the temperature gage fit...

Page 11: ...requires a special alternator see page 22 and bracket which mounts the alternator at the bottom right of the block CLUTCH No matter what engine E R A recommends using a clutch with stock pressure for...

Page 12: ...g 10 MPH 1000 RPM is the longest 1st gear that can be driven smoothly with a fairly mild engine This means that a wide ratio Top Loader will be OK with a 3 31 1 differential ratio a close ratio Top Lo...

Page 13: ...SECTION A PARTS NEEDED 13...

Page 14: ...ng 5 5 8 between centers Same mount as above Two holes arranged side to side and with 6 1 4 center to center distance This very rare transmission requires chassis modifications done on special order o...

Page 15: ...le Both the Stewart Warner and Smiths speedometers are usually geared at 1000 revolutions mile Usually the Ford Top Loader T 5 use a 7 tooth driving gear requiring a LH driven gear Teeth Dif Ratio x 5...

Page 16: ...ond gear transmissions with the Long shifter TOP LOADER Originally AC modified the 1965 66 Mustang shift lever by turning the handle about 180 degrees on its mount This placed the lever forward While...

Page 17: ...o rebuild than the early units Gear ratio There should be a tag on one of the rear cover bolts for example 43 13 on the tag 3 31 ratio If there is no tag mark the input shaft flange and the half shaft...

Page 18: ...e If you decide to build your own system the specifications below may be helpful but should not substitute for good design practices Oil cooler approximately 13 x 4 h or 6 h with AN 10 male fittings T...

Page 19: ...Also available are spring collar wrenches to adjust your ride height The coil over dampers should be adjustable for ride height See the length specifications on page 54 and part numbers on page 24 Bo...

Page 20: ...ine of the wheel to the mounting face Positive offset is where the wheel centerline is outside the mounting face Negative offset moves the wheel in toward the center of the car Some wheel companies ma...

Page 21: ...t are V speed rated To use Avons in the front use 225 65 15 instead of the 235 60 size For 17 wheels tires in 35 and 40 series will fit Ask for current recommendations Before mounting on pin drive whe...

Page 22: ...09 Borg RU 6 SMP RU 4 Wells F795 0 8 1 2 ohm Aftermarket Brakes Bearings Front Brake Rotor Hub bolt on wheels GM 334348 Bendix 141040 GM dealer or many Front GM cars 1970 78 see page 18 Brake Calipers...

Page 23: ...o starter solenoid 32 long eye terminal clamp Starter solenoid to starter 24 long eye eye Rear Battery Cables Engine Trans ground Battery ground Battery to starter solenoid With cutoff switch Battery...

Page 24: ...660 and pickup 15 661 Road race with trap doors Canton 15 680 and pickup 15 611 351 Cleveland Canton 15 710 pan 15 711 pickup Exhaust System Under car complete E R A Side pipes w primaries E R A Emble...

Page 25: ...429 460 Lower Same as FE Upper Gates 20869 trimmed Chevrolet 427 Lower Gates 20620 trimmed 2 off end Radiator expansion tank 1964 T Bird big block E R A Thermostat See page 9 for hints Starter FE eng...

Page 26: ...loader w 2 holes along centerline or 2 transverse holes 5 6 apart Ford C8ZZ 6068A or Republic 31 2258 Ford dealer E R A auto parts supplier Ford Top loader w holes 6 25 apart Ford C9AZ 6068E or Republ...

Page 27: ...ent Fits early 70s Ford with external regulator Ford dealer E R A Windshield Wipers Motor and Drive Parts From 1969 1976 Triumph Spitfire GT 6 or TR 6 Arms Lucas BHA 520l E R A Lucas parts dealer Blad...

Page 28: ...otorsport Performance Equipment Ford parts Clinton Twp MI 48036 810 468 1356 Fortes Parts Connection Transmissions parts 376 Cambridge St Burlington MA 781 273 9900 Genesis Performance genesis427 com...

Page 29: ...the left upper exhaust header flange bolt Tool List Body Installation Pop rivet gun with adapters for 1 8 and 3 16 rivets Electric drill with bit assortment Utility razor knife Paintbrush 1 1 5 buy a...

Page 30: ...e used but these fillers have the disadvantage of setting up rather quickly making the completion time of the bonding operation critical Blind rivets Aluminum panels to chassis 200 1 8 dia x 3 8 1 2 l...

Page 31: ...TS PREPARATION Restrictions or modifications to the donor parts for the 427SC This section does not cover engine transmission or rear suspension rebuilding Use dedicated rebuilding manuals for your sp...

Page 32: ...n page 160 BASIC PREPARATION Remove cooling fan from engine water pump pulley Install the fitting for the water temperature gage in the intake manifold adjacent to the distributor Note that some manif...

Page 33: ...with a straight edge Add washers or shorten the spacer as needed ALTERNATOR MOUNTING FE BLOCK Ford FE Engine Alternator Mounting b Altbrk2 If you have a pressed in pin at D replace it with a threaded...

Page 34: ...available from E R A The standard Ford fork see page 26 for part number should be modified as shown Drill remember that the part is hardened the indentation to 5 8 id Fork not modified installed in TK...

Page 35: ...passenger s side back edge to clear the X member short input tKO mount modifications and installation Elongate the holes as shown above The mount is installed onto the transmission with washers as sh...

Page 36: ...olt of the left engine mount The left rear oil pan tapped hole clslave part 1 BLOWSHIELD MOUNT USE THE APPROPRIATE HOLES TO LINE UP THE SLAVE CYLINDER AXIS WITH THE THROWOUT FORK FE ENGINE The adapter...

Page 37: ...RNAL Some clutch transmission combinations work best with an internal concentric clutch slave cylinder This type of clutch release is self adjusting but requires careful initial adjustment to compensa...

Page 38: ...weld the oil temperature adapter fitting packed with the auxiliary instrument pieces onto the left side With a Ford small block keep the full length pan depth less than 8 3 to prevent the pan from han...

Page 39: ...cast iron water pump others with 2 inlet 62107 Some aluminum water pumps with 2 inlet 21258 Ford Small block WITH OPTIONAL CONNECTING TUBE HOSE TRIMMING INSTRUCTIONS The two lower radiator hoses must...

Page 40: ...rsal joints on half shafts hub carrier and lower control arm bearings Bearings etc are listed on page 154 We have found that the Spicer U joints listed are the only brand that consistently meets the s...

Page 41: ...e USS bolts to loosely attach the upper mounting plate to the differential casting Turn the subframe differential upside down on a padded surface with the differential mounting plate down Loosely inst...

Page 42: ...trailing arms should be installed onto the rod ends when the suspension assembly is installed into the chassis See page 156 for lubricants and capacities HAND BRAKE LINKAGE XKE EMERGENCY BRAKE SYSTEM...

Page 43: ...de with a 10 long x 400 lb in spring Alternately replace all 4 springs with a new 10 x 350 lb in spring If you have the ERA supplied Spax damper with adjustable collar use 8 x 400 lb in springs for al...

Page 44: ...the following parts for a complete assembly Qt Description Part number 1 E R A conversion assembly with subframe lower radius arms upper and lower trailing arms hub carrier all bushings axle spacers...

Page 45: ...he outer bearing onto the hub Make sure that both are completely seated Install the seal race onto the stub axle ADJUSTING HUB END FLOAT When the hub carrier is assembled the end float of the axle bea...

Page 46: ...loat giving 021 Since the Special Collar is 150 thick the thickness of the spacer to be fitted will be 0 150 0 021 i e 129 The nearest spacer is 0 128 or 0 130 For competition use the spacer yielding...

Page 47: ...f to the nearest hole B rsasblyf CONTROL ARMS Install a male right hand thread rod end and jam nut onto each front lower radius arm so that the bushing center to rod end center distance is 16 Leave th...

Page 48: ...e a flange with a 5 x 4 3 4 pattern matching the front Chevrolet hubs If you are using an XKE rear drive with splined hubs for wire wheels they must be changed to the sedan pieces Call E R A for the h...

Page 49: ...n the lever Pull the cable tight through the dog With a pair of vise grips hold the dog in place approximately 1 16 below the surface of its receptacle as shown If necessary have someone hold it for y...

Page 50: ...Drawings for the units E R A supplies are available from E R A Inquire STEERING GEAR See page 25 for part numbers The E R A supplied steering gear does not require the preparation below It is modified...

Page 51: ...knife Work the lower bushing out with a screwdriver by pushing in and down on the locking nubs in the side of the housing Remove the column from the housing Using a dowel just small enough to fit insi...

Page 52: ...to disassemble the wiper motor itself skip steps 4 through 8 Take out the 4 screws holding the cover to the gearbox and remove the cover Remove the circlip and washer from the connecting rod big end a...

Page 53: ...hole from the back Clean and deburr the crankshaft Install the plastic gear onto the crankshaft engaging the tangs of the gear into the crankshaft notches The orientation of the plastic cam is dependa...

Page 54: ...or etched on the end of the spring If you use a different brand coil over do not exceed the extended length by more than 1 4 FRONT SPRINGS Because of small variations in the free length of new springs...

Page 55: ...55 SECTION C CHASSIS PREPARATION Assembling the chassis and preparation for paint...

Page 56: ...56...

Page 57: ...o the hood hinges The trunk hinges are the same from left to right and are stamped with T BUMPERS BUMPER BRACKETS Front If you have the optional nudge bar s detach them from the overriders Remove both...

Page 58: ...ing clamps and pull the hose rearward into the engine compartment Remove the wheelhouse access panel at the rear Remove the front wheelhouse panel It s attached with screws or rivets to the main chass...

Page 59: ...the underside of the fender Remove the flange and hoses Final fastener removal Locate and remove the screws save them please holding the body to the chassis from the Bottom edge of the rocker panel T...

Page 60: ...SECTION C CHASSIS PREPARATION 60 SECTION D BODY CHASSIS ASSEMBLY Assembly of the body and basic mechanical components...

Page 61: ...st use light oil on the threads when assembling General fastener torque specifications are listed on page 158 BODY MOUNTED PRE MOUNTED ON CHASSIS OPTION Many items listed in this section are already i...

Page 62: ...flanges where the floor rests on the X member Remove the floors and remove the drilling chips Using a caulking gun and high quality auto body seam sealer or a silicone base sealant run a bead of seala...

Page 63: ...se in the chassis BONDING STRIPS Special fiberglass angles are used between the inner panels and the latteral steel tubes see above Attach with sealant and rivets The short strips attach to the upper...

Page 64: ...the duct hose onto the valve The actuating cable will be attached later Use a wire tie to secure the hose to the bracket on the inside top of the fender THROTTLE LINKAGE Mount the pedal assembly onto...

Page 65: ...e front of the right foot box and to the top of the front outrigger It s pre installed on every chassis so the holes are already in place d battery_mount BATTERY REMOVE AND REPLACE The engine compartm...

Page 66: ...pplied by E R A is compatible with brake fluid but most other types are not Use caution if you choose to replace the hose Bolt the BMW reservoir and its mounting bracket to the driver s wheelwell as s...

Page 67: ...time to apply the adhesive and carry out the all the subsequent installation steps before hardening Use less catalyst or hardener to increase working time Use a caulking gun to apply body sealant also...

Page 68: ...ill 9 64 holes for 1 8 rivets into the chassis The closing panel should not contact the outer body Once the panel is in place smooth silicone or urethane sealant over the outer fender filler joint cov...

Page 69: ...ny shims found earlier Loosely bolt the trunk lid with factory shims onto the hinges Carefully close the lid not letting the front edge contact the body Center the lid in the opening Slowly lift the l...

Page 70: ...70 SECTION E BODY PREPARATION...

Page 71: ...ON AND PAINT The mold seam lines are the only areas that need a light coat of body filler but the body should be blocked out all over for a show quality paint job Body preparation and painting of FRP...

Page 72: ...ell within the standard flare but you might want to trim the bottom inside of the rear section of the front flare a bit to fit a 245 width tire The driver s side is tighter than the passenger s side S...

Page 73: ...SECTION E BODY PREPARATION 73...

Page 74: ...o match the engine E hoodriv2 Use small screws or Cleco fasteners to hold the scoop in position while drilling all the holes Wait until the parts are painted with color before final riveting To avoid...

Page 75: ...trunk lid COLORS For reference some of the more popular color schemes and contemporary equivalents are listed below Visit us or your local paint supplier to look at color chips Colors are also availa...

Page 76: ...SECTION E BODY PREPARATION 76 ebod stripe...

Page 77: ...drill holes in the bottom of the chassis at the front and rear of the bottom rails You may then spray a wax type material into the chassis even up above the rear suspension Close the holes with plasti...

Page 78: ...tube nut to the motor Install the wiring harness plug Don t install the wiper arms to the splined drive spindles until the motor has been run and the park resting position has been found The wipers w...

Page 79: ...duct hoses through the hole in the back panel of the front inner wheelhouse panels Drape over the upper control arm Final fitting will be completed later TONNEAU SNAPS Chase the holes with a 25 drill...

Page 80: ...er laying out the front harness in the car See the diagram in the wiring list Use the layout diagrams below and the wiring instructions to find reference points in the harnesses FRONT WIRING HARNESS T...

Page 81: ...hed to the brake line with tie wraps and into the brake box through the notch on the inside front edge The brake cover can be re installed now Be very careful installing the sheetmetal screws into the...

Page 82: ...ck for the front end of the harness is with the dashboard module Don t install it until after the rear harness has been passed through the hole in the side of the footbox The rear harness is installed...

Page 83: ...ning rear steel support rail and through the front flange that rests against the vertical support rail Align the edges of the front flange with the side of the vertical rail Note Seal between the fron...

Page 84: ...nce of the bell housing bolts Lower the back of the engine engaging the transmission mount studs into the chassis Removal is done in the reverse order Top Loader Front holes of trans adapter Borg Warn...

Page 85: ...s Mark and punch holes for the two lower bolts through the door pocket Attach the bottom of the hinge and snug the bolts Gently and evenly pull the bottom edge of the door pocket down over the bottom...

Page 86: ...holes on the top of the doors and note the length that each extends past the inner panel Mark each ferrule so there are no more than 2 or 3 threads showing between the mark and the door surface on its...

Page 87: ...he supporting rod end Note This linkage can be adapted to most engines If yours requires something different please call us The FE dual quad setup requires an additional linkage assembly ADJUSTING THE...

Page 88: ...ight and left pieces are marked L and R d htshld2 Hold the vertical shield against the bottom of the tube at the front of the footbox Left the inner edge about 1 2 from the main frame rail Right the i...

Page 89: ...the rubber radiator grommets into the holes in the radiator support tray and install the tray onto the studs in the chassis Drop the radiator into place from inside the engine compartment Fit the rubb...

Page 90: ...y placing the wood between the front of the bottom shroud and the tube Center the fan blades on the radiator and shift the cross tube so that it is horizontal Move each end bracket out flush with the...

Page 91: ...protective strip from the back side of the molding and carefully apply the molding to the front edge of the airfoil Once on it cannot be removed without damage ebod splitter OIL COOLER OPTIONAL See b...

Page 92: ...iator and is tie wrapped to the bottom of the upper control arm inner pivot then through a clamp on the front of the oil pan to the right fitting on the adapter housing The shorter line runs along the...

Page 93: ...INSTALLATION There should be a jumper white and pink wires already connect to the sender at the center of the tank Tape the jumper in place so that it comes out at the left front corner of the tank Ra...

Page 94: ...us amount of RTV silicone gasket sealer on the top surface of the flange Line up the drain hole on the flange and the body Hold the lower mounting flange in place on the underside of the fender INSTAL...

Page 95: ...95 SECTION F SUSPENSION ASSEMBLY...

Page 96: ...u must use light oil on the threads when assembling TORQUE SPECIFICATIONS Use figures below only if unspecified in the relevant instructions The torques listed are for lubricated threads or threads wi...

Page 97: ...all joint as shown sandwiching the control arm between the ball joint and the dust shield boot retainer Torque to 16 lbft Install the arms with 3 shims front and rear for a preliminary camber setting...

Page 98: ...pace nut for the cotter pin and nut Torque to 60 lb ft Tighten further to where the cotter pin can be inserted Rotate the upper control arm down engaging the ball joint stud into the knuckle Install w...

Page 99: ...before putting grease in the hub and installing the bearings and inner seals Install the dust shields onto the steering knuckles if desired Install the hub onto the stub axle with a special tanged was...

Page 100: ...control arm and the pads on the ends of the sway bar Tighten the link bolts so that the rubber bush expands to the diameter of the cupped washer Do not over tighten e fswayb REAR SUSPENSION JAGUAR BAS...

Page 101: ...d trailing arm bush engaging the locking threads in the chassis No lock washer is necessary Move to the trailing arm on the other side of the car Sight through the hole in the chassis and determine wh...

Page 102: ...asses through the right block and connects to the left lever See page 42 Adjustment Fully release the handbrake lever Adjust the cable length by screwing the threaded end out of the block to a point j...

Page 103: ...m and the floor This will allow you to fit the assembly on the jack and still slide it under the car from the back Carefully jack the assembly so that the upper mounts engage into the chassis brackets...

Page 104: ...and clutch pedal onto the shaft Secure the clutch pedal with the shoulder screw Install the clutch throw out arm onto the splined end of the shaft Orient the throw out arm approximately opposite the p...

Page 105: ...out Check the tightness of the brake lines and switch fittings You can temporarily Install the brake cover box The brake or clutch pedal face angle can be changed with the top stop screw See page 104...

Page 106: ...106 DEAD PEDAL INSTALLATION Hold the bracket at the desired height against the side of the footbox and mark for the holes Drill through the footbox and steel tube with a 3 16 bit Secure the bracket w...

Page 107: ...107 SECTION G BODY INTERIOR...

Page 108: ...lied into pieces to connect components as shown above Leave a little extra length so that the tubing can be secured to the wiring harness and or the wiper tubes with wire or tie wraps WINDWINGS AND SU...

Page 109: ...the aluminum trim plates onto the windshield posts with the convex side up and the screw holes to the outside Fill the underside of the trim plates with sealer or ribbon type caulk to make a water tig...

Page 110: ...FIT Use the template included with the heater to drill holes in the firewall Bolt the heater in place as shown using nylon locking nuts Connect the motor ground wire to the steering column mounting br...

Page 111: ...g instructions for electrical details Drill a hole for the switch in the upper corner of the vertical section of the box next to the door Use contact cement to line the bottom and sides of the glove b...

Page 112: ...rfering with the shifting mechanism by attaching the cable to the side of the floor with clamps Secure the cable to one of the bellhousing top bolts CABLE FOR REVERSE ROTATION SPEEDOMETER Some cables...

Page 113: ...EAR 5 SPEED The transmission requires a right angle drive adapter installed as shown The parts required are listed on page 14 TREMEC TKO 500 600 The drive cable is also secured to the top of the trans...

Page 114: ...s on both ends between the left side of the starter solenoid and the terminal on the starter REAR MOUNTED BATTERY Mounting details are available at www erareplicas com 427man index htm The battery may...

Page 115: ...ring swbend With the road wheels straight install the hub on the column with the washer and nut Torque the nut to 25 lb ft only after the suspension is aligned and the steering wheel position is deter...

Page 116: ...ube ASH TRAY Note that some transmissions are taller than others so confirm that you have enough clearance under the tunnel surface before you perform surgery on the aluminum The optional ashtray is l...

Page 117: ...SECTION G BODY INTERIOR 117 eint tunnel...

Page 118: ...ower filler 9 Splash panel right rear 10 Splash panel left rear 11 Bulkhead center top 12 Under door left side 13 Under door right side 14 Trunk right side upper 15 Trunk left side upper 16 Trunk righ...

Page 119: ...the vinyl and carpet Install the vinyl on the central aluminum side panels Trim even with the vertical edges and leave a short amount at along the floor Install the side carpets starting by lining up...

Page 120: ...contact cement on the front and sides Note where the dead pedal mounting holes are Glue in the front panel first When gluing in 2 use the corner below the door hinge area and the front vertical edge f...

Page 121: ...h tube in the aluminum and trim the carpet back Use the rubber grommets supplied to line the holes After locating where the carpet goes on the top apply contact cement to the top of the tunnel and the...

Page 122: ...ing tape to the door opening edge marking the position of the rivets To install hand form the molding approximately matching its curve to the door opening Once close form it directly on the sill Watch...

Page 123: ...Y INTERIOR 123 FLOORS The under seat pieces can be glued in or simply held in place with the seat mounting system The front pieces are held in place with snaps in the floor at the front and Velcro at...

Page 124: ...of the trunk Carefully trim the piece leaving extra material around the edges and glue the center part of this on with contact cement Carefully push the excess material under the lip of the fiberglas...

Page 125: ...and brake lever Screw the tunnel into place To make cleaning easier the two piece floor carpets are held in place with snaps and Velcro Fit the carpets in place and mark the floor where the snaps are...

Page 126: ...g as a pattern as shown below The adjacent holes are placed parallel to the car centerline After removing the shift knob the rubber boot can be stretched over the T of the shift handle SEAT BELT SHOUL...

Page 127: ...h the driver s and passenger s seats The seats have captive nuts for the adjusting tracks in the seat bottom Install the adjustment tracks if used to the seat base first with 1 4 20 bolts Make sure th...

Page 128: ...lightly snugging the bolts If the car is already painted consider using masking tape along the door and body edges to prevent damage when assembling The door edge may be aligned with the body opening...

Page 129: ...is accessed through a plug in the inner splash panel The upper nut is access from the inside of the nose opening Fit the rubber grommets to the body Be sure the lip is seated on both side of the fibe...

Page 130: ...INGE COVERS The fiberglass covers are different from left to right Don t over tighten the screws eint HINGCVR FRESH AIR INLET DUCTS The left and right ducts will only fit one way Use the diagram below...

Page 131: ...ng early 65 66 original 427 Cobras Street style used on the last 2 3 of the production run The lens is held on with two screws Usually used in conjunction with later 66 67 original round taillights e...

Page 132: ...to pinch the wires when the reflector is installed Install after the light is installed by using a second set of nuts and washers REAR REFLECTOR BOTTOM Used only with round taillights Mount with the n...

Page 133: ...connections exit the main harness on the passenger compartment side of the firewall MIRRORS DASH Assemble the mirror as shown The upper and lower clamps hold the rim against the reflector Note that t...

Page 134: ...bled as shown Position mirror pedestal on the fender over the hole markings and within the gasket outline Holding the pedestal in position drill two 1 8 holes where marked making sure to hold the dril...

Page 135: ...TRUNK Follow the same procedure as the nose emblem installation g emblem2 SIDE Project directly up 1 5 8 from the 4th louver and measure forward 1 2 for the rear hole g emblem3 The steering wheel cen...

Page 136: ...the pipes Because of the slip fit into the side pipes mask the last 1 1 2 of the outside surface before coating While ERA specifies extra heavy flanges the primary pipes may have distorted during wel...

Page 137: ...each set of brackets in place Complete the welding when the pipes are removed from the car REAR HANGER BRACKET ebod spipebrk Bolt the rubber hanger to the chassis and the end of the bracket Mounting h...

Page 138: ...ench see special tools on page 29 will make tightening the rear drivers side flange much easier Re torque the bolts after the engine is run and periodically thereafter EXHAUST SYSTEM UNDER CAR For sid...

Page 139: ...in the windshield frame Check that the stud is secure in the windshield frame Secure the stationary brackets to the windshield side posts with the screws provided Locktite recommended on the screw th...

Page 140: ...ng a couple of inches hanging at the sides Trim the excess front fabric and glue the material into the inner surface See above With the top installed tape down the edges of the front bows securely Att...

Page 141: ...emoving the circlips This will make checking fit of the outside pins easier The center pin can be fit afterward Use a round file to elongate the holes in the door skin and inner panel as needed Don t...

Page 142: ...142 SECTION H FINAL OPERATIONS...

Page 143: ...efore resistance is felt repeat the bleeding procedure ADJUSTMENT The slave cylinder has an internal spring that keeps a small amount of pressure to extend the piston at all times Most throw out beari...

Page 144: ...and rear brakes are separate systems it doesn t matter which you do first While you can use a vacuum bleeder it s not necessary Open the right front bleeder and pump the brake pedal slowly until the r...

Page 145: ...In other words to raise the ride height by 1 move the spring collar up by about 0 7 Rear with Jag For small changes you can adjust only one spring per side The ride height will change roughly the col...

Page 146: ...rod Rotate the inner tie rod inside the rack boot to adjust Each turn of the tie rod relative to the end will change the toe by about 3 16 With the ERA steering gear equalize the distance between the...

Page 147: ...of each unit at the slotted pin Rotate the adjustment counter clockwise until you can no longer feel the adjustment clicks This is dead soft If you wish to experiment with your own settings read the...

Page 148: ...ately reduce the pressures on the opposite axle for a better ride Generally it is the difference in front and rear tire pressure that determines handling balance If the car does not behave the same co...

Page 149: ...m Engine oil If the engine has never been run add oil to the filter and oil cooler before starting Build up oil pressure by cranking the engine over with the spark plugs removed Alternately you may us...

Page 150: ...Drill the thermostat as shown on page 38 Open the bleeder at the upper right of the radiator Fill the system with the cooling mixture Once water flows bubble free from the radiator bleeder shut the va...

Page 151: ...ignition off but will normally stop within 5 minutes This feature helps prevent hot soak fuel percolation in the carburetor Check for exhaust leaks Re torque the exhaust manifold bolts Check the hand...

Page 152: ...emperature gage and ammeter may differ from the diagram below Warning lights Blue U High beam Green G Signal Red R Ignition Alternator FUSES 1 Radiator fan heater 2 Horns 3 Wipers Heater 4 Voltage reg...

Page 153: ...uter pivots on the rear lower control arm Jaguar only Grease front upper and lower ball joints and outer tie rod ends EVERY 24 MONTHS OR 2 YEARS Change antifreeze Check rear brakes EVERY 3 YEARS Flush...

Page 154: ...5 mm 81 ID Note that the narrow sealing surface on some replacement slave cylinders prevent a good seal at the hose Consequently we offer an improved hose to fix the problem A drawing of the hose is o...

Page 155: ...aring lower wishbone Timken 03062 03162 Upper trailing arm Frnt HMR 8 Rear HML 8 Upper radius rod inner HMR 8 Upper rad rod outer HML 8 Lower rad rod Rr in r HFR 8 Lower rad rods out r Energy Susp 9 9...

Page 156: ...e DOT 3 or DOT 4 fluid for both the brake and clutch systems We use ATE Blue or Castrol LMA in our rollers Transmission Ford Top Loader Fill to hole with 80W 90 GL5 gear oil Richmond Gear 5 speed 2 US...

Page 157: ...t you must always use coolant or additive that prevents aluminum corrosion We ve had good results by adding Red Line Water Wetter too JACKING FRONT The car can also be jacked up on the lower control a...

Page 158: ...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 E R A has com...

Page 159: ...Check all your systems for proper function Don t go to an inspection station ignorant of the local requirements Don t expect special favors from motor vehicle inspectors and treat them with respect Th...

Page 160: ...lub of Southern California Cardiff Insurance Rich Dunham Tel 818 980 8941 Classic Automobile Insurance Div Modern Home Ins Tel 800 397 0765 44 states limited mileage Condon and Skelly Maple Shade NJ T...

Page 161: ...hts 131 Master cylinder installation 62 Part numbers 154 Parts 18 22 154 Pedal adjustment 104 Pedal height 104 Rear 17 Rotor installation 98 Bulkhead Rear 83 Bumpers 129 Removal 57 Cable Battery 23 Em...

Page 162: ...ntifying casting numbers 160 Installation 84 Mounts 24 Preparation 32 SOHC 10 Exhaust 138 Exhaust system 19 24 Gaskets and sealant 138 Heat shield installation 88 Leaks 138 Primary pipes 136 Side pipe...

Page 163: ...Emergency brake 42 Throttle 87 Transmission shift 27 Lubrication Capacity Type 156 Schedule 153 Lug nuts 20 Manual updates and errors 2 Master cylinder Brake Parts 154 Master cylinder Clutch Parts 154...

Page 164: ...49 Preparation 48 Shift linkage 16 Shipping kit 7 Shock absorbers See Dampers Shrouding Radiator 57 90 Side curtains 86 109 141 Side pipes 136 Signal lights See Lights Slave cylinder Clutch 36 37 Snap...

Page 165: ...Tremec 14 34 Transporting kit 7 Trunk Latch 69 Lid installation 69 Lid liner 78 Stay 69 Weatherseal 78 Weatherseals 69 Turkey pan 74 Undercoating 77 Understeer 148 Unilite 11 Universal joints 40 Volta...

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