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E.R.A. 289FIA/USRRC 289 Slabside

1. FUEL SYSTEM Ball joint lower Moog 6145 Rep 10277 f Ball joint upper Moog 5208 Rep 10268 Filler cap Parts Master 46139 Bushing lower inner Energy Suspenson Filter In line 3 8 both ends pivot 9072G or from ERA BRAKES Upper control arm shaft MOOG K6148 f assembly w bushes pieces listed below are included in the kit but are Bushings only MOOG K6108 listed here for reference and long term Shafts and bushes are from 1970 73 Chevy Camaro replacement Tie rod end outer Republic ES 425R FRONT Rotor Pads Rotor Fits Chevy Vega 1972 Moog ES425RL thickness 1979 max min Tie rod end inner E R A part Sway bar link Republic SL18060 GM 1975 Bendix D525 1 040 Bushing and bracket Suspension Techniques caliper Camaro 0 970 PB 93 Wilwood Wilwood Fits Wilwood 1 250 Bearing Fhub inner A 2 Bower BCA caliper 120 Superlite 1 190 outer A 6 Bower BCA XL 11136 0 8 thick Seal inner F hub National 8871 Left and pad Steering gear Flaming River FR1502 right 150 8854K 3X3 REAR Boot for Mustang based Flaming River FR1502B gear Jaguar 1980 XJ Lucas Girling 0 500 6 GP97 0 470 ERA Rear 93 97 Bendix 0 810 GM MKD750 0 770 body MRD750 PMD750 HYDRAULICS Brake master cylinder front Tilton 74 875U rear front rear EIS SP1358 or Bendix 88264 Tor B1416 Tor TRA1423 H Line
2. 65 Seal Door hinge pillar to body 58 Seat belt installation 110 Seat 17 Anchors 110 Seats Installation 110 Senders tube routing 103 Service Periodic 134 Shift TANK AGEs xn eet 15 Shift lever 42 Installation 105 Shift 141 Shipping companies 27 Shipping kit sess 7 Shock absorbers See Dampers Shock absorberss 23 Shoulder harnesses 110 Shrouding Radiator 52 93 Side curtains 88 101 122 Sill panel installation 86 Slave cylinder Clutch 33 Slave cylinder 1 32 Snaps top tonneau 116 SOftt p enpak eiei See Top Source List 26 Spacer Transmission mount 11 Spare Tite sess oret 19 onto edes 129 Speaker installation In footbox sides 59 Speedometer Cable Drive gear Parts eh 23 Installation 103 Richmond Gear 12 Top Loader 23 Drive gear Calculations 14 Splash panels front 60 Spring Adjusting height 127 18 21 Height
3. 102 LiNE S xat cin ee 85 Glove 103 Grab handle 116 Grill installation and retrofit 111 GOUNA e r a 127 Ground cable 69 Handbrake See Emergency brake Handling 129 130 Harness shoulder 110 Headlights 112 Adjustment 133 Heat shields exhaust 119 Cater isis seite ehm 100 Height See Chassis height Adjusting spring 127 Hinge Door COVEIS a none iiiter 89 Hood seitens 90 Installation 89 Ni DAE 90 Striker iiic artes 90 oven ren 56 Hoses Cooling system 22 Water 100 Hoses radiator Modifications 34 Hub Rear Jaguar suspension 37 49 ID plate installation 78 Inspection eese 139 Insulation Boats ciere 25 29 Insurance 140 Interior panels 86 Introduction ssss 5 Jack 19 Jacking 126 137 111 Jaguar rear suspension Parts 4er 36 Keep it simple Stupid 8 Knuckle steering 71 Konto 129 La
4. 16 21 Pedal adjustment 60 Pedal height 82 Raf ueteres t es 16 Reservoir 21 Rotor installation 72 Rotors Front GM preparation 73 Grinding tolerances 135 Parts ree eo 135 Bulkhead Rear 86 Bumpers 111 Removal sss 53 Cable Battery Installation 68 Parts eee 21 Speedometer Installation 103 eee 23 Cable battery 69 Cable ground 69 Camber ees 128 Adjusting s es 41 Cap Fuel filler See Fuel Capacities Lubricants and coolants eesss 138 Carburetor sees 9 TANK ASE neue 80 Carpet Installation 108 109 Lay oUt eene 107 Chassis 48 127 Painting 54 Chassis number 78 Chip 62 Closing panel Rear fuel tank 91 Clutch veniret rr tte 9 12 Adjustment 125 Bleeding 124 Concentric slave throwout 33 Concentric throwout bearing NOTES 30 F t Kerent sizi i 24 Hose installation 124 Push type slave cylinder 32 Push type throw out fork Rod trat 32 Release problems 82 Return RH 125 T
5. ieee See Oil pan Panic handle 116 Parts Required 8 Pedal Brake and Clutch 60 Picking up kit sss 7 Pin drive HUDS iecur 37 5 25 Pressure 130 Pull strap 89 Pulley engine 26 Pump Fuel 9 Rack and Pinion See Steering gear Radiator Fan Standard 92 Thermo switch connection EEEE S 34 Mounts een 92 Shrouding 52 Rear suspension See Suspension Jaguar part numbers 36 Registration 139 Regulator Voltage 85 Relay Wiper itat 102 Replacement Parts 135 Required Parts 8 Reservoir Brake Parts sso 21 Richmond Gear 5 speed 11 Ratio eet 13 Shift 15 Ride height Specifications 127 Wizench enn 17 Rivets Blind 25 Rocker flange 89 Roll bar 53 Rotors Brake GM Pin drive preparation 73 Parts eant 135 Rugs See Carpet Rust proofing 62 Safety strap drive shaft 78 Scoop
6. 34 Electrical Components 85 Emblems Installation 105 116 Emergency brake ERA rear suspension 78 ERA suspension 37 Handle e 76 Jaguar Adjustment 76 Lever parts 22 Eris Dosen 109 1881005 9 Engine Availability 22 Identifying casting numbers 9 140 Installation 80 81 Mounts ensinan uris 22 29 Exhaust Competition 118 Heat shields 119 119 Exhaust system 18 22 Installation 117 Expansion tank 22 Connections 100 Fani See Radiator Fan Ferrule Side curtain 88 Filter Buel air IMS 22 iS mn 10 First Drive esses 133 Fluid brake and clutch 138 59 Seal between body 58 Fresh air vent Control cable 102 109 Front suspension 71 Fuel Filler cap Installation 96 53 Tank eoi eerte 96 53 Fuel pump eee 9 Inr we 134 Gages Cable routing 103 Gauges Engine connections
7. Routing of the cooler lines when using a remote filter 95 SECTION G BODY II Remove the fuel filler cap See page 53 FUEL TANK Remove the nuts on the tank retaining strap See below Slabside e fueltank From underneath the car disconnect the fuel line at the tank if the tank is empty or the connection at the steel line at the right side if there is fuel Pinch off the line before disconnecting or empty the tank first Remove the supports between the tank and the small tube underneath the rear edge of the tank Connect the fuel outlet on the center rear of the tank to the steel line on the chassis both OD with a length of rubber fuel line An in line fuel filter can be conveniently installed within this section of line Use clamps on all connections The aluminum fuel tank FIA 19 gallon Slabside 15 gallon is located above the rear suspension at FUEL FILLER CAP the front of the trunk It is fully baffled with one way doors separating the volume into thirds The FIA outlet is on the bottom centered at the rear The fuel level sender is mounted on the top with a To remove the fuel tank you can remove the cap wiring harness leading down toward the left side of flange and sleeve as an assembly the tank where the connection to the main rear harness takes place through the access hole REMOVAL REMOVAL INSTALLATION The filler cap will always screw on with the same eee orientation to the flange
8. party To prevent scratches in the paint tape heavy paper over the area of the rear body snap studs Punch holes so the studs protrude through the paper If you have side curtains match the angle of the windshield to their front edge See the Side curtain section below Install the front channels onto the windshield frame The inside portion of each front channel has a stud which inserts into the slot of the frame See below Press down to engage slide to the outside and down 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 threads Assemble the rear bow halves together Turn the knurled adjusters all the way into the ends of the bows Install a ferrule in each of the receptacles adjacent to the body just outside the seat backs Slide the bow assembly into the sockets with the hinged brace toward the rear Do not try to fit a cold top Always work at room temperature or above 120 ENopfitl Install a snap on each rear flap as close as possible to the outside corner Punch a center hole in the fabric Use the snap backing plate as a guide to make 4 small slits in the fabric with a sharp knife From the outside insert the prongs through the small slits Install the snap backing plate to the underside of the material bending the prongs to secure the
9. REAR SPRINGS JAG SUSPENSION You may use stock XKE springs about 250 Ibs in for mild street use but we have found that replacing all four of the springs with 10 x 350 Ibs in ones works better with a high performance engine Alternately you may replace only two springs with 400 Ibs in ones If you are using height adjustable dampers the spring must be 8 9 long free length Preload is approximately 4 for all combinations ERA SUSPENSION Use 9 x 450 Ibs in springs with 2 25 ID The Preload is approximately 4 REAR HUB ADAPTERS BOLT ON WHEELS XJ Sedan units with original bolt on wheels already have the correct flange and are available from us Most Jaguar XKE rear drive units will have splined hubs for knock off wire wheels To accept bolt on wheels these hubs must be changed to an XJ flange 49 SECTION C CHASSIS PREPARATION Instructions for disassembly of the kit for chassis painting Ir SECTION C CHASSIS PREPARATION These must be replaced by blind rivets Almost all BODY REMOVAL the holes are pre drilled in the aluminum but you will have to complete the drilling into the steel SPECIAL NOTES tubing or through a mating aluminum panel If you have not purchased the Mounted Body When doing any disassembly note any adjusting option the body and most of the aluminum inner shims and their location Mark each for panels must be sealed and riveted to the chassis reassembly The kit as delivered
10. 58 Section D Body Chassis assembly FOOTBOXES DNootbox SPEAKER INSTALLATION LEFT For installation of stereo speakers in the sides of the Lift the footbox up and slip in from the center of footboxes holes must be cut into the fiberglass the car towards the outside Don t rivet the area Note that there is only about 2 1 2 depth available where the foot boxes overlap one another The for any speakers rivets will show in the engine compartment Just add sealant and rivet the portion against the transverse support tube and the lower rear section that extends towards the transmission Footbox components FRESH AIR CONTROL VALVES FOOTBOX INSTALLATION Countersink the rivet holes in the footbox fiberglass along the side and the floor RIGHT Push the box forward into the corner and clamp into dNvent place so that the original assembly holes line up If there are no problems remove the footbox apply caulking and fasten the foot box to the chassis in Screw on top of the drivers foot box after putting a the same manner as the floors bead of caulk on the bottom flange Passenger s side assembly is a mirror image 59 Section D Body Chassis assembly Clamp the duct hose in place The actuating cable will be attached later BRAKE AND CLUTCH PEDAL 36 P S FRONT SPLASH PANELS Reinstall the front panels using a sealer along the riveted areas and between the rubber edging and the fiberglass fender fibrpedal
11. Bush Kit 24 E R A wrecking yard E R A E R A E R A Dan Williams GT Performance Mustangs Unlimited GT Performance E R A Richmond Gear Ford dealer E R A Mustangs Unlimited auto parts supplier Auto parts supplier Dealer E R A Dealer E R A Mid sixties Ford E R A E R A 1965 67 Mustang and some other Ford cars of this period Ford dealer E R A has electronic regulators with the sam cover that the mechanical regulator NLA used E R A E R A Lucas parts dealer E R A E R A Lucas parts dealer SECTION A PARTS NEEDED Wheels Bolt on American Racing Torq Thrust 15 x 7 15 x 8 5 Summit Racing others For 12 brakes see notes on page 16 Pin drive 7 x 15 and 92 x 15 E R A PS Engineering Various widths in 17 Trigo Vintage Wheels Spare Tire Wheel Bolt on GM Camaro space saver See note on page 126 SUPPLIES NEEDED The following list covers most of the materials you will need to complete your kit Items marked with an are not needed if you ordered the bond body option Caulking to seal body and Urethane or Silicone 5 For caulking gun floors to chassis cartridges min Adhesive for bonding rear body Polyester resins thickened Corvette body repair boat shops and Chevrolet bonding strip with fillers and binders are dealers body shop suppliers or specialty houses available for boat repair Regular polyester body filler and the stronger
12. Carefully jack the assembly so that the upper mounts engage into the chassis brackets similarly to the Jag installation shown on page 75 Slide the x 4 5 HCS with a flat washer through the chassis and rear subframe bushing Start the threads with an air wrench or a ratchet There is a welded in stover nut on the inside of the chassis bracket so no lock washer is necessary SECTION F MECHANICAL COMPONENTS Rotate the subframe forward until the front mounts see page 40 line up horizontally with the holes in the chassis crossmember Start a couple of the allen head cap screws 13 x 1 to confirm the alignment If there is a gap use shims fill it Tighten the cross shaft nuts to 20 Ibft and then to the nearest cotter pin alignment Tighten the front mounting bolts and upper mounts Attach the lower trailing arm bushing end to the lower holes on the chassis Note the slight angle of the bushing on the forward end of the trailing arm See page 75 for hints Alignment is described on page 128 EMERGENCY BRAKE Attach the emergency brake cables and balance bracket as shown The front cable is attached to the handle similar to the Jaguar cable d eraeblay DRIVE SHAFT The driveshaft is a special fabrication that may be purchased from E R A or built by a local driveshaft shop Driveshaft specifications for all approved transmissions are on page 42 INSTALLATION Use Grade 8 bolts and washers and stove
13. INSTALLATION If necessary clean and grease the needle bearings in the chassis and in the brake pedal Slide the pivot shaft through the chassis bearings with the splined end toward the inside If the engine is installed the shaft must be installed from the outside of the chassis E fsplash Install the thrust washer s brake pedal and clutch pedal onto the shaft Secure the clutch pedal with the shoulder screw FRESH AIR INLET DUCTS Install the clutch throw out arm onto the splined Use the diagram below as a guide for installation end of the shaft Orient the throw out arm approximately opposite the pedal See the illustration on page 124 To adjust the orientation of the clutch arm change the length of the connecting rod between the clutch pedal throw out arm and the clutch master cylinder Remove the retaining clip and the clevis pin Loosen the jam nut at the clevis Turn the threaded rod to change the length as necessary When finished tighten the arm set screw For balance bar parts installation see page 130 Temporarily install the brake master box It will have to be removed later to connect the brake switch wiring d airscup 60 Section D Body Chassis assembly The aluminum inner panel is sandwiched between the scoop and the hose adapter If you drive where leaves etc may accumulate you may want to put some screen between the scoop and the panel too REAR WHEELHOUSE PANELS Note Coun
14. Tighten nut to 35 Ibft The front of the trailing arm is attached the same as the Jag suspension 41 SECTION B PARTS PREPARATION SHIFT HANDLE Handles are available from E R A and Finish Line El bNshiftlev SHIFT LINKAGE E R A has complete linkage and adapters for Hurst linkage for those who don t want to do the modifications required Inquire for details bNhftlink TREMEC 5 SPEED TRANSMISSIONS Tremecs except for the 500 and 600 retain the stock shifter location On the 500 and 600 the rear plate can be turned 180 degrees moving the lever about 3 forward 42 DRIVESHAFT E R A stocks drive shafts for most Top Loader Tremec and Richmond Gear transmissions You may have a shop specializing in power transmission equipment make one to your specifications You must supply them with the Ford transmission slip yoke and the distance from the differential flange to the tail shaft of the transmission Measure and check the distance from the face of the differential flange to the end of the transmission including the seal extension Subtract about for movement note that some seals are accordion like and designed to ride against the flange of the output yoke Drawings for the units E R A supplies are available from E R A Inquire SECTION B PARTS PREPARATION STEERING GEAR STEERING COLUMN UPPER See page 24 for part numbers You may use the E R A reproduction column or the Triumph co
15. e Install the connecting links between the tab on the lower control arm and the pads on the ends of the sway bar e Tighten the link bolts so that the rubber bush expands to the diameter of the cupped washer Do not over tighten d fswayb g steeringgearmt After putting a small amount of blue Loctite or similar thread locker on the bolt threads torque the bolts to 65 Ibft When installing the tie rod ends use a jam nut on the threads so that the tie rod can be secured after alignment 74 SECTION F MECHANICAL COMPONENTS REAR SUSPENSION JAGUAR INSTALLATION mE dyagrs Thread the trailing arms onto the rod ends with jam nuts already installed on the lower control arms See page 37 Thread on until two or three threads are left showing but leave the jam nuts loose Support the chassis with jack stands so that there is at least 19 20 between the spare tire well bottom and the floor This will allow you to fit the assembly on the jack and still slide it under the car from the back 75 d eracage Raise the rear suspension assembly into position with a floor jack guiding the forward ends of both trailing arms into the brackets on the sides of the frame Lubricate the insides of the upper chassis brackets with lithium grease so that the sides of the rubber bushing will slide into them Guide the suspension assembly into the chassis brackets Using a little light oil on the threads install the
16. for shipping Using the holes in the aluminum for a pattern drill holes through the chassis rails Also drill holes through the 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 sealant on all the frame surfaces the floor will contact Don t skimp you don t want any gaps where water and dirt can accumulate Place floor panels into place and rivet with x aluminum or stainless steel rivets Press the floor down while riveting to ensure a tight fit Check for gaps between the floor and the chassis and fill them with more sealant if necessary From under the car smooth out any excess sealant that has squeezed out Bolt the horns to the front side of the front central tower See locations on page 71 BODY MOUNTING Preparation Is Everything Before starting have all tools and materials ready and read the text below The body is attached with sealant and rivets Lightly sand the mounting surfaces at e Cowl sides Firewall flange Inner rocker panel Cockpit back Sides of the front cowl inner panel With assistance carefully spread the body sides while slipping the lower body flanges over the door hinge mounts Lower the body down over the cowl supports and onto the chassis Watch for the left front brake line that runs behind the wheelhouse panel Use small b
17. grundy com Horsham PA 800 338 4005 John Young 310 254 7355 K amp K Insurance Fort Wayne IN Tel 800 540 0858 Northeast 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 Reference Books How to Rebuild Ford Engines Steve Christ HPBooks 708 Ford Performance Pat Ganahl S A Design Publishing 140 SECTIONH REFERENCE DRIVING YOUR E R A 289FIA THE DASHBOARD fia man f dashlay KEYS Record your ignition and trunk key numbers here Ign Trunk SHIFT PATTERNS The original FIA Borg Warner 4 speed used the pattern on the left This pattern is different from the original 427 with Top loader and Ford or Hurst linkage which located reverse next to first or second gear You can use either one by locating the lever selecting reverse on the top or bottom of the selector rod 141 SECTION F INDEX INDEX Accellerator linkage 80 Accent 106 Air hoses 62 Alig
18. has the body and inner panels held in place with a limited number of self tapping screws DRILL RIVET HOLES Do before disassembly of the inner panels Bulb Firewall panel to the cowl support structure Front wheelhouse panels to chassis Steel tube bonded to the hood opening flange Drill these holes e Rear fiberglass wheelhouse panels front of through fiberglass rear wheel to the chassis panels also LEFT SIDE Trunk closing wheelhouse panels at least to dArwhlhous the fiberglass inner body panel Drill the inner trunk panel into the wheel house panels e Rear bulkhead panel to the chassis e Fiberglass inner body panel and a double row into the fuel tank compartment floor front flange e Lower flange of the radiator air inlet to the support tube e Lower trunk opening flange to the rear crossmember e Inner rocker panels to the floor and door opening flange e Rocker panels to the brackets on the chassis longitudinals 3 per side e Through the aluminum firewall panel into the steel crossbar and fiberglass back panel e Remove the aluminum firewall panel Check panel alignment 51 SECTION C CHASSIS PREPARATION Even though the hood doors and trunk lid are factory aligned you must check their fit with the weatherseals in place before you remove any panels Minor clearance problems must be corrected before the car is painted Hold seals in place with masking tape If the panel
19. subframe or the custom TOP LOADER E R A suspension unit with outboard brakes The SHIFT LINKAGE is available as a kit or as a complete Both the original Ford 4 speed shift linkage and Hurst linkage work well The linkage is mounted at JAGUAR BASED the forward location on the transmission Not all top loader tail shafts have the casting bosses for the front mount but the tailshaft can be replaced Some may require drilling and tapping fiavnanNNshiftmt LEVER If you don t want to modify the Mustang lever yourself SELECTION see page 42 E R A manufactures a duplicate the See page 23 for application list original shift lever to fit the Top Loader Richmond Gear and Tremec transmissions The Jaguar differential is the same Salisbury unit that RICHMOND GEAR was used in the original Cobra with only some casting changes It is adequate for 500 BHP and can be made even stronger by using stub axle parts from Concours West Gear wear is not normally a problem even in well used assemblies but always replace seals E R A modifies a Long shifter and rods for the 5 speed using the Ford lever for control The lockout T handle is there for looks but no longer is functional Inquire about available parts Do NOT replace the control arm roller and needle bearings with aftermarket urethane bushings The net result will be wheel hop and generally sloppy handling The vintage of the Jaguar differential is punched in the c
20. 3rd 4th 3 271 1981 1 341 11 TS Speed 1000RPM i Ratios 2 78 1 1 931 1 361 11 Dif Speed 1000RPM 3313 74 11 8 17 4 23 4 34 4 9 1 13 1 18 5 25 2 3 541 6 7 11 0 16 3 21 8 32 1 8 4 12 1 17 2 23 4 TREMEC TKO II 5 SPEED 7 9 11 3 16 1 21 8 4 SPEED TOP LOADER CLOSE RATIO 3 27 1 1 98 1 1 34 1 1 1 83 1 2nd 3rd Dif Speed 1000rpm Ratios 2 32 1 1 69 1 1 29 1 1 1 3 07 1 12 7 188 252 30 4 Dif Speed 1000RPM 3 31 1 11 8 1774 234 282 10 9 149 19 5 25 2 3 547 6 7 11 0 163 218 263 10 1 13 8 18 1 23 4 TREMEC 600 9 4 12 9 16 9 21 8 oa SITO T 5 5 SPEED Ratios 2 87 1 89 1 28 11 62 1 Some T 5 s are geared like the Tremec 3550 DIF Speed 1000RPM 1st 2nd ard 4h 5 3 071 88 133 197 252 307 394 Ratios 2 95 1 1 94 1 1 343 1 1 63 1 3 31 1 8 1 12 4 3 183 234 285 36 5 Dif Speed 1000RPM 3 54 76 116 171 218 266 341 3 31 1 7 9 12 0 17 4 23 4 37 1 RICHMOND GEAR 5 SPEED RATIOS 3 54 1 7 4 11 3 16 3 21 8 347 Ratios 3 27 1 2 13 1 1 57 1 1 23 1 1 DIF Speed 2 1000RPM 2 88 1 8 2 12 6 17 1 21 8 26 9 3071 7 7 11 8 16 0 20 5 25 2 3 31 1 7 1 11 0 14 9 19 0 23 4 SECTION A PARTS NEEDED SPEEDOMETER DRIVE GEARS Ford transmissions used a variety of drive gears The Mustangs Unlimited catalog is a good reference The gears are illustrated and detail specifications listed Note The Ford Top Loader drive gear may come with right or left hand threads The driven gear must match You can calculate the
21. 4 10101 Steering column upper E R A Reproduction or Triumph Spitfire GT 6 1972 mid 1977 Steering wheel Moto Lita Wheel hub Triumph column Moto Lita wheel must be drilled for pattern E R A column Comes with E R A column Steering wheel Center button Reproduction of original either AC or Cobra motif Transmission See notes on pagel0 Ford Top Loader T 5 Tremec Richmond Gear 5 spd Mounts Ford Top loader 2 holes along longitudinal centerline or 2 holes perpendicular to centerline 5 6 apart Ford C 6 Automatic Ford T 5 Richmond Gear Tremec 5 speed Ford C8ZZ 6068 A or Republic 31 2284 Ford C9AZ 6068H or Republic 31 2375 Ford C8ZZ 6068 A or Republic 31 2284 Pioneer 622378 72 73 Camaro w MT Tremecs require an adapter from E R A to use the Pioneer 622378 Ford C80Z 7515D must be narrowed for all but big spline Top Loader Ford C8AZ 7522B Original Ford unit Hurst or other after market units Throw out fork Pivot bracket for above Shift Linkage 4 spd Top loader Richmond Gear 5 speed Shift Lever duplicates original Long or Hurst To adapt to all transmissions Voltage Regulator Ford Regulator DATZ 10316 A D9PZ 10316 A or aftermarket equivalent for 1967 on Ford alternator with external regulator Windshield Wipers Motor and Drive Parts From 1969 1976 Triumph Spitfire GT 6 or TR 6 Lucas BHA 5201 Lucas GWB 164 Lucas 60600 429 Arms Blades Chrome Bezels
22. Jaguar XJ inner axle must be shortened to XKE Series I II length Alternately you may build the axle from scratch Specifications are available from us Complete assemblies and parts are available from E R A Clean and deburr the axle splines Assemble the stub and inner axle together replacing the universal joints with genuine Spicer units 5 160X Hub Carrier Note that the lower pivot shaft is a shrink fit into the aluminum casting It may be removed by heating the assembly or less preferably by using a press Generally removal is not necessary d rerahubx Clean the hub carrier casting of any machining debris especially on the inside Press the inner and outer bearing races and outer seal only into the carrier Install the seal race and the 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 bearing assembly should be adjusted with shims to between 002 preload and 004 float Aim for zero You can change the end float with the correct size of spacer from Jaguar SICP Concours West or E R A See the list of available shims below Pack the inner and outer bearings with good wheel bearing grease Also fill about half way the cavity in the hub carrier Install the inner oil seal SECTION B PARTS PREPARATION Technique One Insert the hub with outer b
23. Lakewood 15200 Top loader Richmond Gear Lakewood 15202 Tremec Lakewood 15203 T 5 12 long woven style 135 long eye terminal clamp 1 gage min If you want an in line cutoff see page 68 32 long eye terminal clamp 1 gage min 24 long eye eye 4 gage min SOURCE Most Fords 1971 1980 Ford GM dealer or many Front GM cars 1970 78 see page 16 GM dealer Local parts place ERA BMW dealer GM or local auto parts E R A E R A Summit Racing Jegs E R A Carrera Dillon AFFCO Eibach Various E R A E R A parts supplier Drive Shaft Components sce page 42 for parts reference 21 SECTION A PARTS NEEDED ENGINES AND ENGINE Complete rebuilt Ford units are available from PARTS several suppliers Mounts Ford 260 289 302 351 63 65 Mustang w 260 289 cid Ford CADZ 6038A Aftermarket Mustangs right C4DZ 6038B left Unlimited E R A Dealer Republic 31 2221 right 31 2220 left MityMount HD FM132 Maximum depth of 8 5 F or R sump Deeper pans E R A Canton Racing will hang below the chassis Windage trays are Products Aviaid recommended for engines running consistant high rpm 289 302 High capacity front sump Canton 15 610 and pickup 15 611 Road race with trap doors Canton 15 630 and pickup 15 611 High capacity front sump Canton 15 660 and pickup 15 661 Road race with trap doors Canton 15 680 and pickup 15 611 351 Cle
24. Raise the radiator fan unit and tray up into place over the front chassis studs Hold in place with nuts lock washers and flat washers Check that the radiator is centered in its mounts Gently let the radiator lean back against the chassis From the top Install the bottom tray onto the chassis Carefully slide the radiator down into grommets 92 fia man e radmt Fit the rubber grommets and steel sleeves to the upper radiator support Install the support over the studs on top of the radiator with the large washers lockwashers and nuts Move the radiator forward and attach the support to the body Attach the support straps or optional rear fan see below between the upper and lower radiator supports OPTIONAL FANS STANDARD fia man e stdfan SECTION G BODY II 15 REAR MOUNTED RADIATOR SHROUDING Attach the bottom radiator shroud to the 2 middle holes in the front edge of the radiator tray as shown Install the left and right shrouds on top of the bottom using the same lower screws Note If you are installing your own not E R A oil cooler the shrouding panels must be modified The E R A oil cooler comes with pre drilled shrouding fia man e optfan HOSES Mounting for the optional expansion tank is shown on page 34 Install the radiator into the chassis as f shown above The hose part numbers and fiatnan e radshrd instructions for modifying the front lower hose are covered on page 34 Note that a connecti
25. Rim size appropriate for tires Max 26 5 26 4 25 2 315mm Min 24 5 Max Width 275mm SECTION A PARTS NEEDED Lower profile tires increase the clearance between the top of the tire and the fender giving the illusion that the car is higher than it actually is If the car is lowered to compensate the ground clearance will be reduced somewhat In most of the pictures you have seen of our car the tires used were Goodyear race tires The equivalent tire for the street would be Front 245 50HR 15 to 235 60HR 15 street Note that Avon tires are sized a little differently Use 225 65 15 in the front Rear 265 50HR 15 to 295 50HR 15 street Larger diameter tires can be used with different wheel offsets The latest information on tire brands and sizes is posted on the ERA web site www erareplicas com 427man tires index htm 20168 Mile Tire OD in inches Revolutions Fi For Reference For 16 or 17 wheels tires in 35 and 40 series will fit Ask for current recommendations Before mounting on pin drive wheels see page 126 SPARE The spare tire well will accept any wheel tire combination that is less than 24 5 in diameter If you keep the width small you will gain trunk space If you are using bolt on wheels you may use a Space Saver spare tire as used on Camaros and other GM models If you buy the tire with the wheel make sure it has uses the 4 bolt pattern If you have a limi
26. Thermostat housing 22 Throttle linkage 80 Tires Pressure sets 130 Rev s Mile 19 Size chart 18 Sparte ici endete 19 Tatle si ieu 139 To n aterert rente 128 Tonneau cover Fitting sss 122 65 Tools Needed 27 Top Fitting societies 120 Remove replace adjust 122 116 Torque Values General 67 138 Trailer shipping 7 Trailering your kit 7 Trailing arm See Suspension Transmission Automatic 11 82 Gearing oo seeded 10 Installation 30 81 eer teet 30 11 24 Selection 10 Shift lever rune 42 Shift linkage parts 24 Shift 141 Specifications 11 12 TKO Short input 31 TKO Standard 31 Top Loader 11 12 30 Transporting kit 7 Tremec Installation 81 Trunk ssec teen 91 NIE 91 Trunk lid Bungy hold down 64 Installation 91 TAMER ent 90 T
27. all possible use the short tail shaft transmission It allows a longer driveshaft SPEEDOMETER DRIVE GEARS Most Top loader transmissions come with a right hand thread drive gear on the output shaft The driven gear on the speedometer cable must match See page 14 for part numbers CLUTCH THROW OUT FORK Part numbers are on page 24 The fork must be modified See page TRANSMISSION MOUNTS TOP LOADER ONLY Check your transmission mounting holes for the appropriate mount Top Loader Mount Transmission Ford C8ZZ 6068A its equivalents i e Republic or Parts Master 31 2284 Two holes in the transmission arranged front to back Two holes arranged side to Same mount as above side and having 5 between center Two holes arranged side to side and with 6 center to center distance Rare Requires a special adapter done on special order only Use Ford C9AZ 6080E Republic 31 2250 or equivalent FORD C 6 AUTOMATIC Use the C 6 appropriate to your engine Because there isn t a transmission oil cooler built into the radiator you must fit an auxiliary one either in place of the engine oil cooler or in front of the radiator Mount Ford C9AZ 6068H Republic 31 2375 or equivalent RICHMOND GEAR DOUG NASH 5 SPEED This transmission is loosely based on Chevrolet gears The 5 speed has a direct 1 1 fifth speed The intermediate gearing is lower than the Ford 4 speed so you may numerically low
28. 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 All states will require a Certificate of Origin for the kit supplied by ERA and reciepts for all major components Many states will want to install a new State Identification Plate in addition to the E R A ID plate Most 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 Department 3 Inspections may be done by authorized private inspection stations 4 No direct inspection is necessary It is also possible to register your car in other states by mail This registration may or may not be valid in your state It may allow you to transfer the registration with only an out of state vehicle inspection We have compiled registration and inspection replies from ClubCobra and CobraForum com at http www erareplicas com statereg htm CAUTION Fewer and fewer states are accepting this type of Titles Unlimited Tel 1 800 325 8136 PO Box 590136 Birmingham AL 35259 World Title Services Tel 1 800 325 2050 US Auto and Title Ser
29. and the right side filler inside the trunk e Remove the access plates at each side panel inside the rear wheel wells and remove the nuts securing the strap 53 e Remove the mounting pads at the rear bottom edge of the tank e Remove the tank by snaking out the left side first SLABSIDE e Drain the tank This can be done from the front or under the car at the fuel filter connection e Remove the trunk lid and the trunk hinges e Remove the back closing panel e Disconnect the fuel line at the center of the tank e Remove the access plates at each side panel inside the rear wheel wells and remove the nuts securing the strap e Slide the tank straight back until it clears the support tube then drop the left side without the notch down The tank can then be rotated up on the other side It just clears the trunk opening with a little jiggling JACK PADS BUMPERS BRACKETS See the illustration on page 111 e Front Remove both fresh air inlet ducts from the front body e Remove each bumper tube assembly from its mounting bracket If you have a nudge bar you may remove the bumpers and nudge bar as a unit Rear Unbolt the bumpers from their mounting brackets Access for the top bolt is inside the trunk for the lower bolt from underneath the car If nudge bar is fitted remove in unit ROLL BAR Remove the access panels from the rear bulkhead See page 92 and 86 Remove the bolts from roll bar one at
30. are also about 25 40 Ib lighter than Top Loader or Richmond Gear 5 speed when you include the shifter The gear spacing is too wide on the TKO 3550 for serious track use but the TKO 600 has an optional close ratio equivalent to the Richmond Gear We also install the Richmond Gear 5 speed with good results The relatively close gear ratio spread of the 5 speed allows a numerically lower differential ratio for better highway cruising with the first 4 gears acting like a close ratio 4 speed As a rule of thumb if you do much stop and go driving 9 MPH 1000 RPM is the longest 1st gear that can be driven smoothly with a fairly mild 302 engine This means that a wide ratio Top Loader will be OK with a 3 31 1 differential ratio a close ratio Top Loader requires a 3 54 1 or 3 77 ratio The Richmond Gear 5 speed is much more flexible allowing a 2 88 1 differential The T 5 and Tremec have a fairly short first gear with overdriven 5th and can coexist with a 3 31 1 and shorter gear Going shorter than 3 54 1 results in a stump puller first gear that isn t particularly useful SECTION A PARTS NEEDED FOUR SPEED TOP LOADER Rebuilt transmissions are available See the list of resources or ask E R A Transmissions come in several combinations of long and short tail shafts large and small splined input and output shafts and internal ratios the wide ratio transmissions have small input and output splines Itis not necessa
31. battery 60 Use tape to insulate the cable where it passes through the roll bar brace mount under the floor Fasten the cable to the footbox and the inside of the frame rails with insulating clamps The cable from the starter solenoid to the starter is shown on page 104 fia man e battery_cable 68 Section Chassis Assembly BATTERY TO CHASSIS GROUND GROUND CABLES gU EREMO Pass the eye of the 32 cable around the back of the TRANSMISSION TO CHASSIS battery support Coat the eye with grease and Fasten one end of a cable to the transmission rear fasten securely to a bottom tray support bolt See cover If you are using the transmission mount page 79 and 104 for illustrations adapter the cable can pass through the slot at the edge of the bracket Fasten to the right side of the chassis mount See page 104 69 SECTION F MECHANICAL COMPONENTS SECTION F MECHANICAL COMPONENTS SECTION F MECHANICAL COMPONENTS FRONT SUSPENSION LOWER CONTROL ARM Lubricate the chassis receptacle brackets and the sides of the control arm bushings with silicone grease or petroleum jelly Use a gentle oscillating motion when inserting the control arm into the mounts Sometimes a plastic dead blow hammer helps Insert the 5 x bolt with a heavy washer through the front bushing into the chassis Use a flat washer under the lock nut Use the 3 x bolt through the rear mount with flat washers and lock nut Torqu
32. blasting chassis Refer to page 60 for pedal assembly details e Floors foot boxes and brake lines e Radiator lower support tray Remove the nuts on the bottom of the front chassis extension See page 92 The footboxes floors transmission tunnel and rear bulkhead panel are temporarily located and secured with sheet metal screws Save the screws for use later in aligning parts for installation Remove the accelerator pedal assembly fresh air control valves brackets etc from the foot boxes Coat the chassis brackets pedals and brake cover suspension components etc It is not necessary to paint the aluminum panels e Clean all parts with wax and grease remover e Etch metal with Metal Prep or by sandblasting e Apply a primer coat appropriate for your paint If possible use non sanding epoxy primer e Paint the chassis and other parts with epoxy or a two part polyurethane paint such as Dupont Imron or Ditzler Deltron When the paint is properly cured support the chassis on padded jack stands at least 18 off the ground at the rear cross member This is the minimum height required for installing the rear suspension 54 Section D Body Chassis assembly SECTION D BODY CHASSIS ASSEMBLY Assembly of the interior panels and mechanical components 55 Section D Body Chassis assembly INTERIOR PANELS FLOORS Done with Bonded body option Hold the floor panels in place with the screws used
33. bolts with flat washers but don t tighten yet fiavnanNNNrailarm Note that the trailing arm bushing is angled slightly relative to the trailing arm tube On one side of the car Rotate the trailing arm so that the bushing angle matches the chassis bracket Holding the bushing against the inside of the chassis bracket sight through from the outside hole Use a large screwdriver to move the assembly so that the sight is straight into the threaded portion of the chassis bracket SECTION F MECHANICAL COMPONENTS Slip the aluminum spacer between the outside of the trailing arm bushing and the chassis bracket See the illustration above Slide the x 3 bolt through the flat washer upper hole in the bracket spacer and 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 whether the length of the trailing arm will have to be adjusted Screw the trailing arm in or out on the rod end as necessary If the assembly does not line up perfectly pry or pull on the hub carrier to shift things around while installing the spacer and bolt If the holes do not exactly line up grinding a taper on the bolt may make it easier to get the threads to start Torque the bolts on both sides to 45 Ib ft Tighten the upper pivot bolts to 90 Ib ft Rotate both the rod ends on the trailing arms all th
34. change needed turn the rod end 2 turn in or out Re insert the inner pivot bolt and tighten to 75 Ibft Change the length of the rear tie rod the same amount by turning in or out 2 the number of turns that the rod end was changed by i e you rotated the rod end by Y turn rotate tie rod by turn To much positive camber can be changed by adding shims between the axle flange and spacer A 0 02 shim will change camber by 4 degrees DAMPER ADJUSTMENT SPAX Spax dampers do not have separate bump and rebound controls but a reasonable performance compromise can be made using common sense and a screwdriver The bump rebound ratio is designed for the ERA 289FIA and only detail changes need be made for optimum handling We have found that all dampers adjusted 5 clicks from dead soft see below is reasonable for the street Damping adjustment is located near the bottom 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 instructions below Custom Settings Initially set all six dampers 2 clockwise clicks from dead soft Drive the car over uneven surfaces to determine whether the car bounces over bumps or wheel control is properly maintained Increase the damping until side hopping begins then decrease the setting until control is regained Read the instructions below for Koni reb
35. each leg and one at the rear end of the rear brace Remove the 4 bolts at the front of the roll bar brace Slide the hoop up and the brace forward to disengage the upper slip joint Unbolt the roll bar hoop from the chassis 2 bolts and pull up and out Remove the rubber grommets from the body Locate and remove the screws save the screws holding the body to the chassis from the e Front inner wheelhouse panel page 60 SECTION C CHASSIS PREPARATION e Bottom edge of the rocker panel save any shims e The interior side of the firewall where the firewall attaches to the steel cross member e Trunk floor on the rear chassis crossmember e Also remove rear wheelhouse closing panels from inside both rear wheel wells These panels are the ones that close off the wheel area from the passenger compartment FINAL REMOVAL Two people per side are required to remove or replace the body from the chassis Gently spread the body sides out working over the door hinge mounts Don t snag the brake line that runs behind the left front inner wheelhouse panel After removal support the body on a flat surface so that there is no stress on the rocker panel area under doors CHASSIS PAINT If chassis is not powder coated from E R A optional all the remaining parts on chassis must be removed e Brake cylinder cover box and pedal assembly Cover or remove pedal shaft needle bearings in chassis before priming or sand
36. fiberglass strand fillers such as Tiger Hair or Rot Out can also be used but these fillers have the disadvantage of setting up rather quickly making the completion time of the bonding operation critical Blind rivets 400 dia x 250 312 McMaster Carr 97524A025 Aluminum panels to chassis or material thickness sealing fiberglass type aluminum body steel mandrel Body to chassis 150 dia x 062 125 McMaster Carr 97524A030 material thickness sealing type aluminum body aluminum mandrel Insulation foam Expanding urethane or Building supply store DAPtex latex 18826 foam Chassis lubricant grease for universal and ball joints Wheel bearing grease disc brake high temp type Weatherstrip adhesive or industrial strengh contact cement Foil faced foam or insulation Frost King duct insulation building supply heating and air conditioning supply mat l for tunnel floor FV516 hardware store supplemental 25 SECTION A PARTS NEEDED SOURCE MASTER LIST Because of rapid changes in area codes these phone numbers may be out of date BUSINESS NAME Arthur Allen Mfg arthurallen com Aviaid Oil Systems aviaid com Branda Performance cobranda com Canton Racing Products cantonracing com Carrera Shocks carrerashocks com Carroll Shelby Ent carrollshelbyent com Cobra Restorers Ltd cobrarestorers com Dan Williams Enterprises toploadertransmissions com David Kee Transmissions 4spee
37. from the wiper motor to the right wheelbox through the grommet For electrical testing see the electrical troubleshooting guide available on the ERA website 45 CONNECTING TUBES b wiper3 Undo the large nut and remove the cable tube wheelbox assembly from the motor Remove the wheelbox backing plates and disconnect the tubes from the wheelboxes Using a tubing cutter or hacksaw cut off approximately 2 from one end of the original tube betwe en the right wheelbox and the motor Save the nut and the piece of tubing removed T is now the new tube C replacing the original Slide the nut onto tube B the shorter of the two supplied and having only one end flared Flare the end of the tube with the nut Slide the drive cable through the tube If the cable is tight at the new flare use a drill bit to clean the inside of the tube SECTION B PARTS PREPARATION MOTOR PREPARATION Put 1 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 STROKE CHANGES Remove the plastic gear from the crankshaft by supporting the edge of the gear and tapping the shaft with a soft hammer Be careful not to damage the circlip groove The position of the crankpin must be changed in order to increase the stroke of the cable Punch the underside
38. in the oil pan Most Canton and Aviad pans already have this fitting fia man b altbrk Install the engine mounts onto the block as shown Install the long bolt through the reinforcing below bracket alternator and spacer tube Bolt the assembly onto the cylinder head Install the top adjusting bracket as shown Loosely secure the inner end of the reinforcing strap to the water pump bolt as indicated Tighten the alternator pivot bolt Tighten the reinforcing strap bolt Check the alignment of the pulley grooves with a fia nan b engmts straight edge Add washers or shorten the spacer as needed 29 SECTION B PARTS PREPARATION CLUTCH Install the clutch pilot bearing driven disk and pressure plate TRANSMISSION Note After installation the centerline of the transmission output shaft should be 3 5 0 25 above the plane of the X member This will give the correct drive shaft angles ALL Install the rear mount onto the transmission Trim flush TREMEC with rib Stock series 600 transmissions have an input shaft that requires a spacer between the transmission and TKO 3550 bellhousing transmission with a shortened input shaft is available from various sources and obviates the need for the spacer The Tremec TKO series have a boss on the right side that must be trimmed back flush with the adjascent rib See at right The passenger s side floor may also require some trimming where the transmission
39. may be removed by squeezing from the backside TRUNK LID Install the trunk lid liner the fuzzy stuff that was with the optional street carpet kit onto the inside of the trunk lid with contact cement Trim the material so that it can be pushed just under edge of the fiberglass inner panel Glue the half round weatherseal provided with the kit onto the trunk opening flange of the body leaving about distance between the edge of the seal and the up curve of the outer lip To keep from making a mess with the contact cement you can use masking tape to border where the weatherseal will be placed Do not stretch the seal while installing Start the process at the center of the bottom lip in front of the latch Continue over the top and back down to the center Trim the excess so that the ends meet tightly See the picture on page 91 SECTION G BODY II ebodNTRNKSEAL Bolt the trunk hinges they are marked with a T on the lid side loosely onto the body with any 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 lid just enough to get your arm and a wrench inside and snug the bolts on the lid part of the hinges Remember to check the front edge while lifting lid The lid can be adjusted further by moving the lid and hinges in unit at the connection
40. may have distorted during welding Use a flat surface to check their condition If there is more than 020 variance from flat grind file or mill the surfaces Rear Hanger viewed from back 118 SECTION G BODY II UNDERCAR HEAT SHIELDS Install insulation on the underside of both the floors to minimize heat transfer into the passenger compartment The optional heat exhaust heat shields help to keep heat off of the footboxes Assemble the left and right pieces as shown Glue or rivet aluminum or stainless faced insulation onto the bottom of the floors e Add jute or foam insulation underneath the rugs The exhaust hanger mounting holes are on the floor transverse supports One in the front support two in the rear Holding each top and vertical assembly in place mark the aluminum wheelhouse for the upper holes and drill for the 10 screws Attach the upper pieces with screws then drill through the bottom holes into the footboxes for the 6 screws 30 drill 119 SECTION G BODY II CONVERTIBLE TOP FITTING THE TOP KIT More pictures of a 427 at www erareplicas com 427man top index htm While it is possible for an individual to fit the top E R A recommends that the top be fit by a professional upholsterer especially if you have a roll bar The following general guidelines will be of some help ERA takes no responsibility for any damage resulting from installation of the top by any
41. much length where they go into the speedometer head This will either cause the speedometer to malfunction or the gear at the transmission to strip Check clearance by disconnecting the cable at the transmission end and insuring that it turns easily If not either shorten the cable where it enters the speedometer or add shims where the cable housing meets the threaded section on the speedo TKO CABLE ROUTING BATTERY AND CABLES The battery is mounted in a hidden compartment behind the right rear wheel Installation of the support tray is described on page 79 BATTERY INSTALLATION SERVICE See the illustration on page 79 If necessary remove the right rear wheel Remove the screws and nuts holding the splash panel at the rear of the wheel well 104 Place the battery onto the tray with the posts toward the outside away from the chassis The negative terminal with the latest batteries is at the rear Attach the 135 long battery cable use a 60 if you are using the cut off switch See page 79 to the positive terminal on the battery toward the front of the car The cable is routed around the back of the battery support The power cable is then routed as per the instructions on page 68 Attach the ground cable to the rear terminal Secure the cable with a clamp at the back bolt Fasten the eye to the front bolt Ground cable routing Slide the hold down rods up through the holes at the front and back of the bottom of
42. of the crank plate exactly opposite the center of the crankpin Use a Blair spotweld cutter or a drill bit to cut the pin from the plate drilling from the back side at the punch mark The pin will be removed together with a small piece of the plate If you are sure that the wiper motor functions correctly and don t want 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 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 Vwiper2 housing to the aluminum gear reduction housing Drill a UA hole in the opposite side of the Remove the two long screws holding the motor housing to the frame Separate the two with gentle soft hammer taps if necessary Do not lose the felt washer and thrust washer in the bearing cup at the bottom of the housing crankplate at the position indicated in the illustration Countersink from the crankpin side just enough that the crankpin will be flat on the plate after insertion into the hole n Weld or braze the pin in the new hole from the Inspect the brushes for wear or sticking the back Clean and deburr
43. on the inner panel Tighten bolts and recheck fit TRUNK STAY Attach the trunk stay to the trunk lid as shown using the sheet metal screws at the bottom stainless steel dome head screws at the top ebod trnkstay TRUNK LATCH Attach the trunk handle and latch to the trunk lid as shown Don t forget the gasket under the handle Attach the latch striker and bracket to the trunk floor 91 Adjust the striker on the bracket so that when latched the lid slightly compresses the gasket and sits flush and centered on the surrounding body fiat man e trnkltch REAR CLOSING PANELS Install the panels that seal the rear wheel area from the passenger compartment with sealant and rivets Hold the panels in place with the original screws and drill ss holes for rivets into the chassis vertical tubes and the bottom outrigger The closing panel with the bulb trim should contact the outer body lightly If you want complete the seal with urethane or silicone sealer fiat man e RCLSPANL SECTION G BODY II ROLL BAR x ENrollbar When installing the bar after paint partially slide the rear hoop into the chassis About an inch before fully seating the hoop install the front brace RADIATOR FANS The radiator can be installed from underneath the car or from the top if the hood is not installed Insert the rubber radiator grommets into the holes in the radiator support tray fiaiNnanNeNradmt From the bottom
44. onto the top plate with cap screws and lock washers leaving the bolts loose 36 steel strap Install the hose mounted on the chassis originally onto the junction with a copper 0 ring Loosely install the side brackets onto the differential case Slide the fulcrum shafts through the subframe and brackets Add shims between the brackets and the differential to take up any side clearance Tighten the bolts holding the brackets to the case If there is a gap between the top of the differential and the mounting plate shim to zero clearance Tighten the top bolts On the E R A subframe toe in is determined by the location of the holes in the subframe which are not adjustable If your toe in is incorrect your control arms may be bent Install the lower control arm with bearings etc into the subframe using the same parts and procedure with the E R A subframe as the Jaguar subframe Install the junction block and hose using a copper washer onto the bracket on the subframe Connect the hard brake lines from the bracket to each caliper SECTION B PARTS PREPARATION b jagcage HAND BRAKE LINKAGE If you have a block on either brake actuating lever at the caliper it must be removed Pry the lever apart to remove then squeeze together again Use a 2 bolt at A a ie bolt at B EB ERA STIFFER SPRINGS You may use slightly stiffer springs in the rear to decrease squat on heavy acceleration e I
45. panel to seal the battery area at the frame rail and over the two studs on the battery box Battery cable installation is described on page 104 Note that the regulator case must be grounded with the black wire from the harness 79 SECTION F MECHANICAL COMPONENTS Install the link from the pedal to the cross shaft so that the pedal is about from hitting the floor ACCELERATOR PEDAL AND LINKAGE C Remove the wire holding the carburetor linkage and All components come preassembled in the standard check whether the pedal is at a convenient height kit If it is too high change the link footbox link to a lower hole on the cross shaft If it is too low change the engine link to a lower hole on the cross shaft Install the return springs and check whether you re still getting full throttle Tighten all bolts and jam nuts check for interference and grease all the pivot points If you want the smooth look shown below cut some 5 46 brake line to length to cover the middle section of the threaded rods Note This linkage can be adapted to most engines If yours requires something different call us For Weber carburetors a duplicate of the original bellcrank pivot stand is available from E R A If you are using a blow shield with a wide flange on a 289 302 the flange must be trimmed around the bracket d throtink When assembling the longitudinal links onto the sides of the bellcranks pick the s
46. smoothly with no drastic attitude changes and without leaning excessively Any increase beyond this point is unnecessary and may in fact be detrimental Final adjustments can be made to effect the turn in of the car that is whether the car has initial understeer or oversteer By increasing the rebound control at one end it will decrease the initial adhesion at that end Conversely decreasing the rebound control increases the initial adhesion In general neutral or slight initial understeer is most desirable There should not be a large difference between transient and final balance although slightly less initial understeer will increase responsiveness TIRE PRESSURES Use initial settings cold of 24psi front 26psi rear Depending upon tire brand and size these pressures will be a reasonable compromise between ride and responsiveness Remember this a light car with large tires High tire pressures are not necessary or desirable except for high speed competition Harshness and vibration become a serious factor at higher pressures If you are using 17 wheels with very low profile tires check the manufacturer s recommendations 130 FINAL OPERATIONS Steady state under oversteer may be adjusted significantly 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 op
47. snap SECTION G BODY II Lay the top in place over the rear bow and secure the snaps to the studs in the body closest to each rear door opening If the top is too tight for the snaps to reach the studs even at the lowest height adjustment remove some material in the where the main bows come together to create some slack If the frame doesn t follow the contour of the fabric it can be tweaked to fit by hand over the knee bending e topfit2 Starting on the passenger side of the car install the balance of the snaps in the center of the flap alternating from each side towards the center If the car has a roll bar carefully make a slit from the bottom edge of the top to about 1 into the plastic window A small boot can be made from two pieces of fabric sewn together sandwiching the top material between them Glue felt pads to the underside of all snaps to prevent paint damage Use 2 masking tape to tape each front channel down to the top of the windshield securely at the outer edges Pull the top fabric over the top of the channels beginning at the center and working over to each side taping the material to the windshield glass as you work 121 Alternately adjust the top over the rear bows and pull and re tape the top material at the front to remove slack from the top and minimize wrinkling Do not pull hard at any time Stress can break the windshield Make sure the top material is centered on the front bows and
48. spring to prevent its collapsing Small block Fords were also available with water pumps that work in either forward or reverse rotation directions Make sure that your pump is designed to rotate in the correct direction Water pumps have been known to fail invisibly The impeller comes loose from the shaft under load Sometimes an extremely tight engine can cause overheating LOW SPEED See the AT SPEED section above Our standard fan is adequate for practically any small block engine under normal conditions it s the same one we use with the 427SC kit If you expect high temperature city driving or you have a large displacement and or highly tweaked engine consider ordering our heavy duty fan The fan only effects water temperature when the car is below I5mph TESTING Fan function The fan thermo switch is in the aluminum connector between the radiator and water pump Because the sensor is in the coolant return line the 75 C switch marking will not correspond to the cylinder head temperature that the gage indicates because of the cooling that occurs in the radiator 132 SECTIONH FINAL OPERATIONS HEADLIGHT ADJUSTMENT Most service stations have a standard set of headlight adjusters If you have a flat area at least 40 ft long you can do the job yourself e Remove the screw at the bottom of the trim ring and pry off the ring with a flat screwdriver Change the vertical horizontal orientation wit
49. subframe over the nose of the differential Loosely bolt the top of the subframe to the top of the differential with 4 USS x 1 L bolts flat washers and lock washers SECTION B PARTS PREPARATION CONTROL ARMS Install a male right hand thread rod end onto each front lower radius arm so that the bushing center to rod end center distance is 16 Leave the jam nuts loose Install the steel brake lines onto the subframe Install the front lower radius arms onto the lower differential bracket as shown leaving the inner bolt loose Install the coil over damper onto the upper mount using a x 2 L bolt with flat washers and stover nut Install the coil over onto the lower arm Turn the assembly upside down Install the bottom spacers too tightening the top and bottom bolts section of the subframe by inserting the rear ears just in front of the rear flanges of the top Rotate down in the front to match the front holes and loosely attach the front with USS x hex cap screws and flat washers Align the rear flanges of the upper and lower sections with the lower radius arm bolts Insert the is USS x bolts flat washers on both sides and secure with stover nuts Use Grade 5 torque specs on page 138 for all fasteners Loosely fasten the bottom of the subframe to the differential using USS x 1 bolts flat and lock washers Shims may be necessary between the channel and the casting
50. the battery support and through the holes in the corner bracket Secure with lock nuts and washers STEERING COLUMN AND WHEEL Before the Triumph steering column is installed check that the signal canceling cam on the steering column shaft is oriented correctly See page 44 The steering wheel center cap see page 105 is installed after final suspension alignment Lower steering column installation is described on page 104 Prepare the triumph steering column as described on page 44 The steering wheel center cap see page 105 is installed after final suspension alignment SECTION G BODY II ASSEMBLY Bolt the steering wheel to the hub The pattern is asymetric the parts will only fit one way With the road wheels straight install the hub on the column with the washer and nut Torque the nut to 25 Ib ft only after the suspension is aligned and the steering wheel position is determined to be correct Move the steering column in or out relative to the housing until there is clearance between the bottom of the hub and the top of the column housing or signal switch E R A column Tighten all the clamp bolts Mount the signal flasher relay onto the bottom of the column mounting bracket as show above Connect the steering column wiring horn signal lights headlight dimmer as shown in the wiring instructions Secure loose wires with cable ties or tape STEERING WHEEL REMOVAL Carefully pry off
51. the center cap and remove the nut and washer Insert the upper column and housing through the hole in the dashboard engaging the lower column as the upper one is slid in While keeping rearward pressure on the steering wheel hub strike the end of the steering column forward with a brass or lead hammer Be carefull not to damage the threads If that does not disengage the taper use a steering wheel puller CENTER CAP The optional cap is held in place with 3 clips Be very careful not to scratch the back surface of the cap It will show on the outside SHIFT LEVER The shift lever boot and chromed trim ring are provided in the kit A Mustang shift lever can be adapted to most transmission to duplicate the original look Inquire Hold the clamp halves of the upper column around the column oriented as shown and slide the clamps together back into the mounting bracket Insert the cross bolts as shown below The shift lever may be mounted in several different locations depending on your transmission If your Top loader mounting matches the diagram on page 15 or you have a Richmond Gear 5 speed E R A makes adapters to move the linkage to the proper position With the driver s seat correctly positioned in relationship to the pedals slide the steering column and housing in or out to suit your driving position Adjust the height of the column to your preference and tighten the cross bolts Align the flat of the lower c
52. the crankshaft commutator for excess wear and arcing and the lower bearing Clean the parts with a solvent if necessary Work the brushes in and out to insure free motion Install the plastic gear onto the crankshaft engaging the tangs of the gear into the crankshaft notches Note that the plastic cam lobe is opposite the crankpin Install the armature carefully into the gear housing until it contacts the sides of the brushes Using a hook shaped wire or other appropriate tool retract each brush in turn so that the commutator can slide past the edges of both brushes and continue into the gear case 46 SECTION B PARTS PREPARATION fia man b wip gear Grease the shaft lightly install the conical thrust washer and insert it into the housing Install the outer thrust washer and circlip Trim the cable so that it measures 38 from crankpin hole to the end Since the wire material is very hard it must be done with an abrasive wheel or bolt cutter Partially fill the gear housing with grease and place the cable into the guide Some guides are integral others have separate plastic liners Install the connecting rod with its thrust washers and the connecting rod circlip Install the cover plate with 4 screws Instructions for wiper installation are on page 97 47 SECTION B PARTS PREPARATION DAMPERS AND SPRINGS Don t panic if the car seems too high when first lowered to the floor The car will se
53. windshield Keep adjusting the fabric at the rear and front of car until the top is smooth and sag free Beginning at the center carefully un tape a portion of the top fabric from the windshield Glue a portion of the top fabric to the front vertical face of the channel with contact cement Do not apply the glue to the top of the front bow only to the front surface Work from the center to the sides until the entire top surface is glued Remove both front bows and wrap the front of the fabric around inside the channel leaving 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 Attach the latch hooks to the windshield frame using the hardware provided See the diagram below Determine where the latches must be installed on the front channel to provide proper tension on the front channel when installed with foam rubber between the channel and top frame Mark the holes for the latches on the fabric of the front channel then remove the channels from the car to drill the holes for the rivets Rivet the latches to the front channel Remove the remainder of the mandrel from the rivets and peen the backside of the rivet as flat as possible Glue the extra flap of material on the top over the exposed rivets on the backside of the front channel SECTION G BODY II Glue thick foam st
54. you install the wiper wheelboxes mock up will go the assembly off the car to check whether the cable e Trim most of the old upper and lower bushing properly engages the drive gear Tighten the cover nubs off with a razor or utility knife Work against the guide tubes If the fit is too loose or too the lower bushing out with a screwdriver by tight bend the guide above the gear up or down as pushing in and down on the locking nubs in necessary There are two typical designs that are the side of the housing currently available e Remove the column from the housing The shaft end play of the second design can be e Using a dowel just small enough to fit inside adjusted by bending the tang on the cover the housing drive the upper bushing out through the upper end of the column from the bottom e Replace the upper bushing using the drift you used for removal Lubricate the outside of the bushing with silicon waterless hand soap etc before pushing into place 44 SECTION B PARTS PREPARATION Insert the wiper wheelboxes up through the holes in the cowl with the cable guides down and forward It may be necessary to cut about from the drive spindle spacer sleeve to compensate for the extra thickness of the fiberglass body Install the gaskets bezels and nuts but don t tighten the retaining nuts Loosen the nuts holding the cable retaining plates to the wheelboxes From the engine side of the firewall push the tube
55. 48 49 50 51 54 55 56 56 56 57 58 58 60 60 60 61 61 62 62 65 65 SECTION E CHASSIS ASSEMBLY Lights 3 3 Q0 5 1303w l2 66 License plate light 113 Brakeandfuellines 68 Back up light Optiona 1 114 Batterycables_ 68 Mirrors 114 SECTION F MECHANICAL Grab handle ________________116 COMPONENTS 70 Top anap S 0 Rear suspension Jaguar 75 Door trim 14146 Rear suspension E R A FIA ONLY 77 Emblems A1 30 1i6 Drive shaft 78 Licenseplat s A 117 Voltage Regulator 79 Heat Suede e Engine and transmission installation 80 top 120 Lower steering column 83 Side curtains 1 12 Wiring harness layout 85 Fitting the tonneau cover 122 Interior panels 86 SECTION H FINAL OPERATIONS Rolbar 92 123 Radiator fans 92 Install wiperrarms 124 Oil cooler optional 1 93 Brake Hydraulics 125 Fuel Tank 96 Jackingthecar 126 Fuel Tank 96 Bolt on wheel notes __ 126 Fuel FillerCap o Pin drive wheel notes 126 Windshield Wipers __9 Suspension adjustments 127 Windshield Washer 98 Brake balance adjustment 130 Windwings and sunvisors 99 Add Fluids Heater Defroster 100 cooingsystem 1 1 131 Windshield 101 Headlight adjustment 133 Dashboard 102 FinalChecks J 133 Speedometer Cable and others 103 Your Fir
56. ASSEMBLY AND SERVICE MANUAL FOR THE E R A 289FIA USRRC Chassis 2126 on and 289 Slabside Chassis 3001 on Revision 5G 4 2013 Era Replica Automobiles 2013 The Manual The text and layout of this manual was done with Word for Windows Some of the illustrations were hand drawn and scanned some were done in DesignCad 2D and 3D Spelling errors are the fault of the spel chekker NOTE ON MANUAL UPDATES This manual was current at the time of your car s delivery Any critical corrections will be mailed to you If we can think of any thing that can be helpful but are non critical I will post them on the internet at http www erareplicas com fiaman The latest entire manual in PDF format is posted on the internet Please e mail us for the location Thanks Bob Putnam ERA E Mail eracars sbcglobal net Parts inquiries to eraparts sbcglobal net The Legal Stuff Information in this manual is correct to the fullest extent of our abilities Era Replica Automobiles assumes no liability for any direct indirect incidental or consequential damage resulting from the information within Contents This manual is arranged by assembly sequence not topic For information on a specific topic assembly or service see the index at the end NOTE ON MANUAL UPDATES read me first SECTION A PARTS NEEDED Picking up your kit special notes Engine Alternator Clutch Notes Oil Cooler and oi
57. EATING temperature 180 F min use the dash manual over ride switch to manually turn the radiator fan on The temperature should stabilize somewhat under 210 F depending on your ambient Use 165 F 180 F thermostat for street use temperature Shut the over ride switch off and allow Leaving the thermostat out will cause overheating the fan to come on automatically This should Remember that the boiling point of a water anti freeze happen about 200 F 210 F If the fan does not mixture with a 15 psi cap is over 230 F It is not harmful and normal for the water temperature to rise to 210 F 220 F with the car not moving Also see the web supplement information at http www erareplicas com fiaman index htm start even at 220 F check the electrical circuits involved Once the temperature drops the fan will AT SPEED automatically cycle off The fan will run even with The E R A 289FIA uses an oversized radiator d ees aff Dot yall normally RE b anos Overheating at speed is almost always the result of 2 This Neuen D Breyent osos tis mechanical failure of the water pump or incorrect engine settings usually retarded ignition timing Check your dynamic timing at idle and 3000 3500rpm or as recommended by your engine builder If you are using significant lengths of hose in the connection from the radiator to the water pump intake make sure that the hose has an internal
58. Flex Bearing shaft clutch pedal Thrust washer Bearing balance bar eim LSS 8 Clutch master cylinder Ce or They Clutch slave cylinder 20 5mm 8 1 SUSPENSION FRONT The upper and lower ball joints are from 73 88 Chevelle 70 96 Camaro and 77 85 Impala 74 875 72 76 2002 BMW 21521104269 135 SECTION REFERENCE TRAILING ARM REAR Front Bushing sleeve set Energy Suspension 9 9105GX SUSPENSION REAR JAGUAR Inner pivot bearing Tor B146 Eoo Outer fulcrum bearing Timken 03062 03162 Porc nd m NE Seal inner fulcrum Jaguar C17168 Seal outer fulcrum National 471652 Bearing inner hub Timken 18620 18690 Bearing outer hub Timken 18520 18590 Beck Arnley 052 0221 Hub seal outer Beck Arnley 052 0643 large Sway bar link Republic SL18050 clamp and bushing Suspension Techniques PA 75 Spicer 5 160X Subframe pivot bush Moog 8169 or Republic 12292 Pinion seal most Jag AAU3381A SUSPENSION REAR OUTBOARD BRAKES Outer fulcrum bearing Timken 03062 03162 HML 8 Lower rad rod F inr HMR 8 Lower trailing arm F Energy Susp 9 9105 Lower trailing arm Rr Subframe top mt Same as Jaguar 1 Ee e BEARINGS SEALS All from 1976 Jag XJ Bearing inner hub imken 18520 18590 eck Arnley 052 0221 eck Arnley 052 0643 Sway bar link epublic SL18050 clamp and bushing Suspension Techniques PA 75 Spicer 5 160X Subframe pivot bu
59. Hwy Clinton Twp MI 48036 810 468 1356 P O Box 19449 Indianapolis IN 46219 317 357 8767 32413 Park Lane Garden City MI 48135 888 729 9070 185 Adams St Manchester CT 06040 800 243 7278 See web site 2675 Skypark Dr 102 Torrance CA 90506 310 534 4477 12351 Universal Dr Taylor MI 48180 800 522 2707 1208 Old Norris Rd Liberty SC 29657 864 843 9231 300 Van Dorn PO Box 81906 Lincoln NE 402 323 3200 580 Kennedy Rd Akron OH 44305 800 230 3030 3933 Foothill Blvd La Cresenta CA 91011 818 248 7446 40 Industrial Park Place Powell OH 43026 800 388 8783 26 SECTION A PARTS NEEDED TOOLS NEEDED Most of the tools required for assembly of the E R A 289FIA are found in the average car person s home workshop Major components like the engine and transmission require some specialized tools and skills If you are not experienced this may not be a good time for your first project Rebuilding the Jag rear suspension assembly can be done at home if you are well equipped A micrometer dial indicator and standard mechanics tools are required No matter what your experience this operation requires a good manual Items marked with an are not needed if you ordered the bond body option We can also cut the side pipe hole for you at the factory Socket wrench and sockets Open end and box wrenches 1 Screwdrivers Phillips and flat bladed 3 or 4 sizes of each Jack preferably a hy
60. If you are going to Remove the large access panel at the front of the remove the cap and outside flange or extension trunk and the small filler on the right side from the tank mark the inside of the flange so that Remove the rear wheels and the access panels it can be assembled with the same orientation to the behind them on the inside splash panels tank Remove the inside cap Unscrew the cap with ring from its mounting flange The threads are coated with anti seize grease If you have to remove the coating it must be replaced before reassembly Without it the parts may gall together permanently 96 SECTION G BODY II INSTALLATION i fia nan e fuelfill SLABSIDE Slabside filler cap See page 53 WINDSHIELD WIPERS Prepare the wiper motor and other components as described on page 47 INSTALLATION Insert the wiper wheelboxes up through the holes in the cowl with the cable guides down and forward It may be necessary to cut about from the drive spindle spacer sleeve to compensate for the extra thickness of the fiberglass body Install the gaskets bezels and nuts but don t tighten the retaining nuts e wheelbx Loosen the nuts holding the cable retaining plates to the wheelboxes From the engine side of the firewall push the tube from the wiper motor to the right wheelbox through the grommet 97 I G wipmt SECTION G BODY II Fit the cable tubes to the wheelboxes so that the WI
61. KES HUB AND ROTOR MOUNTING GM BRAKES aNhubasb Mifz2 8if GM FRONT CALIPER ASSEMBLY More installation details are posted at erareplicas com 427man under GM pad replacement The rotors are directional and must be mounted x on the correct side GENERAL INSTALLATION Replacement parts are listed on page 135 Pin drive If the rotor is not already installed on the pin drive hub torque the drive pins to 35 Ib ft with high strength thread locking compound i e Locktite red and the nuts to 35 Ib ft Note that the pad tabs must be bent to make the pads a tight fit on the bridge 72 SECTION F MECHANICAL COMPONENTS COIL OVER DAMPER If you ever need to remove the pins they will have to be heated to 300 deg to weaken the bond Excessive See page 71 Spacers for the lower mounts are heat will weaken the pins provided with the dampers Orient the damping screw adjuster toward the centerline of the car Use Always grind the rotor after installing the wheel a washer on either side of the top mount Secure bearing races If you don t have a special driver for the top with a 2 long bolt in from the back A 2 the races let the auto machine shop install them bolt is supplied for the bottom attachment Note that replacement rotors for the GM Again slide the bolt in from the back brakes pin drive combination require additional attention remove the ridge at the base of the outside face of the rotor as sh
62. NDSHIELD WASHER flared ends of the cable tubes lock into the slots on the wheelbox housing and back plates Leave the The optional windshield washer uses a manual retaining plates slightly loose so that the tube pump like the original Cobra If ordered with the orientation may be adjusted The short tube on the kit the fluid container and the pump unit are left gearbox is to support the surplus cable outside installed at the factory If you are retrofitting your the left wheelbox car see below for the fluid container and pump If necessary gently bend the tubes to create a mounting locations continuous curve from the motor through each wheelbox Be careful not to kink the tubes Check by sliding the drive cable through each tube after bending Loosely attach the nut on the right cable to the wiper motor See the illustration on page 45 fiat man e wiper2 Coat the wiper drive cable with lithium grease and slide the wiper drive cable into the tube Secure the wiper motor in the receptacle with the clamp and insulators provided Tighten all the wheelbox nuts and the tube nut to Washer the motor Fit the fluid container bracket to the right side of Install the wiring harness plug the firewall as shown Mount the washer jets into the predrilled holes on the cowl jet noses aimed toward the right If you are retrofitting it may be necessary to grind the underside of the body for thread clearance Don t install the wiper arms to t
63. RONT The car can also be jacked up on the lower control arms at the ball joint be careful not to damage the grease fitting or the front crossmember as shown The jack will barely fit by going in diagonally just in front of a front wheel avoiding the oil cooler scoop HNjack REAR Jack up by the differential or the crossmember just in front of the differential The Jaguar suspension can be jacked on the outer end of the control arm or the hub carrier the ERA suspension just under the hub carrier 137 SECTION REFERENCE CAPACITIES LUBRICANTS Brakes Use DOT 3 DOT 4 or DOT 5 1 fluid for both the brake and clutch systems We use ATE 200 ATE Blue or Castrol LMA in our rollers Silicone based fluid is not recommended Cooling system capacity 3 5 4 gallons For optimum cooling it s best to use the smallest proportion of aluminum compatible 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 FREEZING POINTS FOR GLYCOL BY VOLUME Dampers Cover the lower Rose joint spherical bearing with silicone or other heavy grease If the car is laid up for long periods put some silicone grease on the shaft so that the shaft seal doesn t dry out Engine Oil Ask your engine builder for viscosity recommendations e 289 302 engine with Canton pan 6 qts e W oil cooler 6 5 qts e Add for remote
64. RTS PREPARATION Mount the brass junction block on the left front of the cage with the fitting for the flex hose up If your rear suspension core has the junction block pointing forward fabricate a small bracket from JAGUAR LOWER CONTROL ARM LAYOUT AND PARTS Jaguar OEM part numbers ASSEMBLY The description below is a supplement to the Jaguar manual not a substitute Refer to the Jaguar instructions for a detailed breakdown of the assembly sequence and parts Call ERA for the complete manual available as a PDF For hints on assembling the Jaguar hub carriers except for the lower pivot see page 38 Do NOT replace the control arm roller and needle bearings with aftermarket urethane bushings The net result will be wheel hop and generally sloppy handling Because we use a subframe there is no comfort advantage to soft bushings either JAGUAR ERA SUSPENSION SUBFRAME Build the differential installing the brake rotors and calipers Note If you are using the competition 12 vented rotors and aluminum calipers the rotor and caliper must be installed after the differential is installed in the subframe Support the subframe upside down on short pieces of 2x3 wood etc with the differential mounting plate down Find the brake junction mounting tab on the front of the subframe See above and on page 75 Insert the differential unit into the subframe without the lower control arm brackets Fasten the differential
65. UMN e Slide the column back in place e Replace the lower bushing e Replace the horn plate if necessary Cancelling cam Before the Triumph steering column can be permanently installed check that the signal canceling cam on the steering column shaft points toward the left when mated with the steering gear and middle column Normally the cam will be oriented correctly if the flat on the column where it mates to the intermediate column is up INstcoltri Remove the ignition switch column lock Two bolts hold the ignition switch unit onto the column but their heads automatically snap off in assembly for theft proofing They now look like large pins or dowels Use a prick punch and small hammer to turn the bolts out or cut a slot in them and use a screwdriver Replace the bushings if there is any side play in the housing The column bushings are plastic in a steel and rubber collar that have 2 nubs that lock into holes in the column housing e Remove the horn plate located inside the switch hub housing by straightening the two b canclcam metal tabs holding it in place The plate may be discarded if you are going to use the dash WINDSHIELD WIPERS mounted horn button Prepare the wiper motor and other components as e Remove the nylon washer and aluminum cap described on page 46 from the lower end of the column housing e Slide the column up and out of the upper INSTALLATION steering wheel end of the housing as far as it Before
66. adjustment 48 37 49 Starter 33 Stay Hood See Hood stay Steering column Bushing R amp R 43 Cancelling Cam 44 Installation upper 104 LOWE ertet 83 16 24 Preparation Triumph 44 Steering gear Installation 74 Part number 24 43 Steering 1 71 Steering wheel Center 105 Installation 105 eee 17 24 Stover 67 138 Striker Hood See Hood striker SITIES cosi qe 63 Subframe Rear suspension 16 Supplies and materials 25 Suspension Ftont uem 71 Alignment 128 Part numbers 135 REAT 5essoscenoem mee 23 ERA 144 Assembly 39 eed 38 Trailing arms TI Hub Carrier i reenen nenas 38 Jaguar Anti sway bar 76 Assembly 36 Disassembly 35 Installation 76 Lower control arm parts iate each dei 36 Trailing arms 37 1 15 Tuning rere 127 Sway bat eese Tank Euel seh 96 Thermostat 9 34 132
67. al fit each curtain to the door If the pins do not match the sockets it may be necessary to tweak the pins and or elongate the fiberglass holes in the door so that the body ferrules can shift slightly If the pins are not parallel to each other bend them with pliers etc Just because you can start the pin in the ferrule does t mean it won t bind further down If straightening the pins doesn t solve the problem Remove the center ferrule after removing the circlip at the bottom 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 to match the front and rear pin locations Don t make the holes uniformly larger in diameter Oval them in line with the other pins so that the curtain frame will not rock from side to side Once the pins fit in the outside ferrules repeat the process for the center one Replace the circlips Install each side curtain on the door and close the door carefully If the side tilt of the curtain does not match the side of the windshield frame carefully bend the curtain in or out as necessary Trimming the front edge The top corner of the Plexiglas may have to be matched to the windshield frame Peal the fabric back from the frame as necessary and trim the sides with a hacksaw To prevent scratching mask off the Plexiglas Saw the excess material from the top edge of the fram
68. and bearings measure the size of the outer wheel bearings Your rotor and bearings must be compatible with the smaller more common diameter 655 at the axle outer end The wagons used a 750 diameter axle WITH 6 PIN DRIVE WHEELS The E R A pin drive wheel conversion includes the hub and rotor both compatible with the caliper and bearings described for the bolt on wheels above With OPTIONAL COMPETITION BRAKES E R A offers a conversion to 12 18 or 12 8 diameter by 1 wide rotors and Wilwood 4 piston calipers for heavy duty use These require modifications to the steering knuckle The calipers may have interference problems with some wheels Ask about specific wheels The 12 8 rotors will only fit in a 16 or larger wheel DRIVE SHAFT E R A has driveshafts for most applications in stock This is a project for a shop specializing in power transmission equipment or shafting See page 42 for design details PDF drawings are available for each application are available on the 427man section of the ERA web site STEERING COLUMN UPPER You may use a Triumph unit see page 44 as described below or the custom E R A reproduction column The E R A column includes a new hub and signal dimmer switch and requires no preparation TRIUMPH COLUMN Sourced from Spitfire or GT 6 vintage 1972 to mid 1977 Get the upper column and housing upper and lower clamps and both switches See page 44 for preparation
69. and rebuilding of the Triumph column SECTION A PARTS NEEDED STEERING WHEEL The original Cobra used a 16 laminated wood rimmed aluminum steering wheel We have found that a slightly dished 15 wheel allows more knuckle room between the wheel and the cowl E R A offers both diameters in a reproduction of the original wheel A hub center button with either a AC or Cobra logo is also available If you are using a Triumph column you also need to adapt the Triumph hub to the reproduction wheel SEAT BELTS E R A offers custom competition belts identical to the awhlbox CHECKING THE CABLE GEAR WHEELBOX Standard seat belts can be installed in the threaded CLEARANCE chassis bosses shown on page 110 original cars Inquire Before you install the wheelboxes it s a good idea to check that the cable engages the gear properly Unfortunately the quality of the wheelboxes has not been consistent lately Make sure that the tubes line up properly with the gear so that there is no binding WIPER MOTOR AND COMPONENTS and that the cable is held close to the gear but not so close to make excessive drag Modified and rebuilt wiper motors and hardware are available from E R A The best wiper components are found in the 1969 1976 Triumph Spitfire GT 6 or TR 6 Get the entire set up including wiper motor wheel boxes spacers gaskets chrome bezels and the connecting tube between the wiper motor and right wheel box See the
70. asting at the lower right corner of the cover The top number indicates the year the bottom number is a special code Translation we don t know what it s used for A simple way to determine whether a post 1980 unit will work is the presents of inboard brakes The later inappropriate assemblies have brakes mounted on the hub carriers When selecting buying a used rear end look for e Completeness You don t need the Jag trailing arms or emergency brake compensator but you do need everything else SECTION A PARTS NEEDED e Limited Slip Differential Note that some XJ differentials were open A limited slip may be retrofitted at the time of rebuild for about 700 e Brakes Try to get serviceable hydraulic and emergency brakes There were no major changes in XKE rear brake until 1968 when both the calipers and rotors were updated The later units are cheaper and easier to 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 or brake disc for reference and rotate the axles by turning the input shaft For every time the axles and brake disc turns over once the input flange should rotate approximately 3 turns 3 31 1 ratio or 3 times 3 54 1 ratio See the chart on page 13 for the best ratio for your engine transmission combination If you can t find a unit wi
71. atch for shiny spots File these spots being careful to hold the file flat Recheck fit and repeat the process if necessary SECTION G BODY II FRESH AIR CABLES The cables must be installed after the dash is installed g ebtrim1 fiatiman e vent Re bolt the hand brake lever in place LEFT Fold the outer flap of the cover over the lever and Lubricate the rubber grommet located midway up attach to the inner flap with the Velcro and snap the front of the driver s footbox on the left hand side with silicone spray or petroleum jelly Push the cable through the grommet and install the cable loop on the fresh air control valve as shown on page 59 Attach the cable to the side of the footbox with a cable clamp RIGHT Insert the cable through the grommet in the upper right front of the footbox Attach the cable to the vent like the left footbox HAND BRAKE LEVER COVER Using the figure below as a guide open up the hand brake lever cover and align the cut out section on the inside flap around the hole in the transmission tunnel behind the lever bunching it up as necessary in the center Attach the front edge of the boot by drilling holes through the fabric into the tunnel g ebtrim2 Release the lever to the full down position fold and tuck in the rear edges of the cover as shown Fit the cover up against the tunnel drill through into the tunnel through the holes in the cover and attach with the trim screws Whe
72. aulking used to mount the body Pay particular attention to the rear closing panels where they overlap onto the upper trunk panel and the junction at the upper front corner of these panels Section D Body Chassis assembly If you wish to rust proof the inside of the chassis main rails drill holes in the bottom of the chassis at the front and rear of the bottom rails You may then spray a wax type material into the chassis even up above the rear suspension Close the holes with plastic or metal plugs FRESH AIR HOSES Carefully feed the fresh air duct hoses through the holes in the back panel of the front inner wheelhouse panels Attach to the footbox valves as shown below d freshair Secure each hose to the adapter with clamps as shown The rear clamps have speed nuts and are fastened from inside the engine compartment Connect to the vent valve as shown on page 109 BODY PREPARATION 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 is not much different than steel but it does require the same special skills If you have no previous experience it s probably better to have a professional body shop do the work While E R A doesn t do the exterior painting in house we have found very reliable and competent local companies that do all our turn key cars at a fair price In
73. ave adjustable spring collar shocks the rear collar by X thereby height can be adjusted to taste E R A recommends compressing the spring that the main chassis rails be raked about to more the chassis height from front to back will change by roughly 1 5 x X In other words to raise the ride height by 1 move the spring collar up by Rear with Jag For small changes you can adjust only one spring per side The ride height will change roughly 2 the collar change For larger changes change all four of the collar positions equally The ride height will then change roughly equal to the collar height change 127 SECTIONH FINAL OPERATIONS ALIGNMENT FRONT Note Some automated alignment machines require a specific car to tell the operator how to move shims The closest production car is the 73 76 Chevrolet Monte Carlo See pages 71 75 for suspension assembly The chassis height should be within the specifications given above Inquire for recommended starting settings for all out track work Camber 0 deg We ve included 12 shims with the kit which when distributed equally usually results in the approximate correct camber Adding a shim between each bracket and the chassis will increase camber by approximately deg Use standard 1975 Chevrolet Camaro shims or their equivalent All ball joints outer tie rod ends and wheel bearings are Chevrolet The upper contr
74. back when we ve figured this out 34 SECTION B PARTS PREPARATION Right exit water pump UPPER 4 bbl and single outlet Weber manifold FOR 4BBL MANIFOLD ALUMINUM CONNECTOR TO THERMOSTAT HOUSING 70 je e along oute C THERE CUT HERE Use a short neck thermostat housing 20 up on the intake manifold Cut and trim the hose as shown 35 Weber Manifold two outlets Use a drilled freeze plug in the upper hose to restrict flow fia man b uwathose2 SMALL HOSES If you are not using a heater connect the water pump inlet to the expansion tank REAR SUSPENSION JAGUAR DISASSEMBLY Components must be thoroughly checked and rebuilt if necessary brake calipers emergency brake pads and linkage universal joints on half shafts hub carrier and lower control arm bearings Bearings etc are listed on page 135 We have found that the Spicer U joints listed are the only brand that meets the standards required of the Jaguar half shafts and we ve tried quite a few Replace any corroded or damaged brake lines Be sure to use lines with the proper end flare and fittings Note that some British fittings have a convex bubble flare that mates with a concave receptacle in the caliper While this is similar to some metric fittings the threads are SAE It is not possible to make these flares with a conventional flaring tool Aftermarket suppliers and Jaguar dealers have these British style lines SECTION B PA
75. braked design Rebuilding Parts for rear Bearings brake parts etc see page 135 SICP E R A Jag Dealer suspension Coil over dampers See length specifications on page 48 Standard XKE W O height Spax S 200 415 Externally adjustable damping E R A Jag rear adjustment Height adjustable Spax G640 S200 E R A Coil Spring 4 rqd std Spax 10 x 350 Ibs in E R A Carrera Dillon Spax with height adjustment 8 x 350 Ibs in AFFCO Eibach ERA Desgign Damper Lu G452 AS200 See specs on page 37 Spring gt x 2 25 ID x 400 Ibs in DifferentiaVLSD rebuilding various ratios of Dana 44 gears Reider Racing Michigan Driveline es i i d idi only Speedo cable drive See notes on page 12 and 14 for gears E R A dealer auto parts Richmond Gear Cable Champ 400020 Adapter GM 345212 store Ring 7 OD ID Retainer 3708148 Drive gear GM 39879XX where XX number of teeth Speedo cable drive gears etc See calculation and part numberss on 14 E R A Dan Williams Top Loader T 5 Tremec Cable AC 11589234 67 Mustang Speedo drive gear C4DZ 17285A LH 7 tooth black Ford dealer C8AZ 17285A RH 7 tooth yellow Speedo driven gears See page 14 Retaining clip CIDZ 17292A 23 SECTION A PARTS NEEDED Steering gear Flaming River 1502 3X3 Must be modified See page 43 Flaming River E R A for modified gear Mounting bushings for above Flaming River FR1600 or Energy Suspension
76. can be done as shown below Apply masking tape to the body lip along the inside rear edges as shown If the body is already painted use tape all around the inside of the opening to prevent damage while fitting Locate the lower holes by trial fitting the grill in the body hole Insert the grill past the likely mounting location and hold in the center of the body opening Mark the pin locations onto the lower pieces of tape as a line projected directly forward Check that the center to center distance between the holes in the body matches the pin spacing on the grill Measure back from the front edge of the body opening 134 and mark where that dimension intersects with the pin line Check again because that s where you re going to drill into the body Use a small pilot drill and then finish with a 1 3 drill bit Drill straight down first and then tilt the drill back about 20 degrees to make a tapered hole Typically the holes will fall about 1 2 from the lip edge 111 Install the grill lower pins into the holes and rotate the top forward so that the top mount goes under the top body lip You will have to push the grill down agains the rubber cushions to do this Once in place adjust the tilt of the grill to the top distance shown and drill two or 30 holes for the top 48 screws Remove the tape and install permanently BUMPERS JACK PADS The bumpers or jackpads are factory fit and installed The aluminum spacer
77. comes close The TKO 600 shifter can be moved forward from the stock for better positioning TKO 500 600 Some Tremec transmissions require an aluminum adapter between the transmission and the mount In addition many people prefer to use a concentric throwout bearing with the Tremec If you do McLeod and ERA recommends that you remove any centrifigul weights from the clutch pressure plate 30 SECTION B PARTS PREPARATION TKO STANDARD INPUT INSTALLATION Note that the transmission mounting boss is metric threaded 10 x 1 5 on the inner holes 12 13 on the outer holes Install the spacer between the mount and the mounting boss The offset standard length input shaft goes toward the rear TKO 3550 with spacer The 500 and 600 with standard long input do not use the spacer Instead shims are used between the mount and the chassis Some of the GM style mounts may require some trimming on the passenger s side back edge to clear the X member 31 SHORT INPUT MOUNT MODIFICATIONS AND INSTALLATION Elongate the holes as shown above The mount is installed onto the transmission with washers as shown below Note that the hole elongation is toward the front CLUTCH THROW OUT FORK We recommend that you use the fork listed on page 24 for all bellhousings Call us for special instructions for the T 5 See the bell housing notes following The standard Ford fork see page 24 for part number sh
78. d on page 131 EVERY GASOLINE FILL UP Check transmission oil Check engine oil and water Grease rear axle and driveshaft universal joints FIRST 1000 MILES Grease the inner and outer pivots on the rear lower Check the tightness on all chassis bolts control arm EVERY 3000 MILES Grease front upper and lower ball joints and outer tie rod ends Change engine oil and filter Check rear brakes EVERY 24 MONTHS OR 2 YEARS Change antifreeze EVERY 24 MONTHS OR 2 YEARS Change brake fluid See page Check engine drive belts for wear and tension Adjust clutch play if using a return spring EVERY 6000 MILES Inspect front brakes EVERY 12 000 MILES FUSES Radiator fan heater Horns lighter Wipers Voltage regulator Fan relay Signal lights Brake backup lights Fuel pump Parking panel lights Headlights high beams FUSE BLOCKS VIEWED FROM FRONT 8 Headlights low beams See the wiring instructions for any wire color changes DA dx There are also two fast blow 4A fuses under the steering column that protect the rear signal brake lights individually 134 REFERENCE MAINTENANCE PARTS All pieces listed below are included in the kit but are listed here for reference and long term replacement SECTION REFERENCE Part numbers listed are typical but equivalent brands may be substituted unless otherwise stated Fluids and capacities are listed on page 131
79. d rake to match the front edge of the curtains e windshld WITH SIDE CURTAINS See curtain installation on page 122 Angle the windshield back so that the front edge of the side curtains slip inside the windshield posts and are parallel with the windshield See the illustration on page 101 Tighten the outside mounting bolts and fasten the center bracket with two 8 self tapping screws 101 SECTION G BODY II DASHBOARD e dashlay If you are using the rotary street wiper switch Attach the optional windshield washer tubing to install the wiper relay on the firewall before the the pump Hold the dashboard in place on the body dash and loosely thread in the mounting screws and trim washers Don t install the extreme right hand screw and leave the rest of the screws loose so that the glovebox can be installed GAUGE HOSES Pass the lines through the holes as shown on page 85 Run the oil pressure line along the left side of the engine compartment with the wiring harness and down along the corner of the wheel well The dashboard wiring connections can be done off Connect to the block just in front of the oil filter the car with the dashboard resting face down on boss If the original extension is still there the something soft Follow the separate wiring plastic line can be attached there Otherwise run instructions for individual connections the plastic line right to the block Some race clubs require me
80. draulic floor type Caulking gun cartridge type Small needle nose pliers Engine hoist or chain fall Pop rivet gun with adapters for rivets Electric drill with bit assortment Utility razor knife Paintbrush 1 1 5 buy a cheap natural bristle brush Shears or large scissors Rubber mallet Saber saw if you are fitting side pipes Socket head Allen wrenches Jack stands 4 SHIPPING COMPANIES PARTIAL LIST Horseless Carriage Phone 800 631 7796 27 Intercity Lines our preffered shipper Phone 800 343 0802 Fax 413 436 9422 SECTION B PARTS PREPARATION SECTION B PARTS PREPARATION Restrictions or modifications to the donor parts for the 289FIA and ERA Slabside This section does not cover engine transmission or rear suspension rebuilding Use dedicated rebuilding manuals for your specific equipment 28 SECTION B PARTS PREPARATION ALTERNATOR MOUNTING ENGINE COMPONENTS Serpentine belt engines must change to the following components 1 980 lower pulley modify by removing the outside groove Because of the likely variation of your components we obviously cannot give engine rebuilding instructions here What follows are the E R A specific requirements for your engine General torque specifications for typical fasteners are found on page 138 Good reference books for Ford engines are listed on page 140 1980 upper pulley 1979 water pump The alternator pivo
81. dtoploaders com Ford Motorsport Performance Equipment Genesis Performance genesis427 com March Performance Pulleys marchperformance com Mustangs Unlimited mustangsunlimited com National Parts Depot npdlink com PS Engineering Reider Racing reiderracing com Richmond Gear richmondgear com Speedway Motors speedwaymotors com Summit Racing Equipment summitracing com Trigo Inc trigowheels com TrueChoice truechoice com SPECIALTY Speedo reducers angle drives Oil pans and pickups Ford parts Oil pans and pickups Coil Over shocks Springs Engines parts Reproduction Cobra hardware Transmissions and shifter parts Top Loader transmissions parts Ford parts Engines and parts Engine pulleys Shelby Mustang parts Ford parts Pin drive wheels Jag differential rebuilding 5 speed transmissions Misc parts at low prices Misc parts at low prices Pin drive wheels Racing parts fire extinguisher systems ADDRESS 235 E O Connor Drive Elkhorn WI 53121 800 683 500 10041 Canoga Ave Chatsworth CA 818 988 899 1434 Pleasant Valley Blvd Altoona PA 16602 814 942 1869 9 Tipping La Branford CT 06405 203 481 9460 5412 New Peach tree Road Atlanta GA 30341 770 451 8811 19021 S Figueroa St Gardena CA 90248 310 538 2914 3099 Carter Circle Kennesaw GA 30144 770 427 0020 205 E Dogwood Dr Franklin NC 828 524 9085 San Antonio TX 210 967 4161 44050 N Groesbeck
82. e way in at the top and tighten the jam nuts Connect the brake flex line to the bracket on the chassis HANDBRAKE Bolt the handbrake lever to the bracket on the chassis with s USS bolts and lock washers ERA COMPENSATOR Attach the other end of the cable to the compensator lever on the suspension cage as shown above Slip the cable into slot in the block attached to the lower lever of the compensator Screw the threaded end of the cable into the hole in the block Attach the bracket on the cable end to the other lever of the compensator Do not tighten the lock nut 76 e Secure the cable to the outside of the driveshaft hoop with a tie wrap Adjustment Fully release the handbrake lever Adjust the cable length by screwing the threaded end into the block to a point just short of where the handbrake operating levers on the calipers begin to move Check the adjustment by pressing each operating lever at the same time towards the calipers While doing this observe the levers of the compensator on the cage if they move noticeably then the cable is too tight To prevent binding some slack should be obvious Check that the cable will not come in contact with the driveshaft at any time ANTI SWAY BAR JAGUAR SUSPENSION The rear anti sway bar mounts on the extensions of the rear crossmember just in front of the rear subframe d rswayb The chassis is threaded for USS bolts If you m
83. e and bend down to match the sides The Plexiglas can be shaped to match with a bandsaw or with careful grinding Finish with a sanding block and wet 180 or 220 grit paper Trim and re glue the fabric to the frame FITTING THE TONNEAU COVER Stretch the cover over the snaps Mark and install the snaps as described above for the top SECTION H FINAL OPERATIONS 123 SECTIONH FINAL OPERATIONS INSTALL WIPER ARMS CLUTCH HYDRAULICS Without the arms installed cycle the motor through HOSE INSTALLATION high and low speed When you turn off the switch check to see that the drive posts return to the far right passenger s side position Ir Press the arm onto the post so that the blade falls at the base of the windshield just above the frame See above Check the sweep of the wiper and adjust if necessary Removal Use a screwdriver to pry between the post base and the edge of the arm opposite to the blade INclhose Check the tightness of all fittings before bleeding BLEEDING The car must be level for this operation Fill the brake clutch reservoir with DOT 3 or DOT 4 fluid Silicone fluid is not recommended Attach a small hose to the slave cylinder bleeder nipple emersing the other end of the hose in a small cup of fluid Loosen the nipple about turn with a or 7 mm wrench Work the arm on the clutch pedal shaft instead of pushing on the clutch pedal itself until only clea
84. e balance bar shown on page 37 If you supplied the calipers cut a slot in the cable mount big enough for the cable to fit through Camber fia man d hsaxlflg Bolt the half shaft inner ends and spacer onto each differential output flange If you wish install Jaguar shims with about 060 total thickness between the half shaft and the spacer This will make minor camber adjustments easier after basic alignment has been done Slide the axle into the hub carrier using a small amount of light grease on the splines For competition you might want to use a little shaft and bearing mount on the splines but be aware that ANTI SWAY BAR disassembly requires heat Secure with a flat Install onto the rear of the subframe with is USS washer and castle nut nuts flat and lock washers as illustrated Tighten all the lower hub carrier pivot shaft nuts to 20 Ibft back off 1 of a turn to the nearest cotter pin hole and insert cotter pin Insert any shim washers necessary between the rear flank of the rod ends and the cage bracket Install a flat washer and lock nut Install the caliper using M10 x 30 allen screws and ribbed lock washers Install the upper trailing arm bracket with bolts flat washers and lock nuts so that the bracket angles in toward the front Install the upper trailing arms onto the hub carrier bracket b rerasbmt Install the lower trailing arm onto the lower radius arm with flat washers and lock nut
85. e manifold choices The routing above is necessary when the intake doesn t have a second boss for the tap Otherwise the routing below can be used You should use a valve in the system for either method TO RETROFIT Use the template included with the heater to drill holes in the firewall wiring heat2sp Bolt the heater in place as shown using nylon locking nuts Connect the motor ground wire to the steering column mounting bracket or some other ground Install the water shut off valve in the water outlet of the intake manifold NPT fitting Use Teflon joint compound or tape on the threads 100 SECTION G BODY II Cut the heater hoses to length Connect the lower tube on the heater inlet to the shutoff valve Connect the upper heater tube outlet to the fitting on the water pump Connect the blower motor wire to the dashboard harness as indicated in the wiring instructions See the wiring hints above to use the two speed switch WINDSHIELD Slip 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 tight seal between windshield post and body Lower the windshield into place Replace any shims between the posts and the chassis and install the large flat washers lock washers and bolts If you are going to use side curtains leave the bolts loose to adjust the windshiel
86. e on the optional front grill surround or a bracket that mounts underneath the left front parking light REAR g emblem1 The rear plate may be mounted directly to the trunk lid using minimum plastic spacers between the TRUNK plate and the body Alternately E R A offers a Follow the same procedure as the nose emblem plain bracket or a special Carroll Shelby Motors installation frame See page 113 for installation of the basic bracket EXHAUST SYSTEM PRIMARY PIPES Install both primary pipe manifolds from the top Bolt into place with a gasket and high temperature silicone like Permatex Ultra Copper 81878 exhaust sealer Once the car has been warmed up and periodically thereafter re torque the primary pipes Seal the junction of the primary pipes and the side or collector to muffler with silicone or Walker Acousti seal g emblem2 117 SECTION G BODY II COMPETITION PIPES The outside pipes are available in bare steel After the brackets are welded on the bare steel can be painted with a VHT type coating usually must be re done every year ceramic HPC Jet Hot Airborn Coatings etc or chrome plated We recommend that the primary pipe collectors be ceramic coated This decreases the heat radiated in the engine compartment and extends the life of the pipes Because of the slip fit into the side pipes G primpipe mask the last 1 of the outside surface before coating The flanges of the primary pipes
87. e the pivot bolts to 50 ft Ib fia man d fsusp 71 UPPER CONTROL ARM The arms are installed with the ball joint hole offset towards the front of the car The inner pivot axis is offset to the outside of the chassis mount See above Use a little silicone sealer where the ball joint passes through the hole in the control arm This will prevent grease from leaking out of the rubber boot Install the arms with 3 shims front and rear between the pivot shaft and the chassis mounting brackets as a preliminary camber setting Leave the pivot shaft end nuts slightly loose Tighten the nuts to 60 Ibft after the suspension is at normal ride height STEERING KNUCKLE Install the knuckle on the lower ball joint with a washer if needed to space nut for the cotter pin and nut Torque to 40 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 washers and nuts torque to 30 16 6 minimum and install cotter pin at the next line up Insert the tie rod stud into the steering arm from the bottom Fit the washer and nut torquing to 20 lb ft minimum Install the cotter pin If you have difficulty getting grease into a ball joint back off the Zerk fitting about one turn LATE FABRICATED FRONT UPRIGHT Camaro caliper on fabricated upright 4 Piston caliper on fabricated upright SECTION F MECHANICAL COMPONENTS ROTOR HUB 12 BRA
88. earing into the hub carrier Moderately press the outer bearing onto the small end of the hub so that the bearing seats into the bearing cup Check that there is no axial play of the hub but it still rotates freely Measure the distance from the hub end to the bearing surface with an accurate dial indicator Find the next size larger spacer in the chart Assemble the spacer onto the stub axle install the axle assembly into the hub lining up the cotter pin holes in each Install a flat washer and nut Tighten the nut to 140 lb ft Check the end play with a dial indicator If it is correct tighten the nut to the next near hole and install the cotter pin Available shims Jag part Thickness CAC3818 10 CAC3818 12 CAC3818 14 CAC3818 16 CAC3818 18 CAC3818 20 CAC3818 22 CAC3818 24 CAC3818 26 CAC3818 28 CAC3818 30 CAC3818 32 CAC3818 34 CAC3818 36 CAC3818 38 Technique Two Hold the hub carrier vertically in a vise with the inner end of the hub uppermost Place the special collar tool Jag tool No J15 on the hub end Place the inner bearing inner race on the hub and press the race onto the hub until the inner face is flush with the special collar This will provide end flat bearings The end float should then be measured with a dial test indicator A spacer should then be fitted in place of the Special collar to give end float of 002 006 Spacers are supplied in the thicknesses shown below 39 For exa
89. eet resistance when installing the bolts chase the threads in the chassis A broken bolt inside the frame is difficult to fix SECTION F MECHANICAL COMPONENTS Bolt the anti sway bar to the chassis mounts using the rubber bushings and clamps Clamp the axle brackets around the Jaguar control arms Position them behind or just to the inside of the trailing arm rod ends as shown Install the links between the axle brackets and the ends of the anti sway bar Tighten the link bolts so that the rubber bush expands to the diameter of the cupped washer 77 REAR SUSPENSION E R A FIA See the other assembly information starting on page 40 for more diagrams 2 INSTALLATION Adjust the upper trailing arm length to 10 3 between rod end centers leaving on of the jam nuts loose Insert a x 4 HCS from the inside of each vertical chassis rail Insert the left hand threaded rod end of the trailing arm add a flat washer and stover nut Tighten to approximately 75 lb ft fiat rs d erarsins Adjust both lower trailing arms to 16 5 between the centerline of the front bushing and the center of the rod end leaving the jam nut loose Attach the upper trailing arms to the upright extensions Support the chassis with jack stands so that there is at least 19 20 between the spare tire well bottom and the floor This will allow you to fit the assembly on the jack and still slide it under the car from the back
90. er Steering wheel column and hub 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 ALL THE INFORMATION THAT FOLLOWS BEFORE YOU PURCHASE PARTS THAT YOU MIGHT BE UNABLE TO USE SECTION A PARTS NEEDED Pre serpentine belt engines are easily adapted to the A Friendly Reminder All piston engines have a limited torque spread If you decide to build a fire breathing monster expect to suffer somewhat at lower RPMs Because the E R A 289FIA is light every hiccup is felt Unless your car is for the track most of your driving will be in the 1500 3500 rpm range Holley recommends that you size the carburetor by this formula CFMz rpm x cid 3456 Keeping yours reasonably sized will help driveability Very high octane gasoline is scarce in many parts of the country and octane boosters can be a pain to deal with If you re going to do a lot of street driving we recommend a conservative compression ratio E R A turnkey cars are usually built with 9 5 1 or 10 1 maximum If you are using aluminum heads you may be able to tolerate another half point COOLING Always use a thermostat in your system for street use or a restrictor plate for racing In warm climates a 165 F 180 F thermostat works well See page 34 for hints Your oil temperature should also be between 150 F and 220 F If you have an oil cooler you
91. er your differential ratio without fear of bogging down in first gear See the chart of speed in gears on page 13 for particulars The R G 6 speed is too big to fit without major modifications There is also a competition version of the 5 speed using straight cut gears and no synchromesh Not recommended for street use Richmond Gear and Tremec transmissions require a Chevy splined driven disc of the appropriate diameter The pressure plate can be standard Ford SECTION A PARTS NEEDED If you are using a concentric throwout bearing McLeod recommends that you remove the centrifigul weights Rear Mount GM 3870184 Clutch throw out bearing arm e Same as big spline top loader Speedometer drive parts see page 14 e Cable Champ 400020 e Gear Holder Bullet GM 345215 e Retainer 3708148 e OhRing GM 10054241 e 090 deg adapter AA1052 39879XX XXzNumber of Teeth e Generally a 2 93 1 dif ratio will require 19 teeth a 3 07 ratio 20 teeth FORD MUSTANG T 5 This 5 speed transmission can be used with the smaller Ford engines Its overdrive 5th gear gives excellent highway cruising even with a 3 77 1 differential ratio Don t expect high top speeds in 5th gear however The small block engine may not have the torque to exceed 4000RPM in 5th Because the shift linkage is integral the shifter cannot exactly duplicate the original position but mounts a couple of inches to the rear With the standa
92. ervoir and master cylinder dry you will have to start over e Add fluid level to the reservoir if necessary e Bleed air consecutively starting at the right rear and right front then left rear and left front The optional Sierra Wilwood calipers have a bleeder on both the inside and outside caliper half Bleed the inside half first then the outside within the sequence above If you use the hose and jar method you can bleed the brakes without assistance as long as the end of the hose remains immersed in fluid BEDDING IN THE PADS The pads react positively to a hard initial break in Bring the car up to approximately 60 mph put the transmission in neutral and bring the car almost to a stop Do this several times in sucession to heat the pads up Allow the pads to cool slowly PERIODIC FLUSHING The most compatible fluids are Castrol LMA and ATTE type 400 Both are DOT 3 or 4 Don t use DOT 5 it s silicone based and may create problems with seals You will need about a pint of fluid total Since the front 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 e Open the right front bleeder and pump the brake pedal slowly until the reservoir is almost dry or the fluid runs clear With Sierra Wilwood calipers flush the inner half then the outer Always leave enough fluid in the reservoir to cover the bottom ports e Top off the reservoir e Do
93. es and procedures shown here are particular to Weber yours may be different Always read and follow the instructions for your installation Weber brand cylinders and most others have no system to keep the piston from being pushed too far out of the cylinder and puking fluid all over the floor The ERA requires a pedal stop so that the master cylinder stroke is limited NOTE McLeod recommends that you remove any centrifigul weights on the clutch pressure plate when you use a concentric throwout bearing ADJUSTMENTS Permantly install all the clutch components onto the flywheel using an alignment tool for the driven disc 33 Install the bell housing Using a straight edge across the bell housing opening measure the height of the fingers below the opening Make sure that the cylinder piston is pushed all the way into the housing Adjust the height of the bearing on the transmission by screwing the threaded adjusting sleeve in or out of the slave cylinder so that when the transmission is installed there will be the indicated clearance After the transmission is installed permantly recheck the clearance and connect the pressure hose to the clutch master cylinder Attach the bleed hose to the bellhousing flange at a conveniently accessible location OIL PAN There are several aftermarket pans and OEM Ford designs listed on page 22 If the pan does not have a oil temperature bung weld the oil temperature adap
94. et and slave cylinder assembly is fastened in three places e tapped hole on the left side of the block bell housing flange where the original clutch shaft pivot ball went e The rear bolt of the left engine mount e The left rear oil pan tapped hole Note When the slave cylinder is installed in the bracket the bleeder must be at the top fia nan b clslave 1 BLOWSHIELD MOUNT Use the appropriate holes to line up the slave cylinder axis with the throwout fork CLUTCH THROWOUT ROD E R A supplies two threaded rods with the push type slave cylinder to link with the throw out fork in the bell housing If your throw out lever has a hole in it use the long threaded rod If there is just a socket use the short rod See page 125 for assembly Install the correct link either by shortening the adjustment or loosening the adapter bracket from the block A return spring is optional T 5 PULL TYPE Inquire at ERA SECTION B PARTS PREPARATION SLAVE CYLINDER INTERNAL 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 compensate for different clutch finger heights It is very sensitive to proper setup We typically use Weber brand and have found them to be reliable if properly done When you assemble your car it is essential to follow the installation guidelines Pictur
95. filter 5 qt Transmission e Ford Top Loader Fill to hole with 80W 90 GL5 gear oil e Richmond Gear 5 speed 2 US qts of Redline 75 90 NS e Tremec GM Synchro trans fluid or Dexron II 138 e Ford T 5 Ford Automatic transmission fluid Differential The filler and drain plugs are 2 square Fill with Moroso climbing gear lube SAE 90 part number 34800 Mix with 4 to 8 oz of Amalie limited slip additive part 505 6775 If the above are not available you may use 80W 90 GL5 lubricant with an equivalent limited slip additive If the limited slip seems to be sticking ratcheting around sharp corners drain and refill replacing the Amalie additive with 2 tubes of GM additive 1052358 or MOPAR additive 4318060AB Suspension Use an EP type grease on all pieces with grease nipples Use a silicone grease when lubing the front lower control arm inner bushes only necessary when you are replacing them TORQUE SPECIFICATIONS Use figures below only if unspecified in the relevant instructions Torques listed are for lubricated threads or threads with liquid thread locker stover nut threads should be lubricated with light oil Inch bolt Grade 5 Grade 8 shank size VP 9 Ib ft 13 Ib ft hse 18 28 A 31 46 The 50 75 P 75 115 s 150 225 Metric Grade 10 9 Grade 12 9 M8 25 lb ft 29 Ib ft M10 47 58 M12 83 100 SECTION REFERENCE INSPECTION AND REGISTRATION Without researching and writing
96. fyou have stock XKE springs on non adjustable Jag dampers you may replace just one stock spring on each side with a 10 long x 350 Ib in spring If you have the height adjustable Spax dampers use one 8 x 350Ib in spring spring on each side All springs are 2 ID e 300 lb in rate springs see length above if you are replacing all 4 springs 37 REAR HUBS BOLT ON AND WIRE WHEELS XJ sedan rear suspension units with original bolt on wheels have a flange with a 5 x 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 hubs We ve got take offs in stock PIN DRIVE WHEELS One piece drive hubs 6 pin are part of our E R A pin drive option or available separately They are installed in place of either style Jaguar hub TRAILING END ROD ENDS Install the trailing arm rod ends onto the lower control arms in place of the original trailing arms Use the spacers provided to center the rod end on the bolt On late rears the securing bolt enters from the inside of the brackets On earlier cars the bolts are inserted from the outside hub side If the bolt head protrudes from the recess on the control arm grind it flush with the outer edge of the recess Otherwise it will contact the hub carrier TRAILARM Reinstall the hub carrier onto the half shaft and lower control arm The t
97. g hornwire instructions DASHBOARD HARNESS From the engine compartment pass the multi Wire the dashboard off the car See the separate connector blocks one at a time through the large wiring instructions for individual connections hole in the center of the firewall Once all the Make the final connections to the dash and steering connectors are through insert the grommet into the column after everything is installed in the car hole using a dull screwdriver to push the back edge of the grommet through the hole bit by bit REAR HARNESS FIREWALL Don t install the multi connector block on the front end until the harness has been passed through the hole in the side of the footbox Install the harness from inside the trunk as shown Tape a stiff wire to the harness then pass the stiff wire through the passage dragging the electrical harness behind See the diagram in the wiring instructions Pass the harness under the door sill and through the hole in the driver s footbox as shown g fwwire SECTION G BODY II SILL PANELS The rear wiring harness must be in place before installing the sill panels Secure in place with the screws used for shipping Drill holes for pop rivets every 2 or 3 on the bottom flange door opening 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 front hori
98. h the adjusting screws at the top and side of the headlight retaining ring See the diagram below Replace the trim ring and screw JMidltaim FINAL CHECKS Make sure the head stop parking and signal lights are working Check the horn and wipers Check tire pressures Check for exhaust leaks Re torque the exhaust manifold bolts Check the hand brake This disk brake system may require more effort than your other car CONGRATULATIONS You have just assembled a complete automobile from the ground up Your E R A will give you the exhilaration and uniqueness of an outstanding high performance automobile Enjoy See page 139 for hints on inspection insurance and registration YOUR FIRST DRIVE The E R A 427 is an amazing sports car but it requires caution and care to drive especially in the beginning when you re not accustomed to the power The Loud Pedal is your friend and your enemy If you add throttle the car will react as you would expect with more or less wheelspin Where people get in trouble is with trailing throttle If you back off too quickly in a corner or if the car is already sideways from over throttle the rear end will snap around as much as with excess throttle Squeeze on squeeze off good driving reference is at this site http www drivingfast net So Be Careful Out There But Always Have Fun 133 SECTIONH FINAL OPERATIONS RECOMMENDED SERVICE Fluids and capacities are liste
99. he engine above 3000 rpm they did run pretty well The 2V heads are more streetable than the 4V heads We don t have primary pipes for either engine so you will have to fabricate them ALTERNATOR To keep that original look most engines in an E R A are designed to use a classic style Ford alternator with a external voltage regulator 50 60 amps capacity is adequate See page 21 for part numbers If you wish to use a later alternator with integral regulator you must modify the wiring harness to use a 10 ohm resistor in a trigger wire from fuse 4 CLUTCH NOTES Because these cars are light they put very little stress on the clutch so a standard presssure plate is usually OK for a street driven car Richmond Gear and Tremec transmissions require a Chevy splined driven disc of the appropriate diameter The pressure plate can be standard Ford Many Tremec installations have used a concentric throwout bearing McLeod recommends that any centrifigul weights be removed with that combination OIL COOLER AND OIL FILTER Both the FIA and Slabside come standard without an oil cooler scoop but one can be factory added optional SECTION A PARTS NEEDED The optional E R A oil cooler system requires a Fram PH16FP filter or its equivalent Length and shape of the filter is absolutely critical Larger filters will require that the engine be raised off the mounts for installation removal Check that your sandwich adapter engage
100. he X e Richmond gear No adapter necessary 81 SECTION F MECHANICAL COMPONENTS Because the front brake wheel cylinders require more fluid than the rears the balance bar is always set up with the outside push rod longer than the inside one aNransmt gif Check that the engine is level side to side in the chassis Adjust if necessary BALANCE ADJUSTMENT The rod length has no effect on the front rear brake BONS bias which end locks first If necessary the bias Removal is accomplished in the reverse order can be adjusted as described on page 130 Special Note for Automatic Transmissions For a preliminary setting adjust the outer rod so that there are of threads showing on the outer master cylinder rod on the inner rod with the jam nuts against the rod end There is no transmission oil cooler built into the radiator To avoid transmission overheating you must mount an auxiliary cooler in the system It can be mounted in place of the engine oil cooler or in To change the brake pedal height turn both front of the radiator threaded rods equally in or out Clutch height adjustment is covered on page 82 Check the tightness of the brake line junctions and switch fittings BRAKE PEDAL HEIGHT Install the brake cover box Master cylinder installation is described on page 68 The brake or clutch pedal face angle can be changed with the top stop screw See page 60 For pe
101. he splined drive spindles until the motor has been run and the park resting position has been found Mount the pump in the dashboard The location is shown on page 102 Pass the plastic tubing from the fluid container cap through the s hole in the firewall as shown Cut the tubing supplied 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 98 SECTION G BODY II WINDWINGS AND SUNVISORS SUNVISORS With a small stiff wire clean out the holes tapped The windwings and sunvisors are pre installed with in the upper windshield frame the street car option or can be retrofitted to a comp car They can be attached to the windshield frame Push the wire to the bottom of the hole and mark before or after the windshield is mounted on the where it is flush with the windshield frame surface car Check each hole to make sure they are all the same Check the hole depth against the length of the chrome 6 32 oval head screws used to attach the angle brackets to the windshield frame Shorten the screws if necessary If the screw hits the glass the windshield will crack Double Check Attach the angle brackets to the windshield Caution Be careful when installing the screws into the windshield frame If the screws contact the glass they will break the windshield Check the screw length and clear o
102. hen use wax and grease remover For the show quality body we recommend that the entire body be covered with a thin coat of polyester or epoxy filler The body can then be blocked out to perfection without using excess primer Don t lose the holes for the tonneau snaps cowl mirror defroster vents or windshield center bracket in the process of filling Once the body is painted clean out the holes with a drill Paint all panels including the inner frame portions of the doors hood and trunk lid We also finish and paint the rough fiberglass underside of the hood The street option includes a fuzzy liner for the trunk underside FIA REAR FENDER PROTECTION Because the fender extends out from the body somewhat in line with the front tire the fender benefits greatly from some kind of chip protection Use Chip Guard under the paint or apply 3M 84911 film over the paint Also available in kits as Invinca Shield Both are available over the WWW or from body shop suppliers Section D Body Chassis assembly BRAKE SCOOPS You can lightly sand the inside surface of the fiberglass to duplicate rough aluminum Paint with satin finish aluminum color on the inside The outside can be done in aluminum or matched to the car s color Installation details are on page 65 FIA STRIPE STYLE E stripe2 Also shown is the layout of the longitudinal stripess that some have used in conjunction with the side to side stripes See the p
103. her tools are available from E R A SECTION A PARTS NEEDED 20 SECTION A PARTS NEEDED PART NUMBERS AND SOURCES Source addresses etc are found on page 26 PART Alternator Ford Small Block Insert to reduce head threads Ballast resistor Fan belt Front Brakes Suspension Brake Rotor Hub bolt on wheels Brake Calipers Front Pads Mounting pin kit Banjo bolt Brake reservoir standard optional 3 Bearings Front Wheel Outer Inner Seal inner Spindle nut Spindle washer Shock absorbers See spec s on page 48 Coil Springs Bell housing See mod s necessary on page 32 Cables Battery Trans case to chassis ground Battery pos to starter solenoid Battery neg to ground Starter solenoid to starter PART NUMBER Delco 321 147 rebuilt or any 70 s Ford with separate regulator F4ZZ 6E086 A see mounting page 29 Nieh FF 109 Borg RU 6 SMP RU 4 Wells F795 1 2 1 6 ohms Gates 7450 XL most app s GM 334348 Bendix 141040 GM 18002421 18003761 Rebuilts Bendix L55001 L55002 Includes pads Bendix D52S Semi metallic for street use GM 487293 BMW 34321 112 399 ERA steel cans optional GM 7450627 Timken LM11910 LM11949 GM 7450630 Timken LM67010 LM67048 GM 3966202 National 8871 GM 387137 GM 457707 Spax G135 PAS 200 Koni 8212 1126SPA1 Double external damping adjustment w aluminum body 12 x 250 Ibs in or 12 x 275 Ibs in See page 18
104. hrow out fork Modifications 31 142 24 Column Steering See Steering Column Compression 9 Control arms Bronte 71 Front see 71 Control valves fresh air 59 Cooling system ies 19 22 100 131 Thermostat See Thermostat Dampers Fine tuning 129 Bronte 21 Installation 73 Rear oce ee 23 Road settings 127 Specifications 48 Dash tubes s 108 Dashboard 102 Removal ess 52 omen 85 Dead pedal 108 Installation 83 Defroster sssssssss 100 Differential Lubrication 138 Ration sederet 16 Differential gears 23 Differential problems with 138 Distributors 10 Dolly wheels 7 Door Adjustment 108 Installation 89 Pocket installation 87 Removal 52 Step molding 116 Doug Nash See Richmond Gear Drive shaft 42 78 Angle gem 30 Driving cautions 133 Electrical Fan thermo switch
105. ictures on our web site for our finished cars 63 Section D Body Chassis assembly FIA REAR TRUNK BUNGIE HOLD DOWN The washers placed 2 14 below the lip of the trunk opening and separated by 10 on center E USRRC STRIPE STYLE I aNstripe Section D Body Chassis assembly Optional Finish and paint the rough fiberglass FRONT BRAKE SCOOPS inside the hood so that it looks like the original aluminum Using two 10 sheet metal screws mount the scoops 5 4 from the centerline of the car and set back as shown strap attached to the inside of the TONNEAU SNAPS chassis supports the rear edge This operation can be left until last so that the paint can be buffed one final time Chase the holes with a 25 drill 150 Install the tonneau snaps with the fiber washers Don t force The snap screws may twist off leaving you with half a broken screw in the body For extra safety and ease use a 10 steel screw to chase the threads into the fiberglass before you install the snaps 65 Section E Chassis Assembly SECTION E CHASSIS ASSEMBLY 66 Section E Chassis Assembly FASTENER NOTES We include Grade 5 fasteners throughout our kit They are quite strong enough for any abuse you can put your car through and offer a bit more ductility than Grade 8 which means they will bend before they snap Almost all the locking nuts in the kit are Stover style Stovers are reuseable several t
106. imes unlike the nylon locking type However you must use light oil on the threads when assembling TORQUE SPECIFICATIONS Use figures below only if unspecified in the relevant instructions Torques listed are for lubricated threads or threads with liquid thread locker All stover nut threads should be lubricated with light oil and may be reused several times Grade 5 Grade 8 13 Ib ft 28 46 75 115 225 Grade 12 9 29 Ib ft 58 100 67 Section E Chassis Assembly BRAKE AND FUEL LINES x Bolt the brake and clutch master cylinders in place zl DNeeslines avnastcyl Note The rubber hose supplied by E R A is compatible with brake fluid but some others are not Use caution if you choose to replace the hose The clutch master cylinder is shown on page 124 Replace the brake and fuel lines on the chassis Secure the lines in place with the plastic clips and BATTERY CABLES Tek screws Seal the thread holes with silicone to prevent rusting The brake and clutch filler tubes standard BMW reservoir are run as shown below The optional POWER CABLES three can reservoir setup uses the same steel feeder ee ate lines but with appropriate rubber hose connections Parts listings are on page 21 See illustration on the next page The cable from the battery to the starter solenoid is shown below If you wish to install a cut off switch the main cable lengths are e Solenoid to switch 72 e Switch to
107. ing and adjustment are described on page 124 D deadped LOWER STEERING COLUMN INSTALLATION ERA MODIFIED MUSTANG II Because the connection is splined the intermediate column will fit no matter what the orientation of the shaft Final steering wheel alignment is done with the splines at the steering wheel hub D Ncol era 83 SECTION G BODY Il 84 SECTION G BODY II PARKING LIGHTS WIRING HARNESS LAYOUT s for harness All individual connections are detailed in a separate list that comes with the harness A wiring diagram and trouble shooting guide are also included The wiring system is divided into three modules held in place with the clamps provided The front harness makes connections from the front lights to the firewall The dash harness makes all dashboard and column connections e third harness runs from the left side of the gyparkwir dashboard area to the rear components X MEMBER Install the electrical components on the firewall and foot boxes into the pre drilled holes as shown in the wiring instructions The general layout is described on the next sections Install the ballast resistor if you are using one after laying out the front harness in the car See the diagram on page 79 Use the layout diagrams below and the wiring instructions to find reference points in the harnesses FRONT WIRING HARNESS Also see the detailed diagrams in the wiring
108. ing parts that may need replacement after use are also listed Replacement parts for long term service are listed on page 135 Read this section thoroughly before purchasing any parts Don t waste your time and money on stuff you don t need or can t use SECTION A PARTS NEEDED PICKING UP YOUR KIT The kit can be transported from our factory in an enclosed trailer standard automobile trailer or rampback hauler Shipping space for the parts in cartons will also be required although most will fit inside the kit We have used several shipping commercial companies with excellent results See page 27 for names DIMENSIONS AND WEIGHTS 800 Ib bare 200 Ib of boxes 600 Ib for roller aNshipdi ss TRAILER REQUIREMENTS If you didn t buy a roller from us the kit is usually shipped on the dolly wheels that we use for assembly if your trailer is well sprung The dolly wheels require a 300 refundable deposit Many people keep the wheels until their kit is completed it s very convenient for the kit to be mobile and at the correct height during construction The track of the Cobra dolly wheels is only about 20 Your trailer may require additional boards to support the dolly wheels Without tires or dolly wheels you can put tires as buffer between the chassis and the trailer The kit will have to be lifted on and off the trailer manually Have 3 strong friends to unload If you re coming on a weekend to pick up your kit please wa
109. ith the side closing plates and original shims that go behind them The plates seal off the cowl area from the engine compartment and have weather stripping glued to their outer edges to seal against the body See page 86 Don t tighten the hinge bolts rocker Bolt the door to the hinge lightly snugging the bolts If the car is already painted consider using DOOR PULL STRAP masking tape along the door and body edges to Drill a hole 30 bit just to the rear of the side prevent damage when assembling curtain ferrule Loop the strap over the latch ball The door edge may be aligned with the body and use the screw and countersunk washer at the opening by loosening the bolts where the hinge front attaches to the door To adjust the surface of the door relative to the body loosen the hinge where it attaches to the chassis Once the door is properly located tighten the hinge bolts HINGE COVERS The fiberglass covers are different from left to right Don t over tighten the screws when installing fiat man g drlatch Bolt the latch striker to its mounting plate and install the assembly loosely to the chassis Remember to replace any shims found earlier Close and latch the door while allowing the striker to self align with the latch on the door Tighten the striker bolts Don t worry about the einNHINGCVR door fitting flush at the rear The latch striker must HOOD be refit when the rugs are installed Bolt the hinges loosely into the body f
110. k with us for details EXHAUST SYSTEM ORIGINAL COMPETITION STYLE Side under pipes were used on the original competition cars Primary pipes for most Ford small block engines are available from E R A Exact reproductions of the original side pipes with a glass pack type muffler are available in various coatings and materials also STREET STYLE For those desiring something quieter the E R A 289FIA and Slabside have provisions for a street style under car system with the exhaust exiting just in front of the rear wheels or at the rear bumper The system uses a reverse flow muffler so there is a small horsepower penalty The primary pipes are the same as used in the competition exhaust but with a different collector WHEELS FIA BOLT ON Bolt on wheels require a 4 bolt circle Chevrolet pattern 7 wide wheels for the front 8 10 rear with 4 back spacing will result in the right look Using wider wheels on the rear may prevent use of the under car exhaust system The offset of your wheels must be similar to those listed for the pin drive wheels below Lug nut sizes are Front 20 Rear 20 E R A recommends American Racing s Torq Thrust D wheels in 15 x 7 and 15 x 8 5 sizes 3 75 backspacing This wheel or one similar from Halibrand was apparantly used on one of the original racecars in pin drive design The front wheel however will not fit the large brakes discussed on page 16 If yo
111. king the wiring connections and inserting the bulb use a light electrical grease to prevent corrosion from water and road salts Mount with the supplied 10 stainless nuts and bolts The lights have male and female terminals which mate with the harness only one way ebodNiclite Connect the black ground wire with the eye INSTALLATION terminal to one of the light mounting bolts A Remove the attachment screw lens and cover On some twist off lights it is possible to insert the bulb two ways If the the signal light is dimmer Insert the red wire through the larger of the 3 holes than the parking light remove the bulb turn it 180 in the deck lid and through the back of the light and reinsert it gasket TAIL LIGHTS Connect the black wire to the case and the red wire to the loop on the bulb holder Attach the light to the deck lid and refit the lens and cover The lenses of the lights are mounted with the lettering on the lens right side up Taillights may have pigtails with female connectors Otherwise connections are made directly to the small receptacles on the light socket 113 SECTION G BODY II STREET STYLE BACK UP LIGHT OPTIONAL ebod bulite Back up lights may be required in some states The type and location of the light is the customer s choice but we recommend mounting the light on a bumper bracket or the nudge bar Partial back up light wiring is built into the harness The wi
112. l Filter Ignition Notes Transmission Bellhousing Speedometer drive gears Shift linkage Rear Drive Suspension Assembly Steering Gear Front Rotors and Calipers Drive Shaft Steering Column Upper Steering Wheel Seat Belts Wiper Motor and Components Front Shock Absorbers Front Coil Springs Exhaust System Wheels FIA Tires Wheels Slabside Radiator Hoses Expansion Tank Jack etc Part numbers and sources Supplies needed O 2 Ue MAAN U N N ph p e O 2 2 o c lt lt A amp Source master list Tools needed Shipping companies partial list 26 27 27 SECTION B PARTS PREPARATION Engine Components Rear Suspension jaguar Rear suspension E R A FIA ONLY Shift handle Shift LInkage steering gear Steering Column Upper Windshield Wipers Dampers and springs Rear hub adapters bolt on wheels SECTION C CHASSIS PREPARATION Body removal Chassis paint SECTION D BODY CHASSIS ASSEMBLY Interior panels Horns Body mounting Attach under door flanges Attach Rocker panels Seal engine compartment to body Brake and clutch pedal Front Splash Panels Fresh Air Inlet Ducts Rear wheelhouse panels Detail Undercoating fresh Air hoses Body preparation and paint Tonneau snaps Front brake scoops 28 29 35 38 42 42 43 43 44
113. led in the car cement to fasten aluminum foil backed jute foam measure from the side and back to the base of the or high temperature material see page 25 on all shift lever surfaces except for the areas of overlap at the front Temporarily remove the lever and mount the tunnel edge and the bottom flanges Check for adequate in the car Mark the shift lever location on the clearance along the left side of the tunnel adjacent tunnel Cut the hole for the shift lever a little to the shift linkage undersize and refit the tunnel to check the location Glue low density foam weather stripping the same type used on edge of the wheelhouses onto the bottom of the tunnel flanges ACCENT TUBE HOLES These non structural tubes duplicate the look of the dash support tubes that were used on the original 289 Our tubes are held at the top by a bracket Remove seats mounted on the firewall at the bottom by the tabs Remove dash support tubes or grommets in the tunnel Removal after car is completed Remove shift lever boot and bezel Remove the rear bulkhead access panel Paint the tubes gloss black and install after the dashboard is in place They can also be covered in vinyl Remove screws along floor flange and lift the tunnel out fiaNnanNeNunltube 106 SECTION G BODY II CARPETS LAYOUT Installation details start on page 108 x 107 SECTION G BODY II INSTALLATION The carpet installation diagram and general i
114. lid from their hinges 52 SECTION C CHASSIS PREPARATION WINDSHIELD Don t lose the screws for the center bracket windwings or sun visors They have special British Whitworth threads and are hand trimmed to length You can t get them at your local hardware store unless you live in England Before removing windshield mark the location of the center windshield bracket on the body with a sharpened piece of stiff wire or a scribe e Remove the two small screws from the windshield post trim plates on both sides of the windshield e From under the cowl remove the 4 bolts holding the windshield to the car make note of any shims e Slide the windshield up and out Store in a protected place For installation see page 101 GAS FILLER CAP FIA See the exploded view on page 97 e Remove the cap and adapter by removing the inner cap and the 6 screws connecting the adapter to the tank e Gently rotate and slide the assembly out with body seal note the orientation Save the assembly gasket and screws in a safe place SLABSIDE e Remove the access panel behind the tank e Loosen the hose clamps aecuring the hose e Rotate the filler to break the seal The filler pulls straight up FUEL TANK FIA See the fuel tank notes on page 96 e Drain the tank This can be done from the front or under the car at the fuel filter connection e Remove the trunk lid and the trunk hinges e Remove the front closing panel
115. locks of wood etc to keep the body at least 3 above the bonding strips and chassis 56 Mix a trial batch of bonding adhesive see Supplies and Materials on page 25 to check the set up time before you start You must have enough time to apply the adhesive and carry out the all the subsequent installation steps before hardening Use less catalyst or hardener to increase working time Use a caulking gun to apply body sealant also used on the floors and foot boxes to the chassis and corresponding body parts Apply the bonding adhesive between the surfaces indicated on the diagram Section D Body Chassis assembly Remove the spacer blocks between the body and chassis lining up the original screw holes used for shipping Re fasten the rocker panels firewall and rear crossmember Smooth out any excess sealant at the same time sealing gaps hee water and dirt could ATTACH UNDER DOOR FLANGES accumulate Wipe off excess bonding material If the strips are not already bonded remove the from all joints and clean up with lacquer thinner or temporary screws Reattach the strips with the acetone taking extra care near painted surfaces main body bonding material or silicone using Use aluminum or stainless steel blind rivets to rivets Countersink the holes so that the rivets are complete the body attachment Drill holes 3 flush to the door opening surface to 4 apart most of the aluminum is pre drilled at inter
116. lumn listed on page 16 The E R A supplied steering gear does not require BUSHING REPLACEMENT EARLY Start with a Flaming River 1502 3X3 gear Based on a Triumph Spitfire bushing Remove both end boots Trim off the threaded end as shown Weld on the new E R A tie rod adapter optional Paint the tie rod and replace the rubber boots securing with plastic tie wraps or narrow metal straps Leave the tie wraps slightly loose until the toe in is adjusted Install mounting bushings The bushing consists of two parts an outer rubber steel insulator and a nylon sleeve e Make sure that the nylon sleeve is seated inside the insulator e Puta little grease on the inside of the housing to reduce the friction e Line up the retaining lugs and the hole and push the pieces fully home Remove the bushing by pushing the lugs in and toward the housing end BUSHING REPLACEMENT LATE Part number Page 136 The one piece nylon bushing is staked into the housing If the bushing needs replacement it must be split and pried out After pressing in the new bushing it may need reaming or hand fitting The column should fit with zero clearance or a slight interference When inserting the column through the assembly be very careful that you don t push the sleeve out E R A COLUMN The E R A column is ready for installation No preparation is necessary 43 SECTION B PARTS PREPARATION TRIUMPH COL
117. may have to block the air flow or use an in line thermostat in cold weather Note that the standard E R A kit includes a thermoswitch that turns the electric fan on around 195F EMISSIONS Requirements vary from state to state Most states require that your car meet the specifications of the year of your engine Check with your local authorities Ford Small Block Engine Specifications Years Bore Stroke Comp ression 2 87 2 87 3 0 3 5 3 5 A detailed chronology of engines with casting numbers is in the books listed on page 140 Early engines did not have stamped numbers in the block and can only be identified by the casting numbers on the block and or head 289FIA E R A supplies a special alternator adjusting bracket and clutch slave cylinder bracket for all of the supported engines Use the alternator as listed on page 21 Install the alternator as shown on page 29 If you have a late engine with a serpentine belt it may be converted by changing the lower pulley water pump and pump pulley Preparation is on page 29 FUEL PUMP E R A recommends a mechanical fuel pump for simplicity We normally install the Carter M6904 120gph on engines that require a pump 351 CLEVELAND AND BOSS ENGINES These rare engines shared little with the Windsor series having different heads and block Built primarily for track use ports were much too large for a wide torque spread If you were willing to keep t
118. mmend that the rim from bead to bead inside the tire area be sealed with epoxy paint Some tire dealers have a special wheel sealant Note The right hand thread wing nut is installed on the left side left hand thread on the right Use anti seize on the knock off threads drive pins and on the wheel mounting surface to prevent long term seizing of the wheel to the hub When installing the wheel on the hub make sure the pins line up with the holes Use a dead blow or lead hammer 3 165 to tighten each wing nut Tighten wing nuts in the direction opposite to forward wheel rotation For backup drill a hole in each wing of the knock off and use safety wire to secure one wing to a spoke in the wheel so that it is always being tightened of course SECTIONH FINAL OPERATIONS SUSPENSION ADJUSTMENTS PEE e The specifications for the standard front spring preload are on page 48 This will result in about 7 from the ground to the bottom of the front crossmember 4 to the front of the main rails CHASSIS HEIGHT Once the height is correct tighten the front upper control arm pivot bolts See page 71 After setting the springs as described on page 48 the car should be driven to settle everything in Don t change the spring heights before driving the car at least 50 miles COIL OVER HEIGHT ADJUSTMENT PEN Mite REAR SPECIFICATIONS Front When you raise both sides of the coil spring If you h
119. mounting perches adapter Loosely install the washers and nuts onto the Note that some bell housings for Tremec units also engine mount studs require a spacer between the bell housing and Raise the back of the engine either by changing the transmission so that the input shaft doesn t bottom tilt of the adjustable engine lift or with a jack out in the crankshaft underneath the rear of the engine Install the clutch and bell housing on the engine See notes on page 32 Carefully install the transmission onto the back of the engine You may have to rotate the transmission input shaft to engage the clutch disk Immediately install the top bolts to prevent clutch disk damage from the transmission hanging free Install the starter and the balance of the bell housing bolts Lower the back of the engine engaging the transmission mount studs into the chassis e Loader Front holes of trans adapter transmt jpg e Borg Warner Front holes of adapter Tremec transmissions with short input shafts that e 5 3550 Rear holes of adapter don t use the front spacer are mounted on the rear Depending on the transmission casting you holes of the adapter Tremecs that use the spacer may have to relieve the front of the are mounted without the adapter with the same transmission mount Use spacers between the mount as the Richmond Gear See page 81 adapter and the mount to raise the output centerline to 3 above t
120. mple assume the end float measured to be 025 Subtract the nominal end float of 004 from the measured end float 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 more end float When the axle shaft has been fitted and nut tightened 140 Ib ft check the end float with a dial indicator If it is correct tighten the nut to the next near hole and install the cotter pin Install both the seals into the hub carrier Re assemble the hub carrier with hub and axle Install the washer and retaining nut Tighten the nut to 225 Ibft Without an air wrench you may want to wait until the car is on the ground for final torqueing Install the upper bracket onto each hub carrier and torque the bolts to 75 Ib ft Note the orientation below for the left hub carrier The right is the mirror image Use grease on shaft and thrust surfaces LEFT SIDE HUB CARRIER fia man d erahubc ASSEMBLY INTO SUBFRAME Rebuild the differential as necessary Some units have a separate caliper mounting bridge on the side bearing housing This bracket and the original Jaguar rotor can be left off Place the differential on the bench right side up Allow the snout to extend over the edge of the bench several inches Raise the back up about with a block of wood etc Loop the front of the
121. n the floor carpet is installed lay it on top of Hold the attaching plate against the cover and the cover material extending out onto the floor tunnel Drill four holes into the tunnel Attach the plate and cover to the tunnel 109 SECTION G BODY II SHIFT BOOT Slide the seat all the way forward and lubricate the tracks with white lithium grease Slide the seat Once the large hole in the tunnel is cut locate the back and forth to distribute the grease evenly small holes by using the trim ring as a pattern as shown below The adjacent holes are placed parallel to the car centerline If the seat does not slide freely loosen all four bolts slide the seat back and forth to align the tracks and re tighten If seat adjusting tracks are not used follow the instructions for type I seats for marking the holes Spacers can be made of marine plywood cut to size and drilled for the bolts SEAT BELT SHOULDER HARNESS E R A offers reproductions of the original competition belts Inquire Locate the seatbelt holes in the floor next to the tunnel and in the rocker panels as shown threads are standard 4 20 After removing the shift knob the rubber boot can be stretched over the of the shift handle SEAT MOUNTING Screw the seat belt anchors into the captive nuts provided on the lower chassis see page 86 If necessary clean the threads with a 20 tap to remove any paint build up If you have sh
122. nce we have tried to make the design as flexible as possible Now there is room for the 351 engine and various other transmissions In the end though your mechanical components must conform to similar space limitations as the original car Some configurations fit together better than others and some cannot be done without major surgery The foot boxes have been designed to accommodate the 351 Windsor engine Don t expect to put an FE engine in without major modifications WHEN YOU BUY PARTS KEEP THE RECEIPTS They are frequently necessary for inspection and or registration The following items are critical to the proper assembly of the E R A 289FIA Details for selecting each component are listed in this section Components requiring special preparation are detailed in Section B All the items listed below are available from E R A Engine page 9 Front brake rotors and calipers Engine accessories page 21 Front coil over shock absorbers Oil cooler system optional Exhaust system side or under car Transmission Ford Top loader 4 speed C 4 or C 6 Speedometer cable automatic T 5 Tremec or Richmond Gear 5 speed Wheels and tires Transmission shift linkage and lever Radiator expansion tank and hoses Driveshaft Windshield wiper motor and drive components Jaguar XKE or XJ Sedan rear drive suspension unit Emblems Hand brake lever and cable Spare tire Flaming River rack and pinion steering gear Jack and lug wrench or knock off hamm
123. ng tube OIL COOLER OPTIONAL availble from ERA is required for the upper hose Assemble the upper hose as shown on page 35 ALWAYS clean the hoses adapters and fittings before you add oil to the system It may take some time to fill the lines and cooler with oil You might want to get initial oil pressure with an oil pump driver through the distributor hole RETROFITTING fiat man e lwathose The radiator cooling fan thermostatic switch is in the lower hose connector Connect the harness wires as shown on page 85 and detailed in the wiring instructions There is also an over ride switch on the dashboard Remove the bottom baffle and seal 93 SECTION G BODY II Install the edge retainer to the bottom radiator Mount the oil cooler on the shroud support Connect the hoses to the adapter and cooler as Attach the oil cooler to the bottom tray with shown below Use Teflon tape or pipe joint bolts compound on the threads Install speednuts onto the top flanges of the cooler The adapter housing mounts onto the engine filter threaded side down housing using the substitute fitting included The oil filter mounts on the adapter as shown on page Install the sides over the top speednuts and connect to the bottom tray through the side hole 94 Temporarily install the assembly fitting the front tabs on top of the fiberglass scoop and the rear flange of the side pieces against the radiator tray Drill thro
124. nment suspension 128 Alternator 29 Part numbers 21 SeElECtION 0ccccccessesseccvceveeneee 9 138 Anti sway bar Frontazc 74 Rear usse 41 76 Ash tray 106 Automatic transmission 82 Back up light 114 Ballast resistor 85 Part numbers 21 Battery Cables with cut off switch 68 Ground cable installation 104 Installation 104 Mounting tray installation 79 Part number 21 Battery cable Installation 69 Bell housing Modifications 32 Parts esee 13 Blind rivets See Rivets Blow shield See Bell housing Body Painting eee 62 52 Bodywork sss 62 Bonnet esses 89 Books engine rebuilding 140 Brake air Scoops 65 Brakes Balance 82 Bedding in the pads 125 Bleeding 125 Cover 60 Emergency brake linkage cents 22 F R balance 60 130 Elit casu eus 138 Front rotors Installation 72 Hard lines 68
125. nnel o e 106 Undercar exhaust 119 Undercoating 61 130 Unilite 10 Universal joint halfshaft 35 Voltage regulator Part number 24 Washer Windshield 102 Water neck intake manifold 100 Water neck part number 22 Weatherseals DOOS ioter trees 88 Hood e 90 eene 91 Wheel bearing Installation 73 Patisserie ee 21 Wheel Steering See Steering wheel Wheels 25 Bolt on Special notes 126 Parts and specifications 18 Pin drive Sealing air leaks 126 145 Wing nuts 126 Windshield Installation 101 53 Windwings esses 99 Wing NUS ee eee eee 126 Wiper Arm installation and removal P 124 Linkage wheelbox installation I 44 Motor installation 98 e Ree 17 24 Relay Rete 102 Wheelboxes 97 eek 85 Dashboard 102 Rear 85 Wiring harness layout 85
126. nstructions are on page 107 the exposed carpet edges are cut and bound Unless specifically noted are all glued into place All the sections are glued onto the fiberglass or aluminum except for 16 and 17 which are held in place with snaps and Velcro See page 109 for the emergency brake trim Two supplemental pieces are also included when the carpet is ordered e A piece of fuzzy material thick to cover the inside of the trunk lid 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 fiberglass inner panel e A thick piece of vinyl to line the glovebox also fastened with contact cement SPECIAL NOTES 2 4 Trim sections 2 and 4 to fit under the door hinges as shown The kit is shipped with shims under the hinges to compensate for the rug thickness When the doors are finally installed don t use the shims Use an awl to locate the mounting holes for the dead pedal Cut small holes for the screws 4 Remove the dead pedal see page 83 10 11 Remove the door strikers mounting brackets and any shims Carpet sections 10 and 11 fit under the strikers with the front upper edge of the carpet folded out on top of the closing panel below the hinge Trim the excess rug on the door opening flange 10 11 14 15 Locate the holes in the carpet for the lap and shoulder belts if neces
127. ntricity of the hole that locates the transmission Put a dial indicator on the flywheel and indicate the hole ID If the eccentricity exceeds the recommendations generally about 0 010 you must use offset dowels to locate the bell housing on the engine block Install the engine mounts as shown on page 29 Here at E R A we first assemble the engine clutch bellhousing and transmission on the floor just as it would function in the car The primary pipes will be installed once the engine and transmission are insalled Once everything is checked we remove the transmission from the engine bellhousing assembly Adapter required with Tremec transmission except the 500 and 600 series It s easiest to install the engine and transmission separately If you have a stationary engine lift VNremecmt have the dolly wheels or the suspension installed so Wrap rags or towels over the front tower and over that the chassis can move under the engine the top of the transmission tunnel to prevent paint The engine bellhousing is then installed in the scratches chassis With the engine on a hoist and tilted down at the If you are using a Ford Top Loader T 5 or Borg clutch end carefully lower it onto the engine Warner 4 speed install the transmission adapter on mounts the front of the X member The Richmond Gear Lower the engine engaging the studs on the engine and Tremec 5 speed transmission don t use the mounts into the slots in the
128. number of teeth on the speedometer drive gears part s on page Error Bookmark not defined using the formula Dif Ratio X Tire revs mile X Teeth on drive gear _ Teeth on driven gear Speedometer revolutions mile A 295 50 15 tire rolls 760 revs per mile 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 3 Usually the Tremec uses a 7 tooth driving gear requiring a RH driven gear So Teeth Dif Ratio x 5 3 The Richmond Gear transmission uses an 8 tooth driving gear So Teeth Dif Ratio x 6 06 See page Error Bookmark not defined for gear selection DRIVEN GEAR SELECTION AND PART NUMBERS Ford Top loader T 5 and Tremec Richmond Gear 5 Speed Ratio Teeth en hand Sete hand Ratio Teeth 2881 18 3987918 Brown a a ee 17 C2DZ 17271G C3DZ 17271C 3 31 1 20 3987920 Blue Purple tip White 21 3987921 Red 3 31 1 18 C2DZ 17271K CODD 17271B 3 54 1 22 3987922 Gray Green tip Yellow 3 54 1 19 CADZ 17271A CODZ 17271B Pink tip Pink 3 77 1 20 C2DZ 17271H CIDZ 17271A Blue tip Black C8SZ 17271A Orange Gear retainer for CIDZ 17292A all above 14 SECTION A PARTS NEEDED SHIFT LINKAGE REAR DRIVE SUSPENSION ASSEMBLY Al shift image is available om ERA The 289 FIA is designed to use either the Jaguar rear suspension in an E R A
129. ol arm pivot shaft is an aftermarket part for the same application but is offset for more camber adjustment Replacement part numbers are on page 135 Caster 4 deg e The caster value of the left and right sides of the car should differ by less than deg and the right caster should always be equal or greater than the left to compensate for road crown e Shifting a shim from the front of the bracket to the rear will decrease the caster by about 1 deg Toe in e Loosen the jam nut on each tie 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 With the ERA steering gear equalize the distance between the tie rod center and the end of the inner sleeve e the toe is correct remove the steering h camber wheel hub from the splines and re install so that is centered Temporarily install the large washer wave washer and nut torquing to 10 Ib ft Final adjustment of the wheel can be done after the car is test driven When the steering wheel orientation is correct tighten the column hub nut to 25 Ib ft Install the hub center cap as described on page 105 128 SECTIONH FINAL OPERATIONS Toe in 0 00 to 16 0 to deg toe in per side Adjust Camber by adding or removing shims from between the brake rotor and the inner drive axle flange 0 02 shim will change camber by 4 degrees Most setu
130. old the nudge bar between them aligned with the body opening and with about clearance between it and the body Transfer the hole locations from the nudge bar to the uprights Drill holes in the uprights and install the threaded inserts with a special tool or a nut and bolt ebod rivnut eylightsl Mount the headlight assembly and gasket with four 10 Phillips pan head tapping screws Pass the headlight wires with the parking light wires through the rubber grommet in the inner panel and rearward to the top of the spring perches Connect to the wiring harness and ground as shown in the separate wiring instructions Leave the rims off till the headlights are adjusted 112 SECTION G BODY II SIGNAL LIGHTS g tailites To make the tail light connections Make sure that the rear harness black ground fiaNnanNeyparkwir wire is connected to the light stud or ground Install the parking light harness along the inside of receptacle the inner panel above the corner of the radiator e With the parking lights on the red wire should securing it with the clamps on the top inner panel belive Touch the red wire to each pigtail or connector loop Connect that wire to the Connections are as shown in the following di ttil i immest filament illustration Check the wiring instructions for further notes e Connect the other wire to the remaining receptacle at the bulb bottom LICENSE PLATE LIGHT gylights2 When ma
131. olumn with the notch in the upper tube and fit the clamp over the column tube Snug the bolts slightly but don t tighten 105 SECTION G BODY II TUNNEL The optional ashtray is installed into the tunnel at the factory For retrofit call us about the location If you are using a backup light use a transmission Cut the tunnel and carpet hole slightly smaller than marked and file to fit A snug fit is all that holds the ashtray in place mounted switch actuated by the reverse gear lever The wires can be attached to either terminal If your tunnel is not pre riveted use x 4 long INSTALLATION aluminum body steel mandrel rivets If you are not PC OPENS going to cover or insulate the tunnel you may want to use urethane sealant between the panels With the tunnel held in place with the shipping screws drill holes 4 5 apart along the length of the bottom flanges and through the floor Also SHIFT LEVER HOLE drill two holes one on either side through the The hole location marked on the tunnel is the vertical surfaces at the front of the tunnel near the correct location for the original type shift lever top Your location may need slight adjustment to match Enlarge the holes in the tunnel to so that the your transmission s lever especially if you are hold down screws will drop through using a T 5 or Tremec with integral shifter Insulate the inside of the tunnel Use contact When the transmission is instal
132. ople of average height set the distance from the rear of the pedal face to the forward part of the CLUTCH PEDAL HEIGHT foot box to about 7 If you are much taller or shorter you may move the pedal up to forward See page 60 for parts assembly or backward as needed ADJUSTMENT The clutch pedal face should be approximately even with the brake If your clutch requires more throw than normal you may need to keep the pedal face higher or in desperation use a larger clutch master cylinder A modified 7 or 1 Tilton master cylinder can be installed on the stock bracket but is rarely necessary Almost all clutch release problems are the result of incorrect installation or incompatible parts Stock linkage and hydraulics give approximately throw at the outer end of the fork See page 125 ADJUSTMENT The throw out arm angle can be changed to raise or lower the pedal fwraklink 82 SECTION F MECHANICAL COMPONENTS e Loosen the retaining bolt and slide the arm off the spline It may be necessary to disconnect DEAD PEDAL INSTALLATION the clevis from the arm Drill the footbox as indicated through fiberglass and steel sheet metal for the included sheet metal e someone hold the clutch pedal at the screws to secure the dead pedal desired height and re install the arm Tighten the retaining bolt You can make small height changes by changing the length of the connecting rod Clutch bleed
133. ould be modified as shown Drill remember that the part is hardened the indentation to 7 id Drill optional to 5 8 Trim here Looking at front convex side SECTION B PARTS PREPARATION BELL HOUSING Notes The bell housing depth face to face for the T 5 is about 6 8 If you are using a push type release lever the pivot must be spaced about forward The Tremec transmission also requires a deep bell housing or a bell housing with a spacer for the input shaft not to interfere with the pilot bearing Many blow shield type bell housings have a large bottom flange that will extend below the chassis Trim the engine plate as shown and use it as a template to trim the bell housing flange This dimension applies to all engines although the trimming operation may not be necessary for some b belltrim For other engines trim the bell housings similarly using the distance from the centerline of the crankshaft to the bottom edge of the flange CLUTCH SLAVE CYLINDER We recommend the following combinations with small block Ford for easiest installation Concentric throwout bearing T 5 Tremec External slave cylinder Top loader Richmond Gear 5 spd Details for using the concentric bearing are available from ERA and on the internet Inquire 32 PUSH TYPE See page 124 for hose installation and other details Part numbers are on page 135 The brack
134. oulder harnesses cut holes in the carpet and if necessary SEATBLTH chase those threads also Slip the ends of the belts in the clip to the eyelets of Street interior Lay the floor carpets in place and the anchors already in place locate the seat mounting holes through the carpet SHOULDER HARNESSES Mark and cut holes for the bolts in the carpet n Locate the mounting holes in the chassis with an awl and cut holes in the carpet if necessary The E optional four point shoulder harness are installed the cushions to drop into place with the is 20 attaching bolts above the belt WITH ADJUSTING TRACKS loops The lever for the seat tracks falls on the right side of both the driver s and passenger s seats If you are not using seat adjusting rails each seat must be raised up approx with spacers to allow 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 20 bolts Put shims under the three holes not covered with the tunnel Place the seats so that the studs in the tracks go through the floor Adjust alignment as below Loosely bolt the front of the tracks down 20 bolts Slide the seat forward to expose the rear mounting holes and install the two rear bolts Tighten all four bolts g shouldh 110 SECTION G BODY II GRILL If ordered with the kit the grill is already installed Retrofitting
135. ound damping adjustments for transition understeer oversteer adjustment KONI RACING EXTERNALLY ADJUSTABLE Bump control The control knob is located at the bottom of the damper Turning the wheel clockwise increases the bump control damping Set all four dampers on minimum bump and rebound settings Drive to get the feel of the car over uneven surfaces Observe the behavior over bumps disregarding body roll Notice if the car walks or side hops in a rough turn Increase bump adjustment 3 clicks on all four dampers SECTION H Drive the car again over uneven surfaces Increase the adjustments until the car starts to feel hard over bumps Back off the adjustment 2 clicks The back off point will probably be reached sooner on one end of the vehicle than the other If this occurs keep increasing the bump adjustment on the soft end until it too feels hard Then back it off Final adjustment can be made after you get used to the feel of the car Rebound control The adjustment is made by inserting a pin in the wheel at the top of the damper Turning the toothed control wheel from left to right will increase the rebound damping With rebound control set on full soft and the bump control set from your testing drive the car paying attention to how the car rolls when entering a turn Increase the rebound damping three sweeps on all four dampers and test drive the car Continue increasing the damper setting until the car enters the turns
136. own below GM Rotor Cleanup Clean off the grinding dust thoroughly before putting grease in the hub and installing the bearings and inner seals Install the hub onto the stub axle with a special tanged washer and castle nut With new wheel bearings torque the axle nut to 20 Ib ft Loosen the nut and re torque to 15 Ib inches then tighten to the nearest cotter pin hole Install the cotter pin through the access hole in the side of the pin drive hub Note that the calipers and handed Install them with their bleeder nipple at the top Install the brake calipers and pads using new hardware kits Use silicone grease on all sliding surfaces Connect the brake line to the caliper using the supplied banjo bolt and copper washer If you still get seepage past the copper washer but the seat is not too bad you may use a special sealing washer available from Earls or E R A 73 SECTION F MECHANICAL COMPONENTS STEERING GEAR ANTI SWAY BAR Threaded holes are already on the chassis Chase The lower steering column must be installed before any paint in the threads before installing the 18 the steering gear See page 83 bolts washers and nuts The front bar is mounted under the front frame extensions just behind the radiator e Boltthe bar in place with the rubber urethane bushes and clamps The ends slant up slightly toward the outside Prepare the rack and pinion assembly as described on page 43
137. posite 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 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 BRAKE BALANCE ADJUSTMENT Do not change the brake bias until after the brakes have been thoroughly bedded in The factory set bias will be fine for most applications Changes may be necessary because of unusual pad material and or different calipers All our standard and optional brakes are roughly compatible with the standard brake bias setting First check that your link length is correct See page 60 Generally on a road with good traction the front brakes should lock slightly before the rears Front to rear bias is adjusted by changing the spacers on either side of the balance bar bearing Custom spacers are available from E R A Retain the total number of the spacers shifting them from one side of the balance bar to the other Standard spacing on either side of the balance bearing is equal If you have special calipers and require more change than is available at the balance bar new master cylinders are available in diameters from to 1 SECTIONH FINAL OPERATIONS ADD FLUIDS Top up the proper oils or fluids to the engine transmission rear end cooling system and braking system Engine oil If the engine has ne
138. ps will require only one shim less than is normally used in the original car so you will have extra ones left over New shims are available from us or your local Jaguar dealer or one of the Jaguar specialists listed on page 26 The rear wheel toe in is not individually adjustable If the toe is out of range the lower control arms must be bent or replaced Tracking longitudinal alignment of the front and rear suspensions may be changed by adjusting the length of the trailing arms at the rod end to shift the assembly in the chassis E R A w outboard brakes Camber deg deg Toe in 0 ie 0 deg Procedure Set the trailing arm lengths as described on page 77 Set the height as described on page 127 Use the rear tie rod to bring the toe in into spec but don t tighten the jam nuts The threads on the outer section of the tie rod are right hand the threads into the inner rod end are left hand so turning the adjuster forward at the top will decrease toe in For each complete turn of the tie rod toe will change by 0 2 75 deg Turning the tie rod of a turn one flat on the adjuster will change the toe in by deg 129 REAR e Measure the camber Jaguar w inboard brakes e change the camber the front rod end must be Camber 3 deg disengaged from the inner bracket Jack the car up to unload the suspension and remove the inner pivot bolt For each degree of camber
139. quire COWL EDGES You may round the edges of the front and back cowl to give the original aluminum wrapped around tubes look Sculpt the existing glass with a grinder or coarse sandpaper 62 SPECIAL SLABSIDE HINTS The rear wheelwell flares are slightly different from side to side compared with the longitudinal tire placement We recommend that the flat area of the right flare be made slightly narrower than the left side about 3 8 at the front to keep the wheel centered in the hole GENERAL HINTS The body is easier to prepare if it is mounted on the chassis On our factory turn key cars we always permanently attach the body to the chassis before any body preparation is done This avoids doing damage to the paint when the body is installed onto the chassis and insures that all body panels match We do however leave the front wheelhouse panels off during the body preparation and painting process to minimize any staining of the aluminum Check the fit of the doors and adjust as described on page 89 Leave the hood and trunk panels mounted as well with small pieces of weatherstripping in place to hold the surfaces at the same position as in a finished car e the body is to be painted on the chassis carefully mask so that overspray is kept off the chassis and mechanical parts e Remove any clay that remains on the mold break lines e Wash the body with soap and water to remove any mold release still present t
140. r Apply contact cement to the edge and backside only of the FERRULE attachment plate and the back side of the pocket Slip the ferrules into the holes on the top of the material Let dry to a tack free condition doors and note the length that each extends past the Carefully stretch the material over and partially inner panel around the attachment plate Mark each ferrule so there are no more than 2 or 3 threads showing between the mark and the door Remove the attaching plate from the door Tape or surface on its shortest side clamp the upper edge to a flat surface and finish gluing the edge Cut off the excess at the mark and slightly round Before attaching the pocket to the door glue the off the edges with a file or sander rug items 7 and 15 in the rug installation diagram Hold the ferrules in place with the retaining rings on page 108 to the inside of the door with contact provided Seat the retaining rings against the door cement Install the door pocket and the latch onto surface tightly each door 88 SECTION G BODY II DOOR INSTALLATION With the door shut the rear edge must be adjusted parallel to the body opening from top to bottom Hold the door so that the top edge matches the body If the bottom edge of the door does not match adjust the rocker panel by shifting and or shimming the rocker on the chassis mounts at the front of the door opening and at the end of the Bolt the door hinges onto the chassis w
141. r fluid comes out of the hose 124 SECTION H Close the bleeder nipple and pump the clutch pedal several times If there is more than 1 travel at the pedal before resistance is felt repeat the bleeding procedure ADJUSTMENT If no return spring is used on the clutch lever the clutch will be self adjusting Most throw out bearings will operate with the small constant pressure involved Those that cannot have pressur must use a return spring and be adjusted periodically See page 82 for clutch pedal height adjustment WITHOUT RETURN SPRING Increase the length of the throw rod by unscrewing the ball end forcing the piston in the cylinder to just bottom out Note that the cylinder is spring loaded to the fully extended position Decrease the length of the rod so that there is about play when you push the transmission arm forward ficltchadj WITH SPRING Remove the spring Adjust as above but leave just e clearance This should result in about free play at the pedal Lack of free play will result in premature throw out bearing failure or a slipping clutch The free play must be adjusted about every 3000 miles 125 FINAL OPERATIONS BRAKE HYDRAULICS BLEEDING Have the car level or with the rear higher than the front e brake hydraulic system is bled like the clutch except that there is a bleeder or two at each wheel Check the fluid reservoir level periodically If you run the res
142. r nuts if possible Aircraft style shoulder bolts are available from E R A Lubricate the inside and outside of the slip yoke with light oil If your transmission tail shaft uses a leather seal lubricate the seal with light oil also Use EP grease to lubricate each universal joint 78 SAFETY STRAP ID Install the strap into the holes on the chassis support below the driveshaft and bolt into place Note that the bracket for the emergency brake ballance assembly E R A suspension only mounts between the strap and the chassis See the Emergency Brake section above PLATES Install the car ID plate with diam x L aluminum blind rivets as shown There are usually shadows of the rivet holes in the surface of the fiberglass d idplate MORE CHASSIS AND BODY ID NUMBERS The chassis is stamped with the ID number in two places The top of the left front shock mount under the brass ID plate On the outside of the horizontal section of the frame just inside the right rear tire just above the subframe bracket SECTION F MECHANICAL COMPONENTS BATTERY MOUNT VOLTAGE REGULATOR Bolt the tray in place onto the right rear frame rail as shown The chassis is pre threaded with 16 18 inserts x dWoltreg The regulator part number on page 24 installs with 10 screws on the left inner fender panel into plastic inserts dNbatbox Install the inner panel at the rail side Install the splash
143. railing arms should be installed onto the rod ends when the suspension assembly is installed into the chassis See page 138 for lubricants and capacities SECTION B PARTS PREPARATION REAR SUSPENSION E R A FIA ONLY The E R A rear suspension is carried in an aluminum subframe using a Salisbury differential driving special cast aluminum uprights with outboard brakes Most of the axle and bearing parts are Jaguar Brake calipers are late model Corvette Rotors are Wilwood on E R A adapters The subframe is mounted to the chassis at the top and at the cross member through urethane bushings Replacement parts are listed on page 135 You will need the following parts for a complete assembly Part number 1 E R A conversion assembly with subframe lower radius arms upper and lower trailing arms hub carrier all bushings axle spacers and all rod ends and fasteners Also included brake hat rotor Optional Emergency brake cables with balance assembly Carrera 3356 or 3257 Koni Ask Coil over dampers Carrera requires coil conversion kit 14 5 extended length Spax G452 10 5 compressed length AS200 Springs 9 L x 2 25 ID 400lb in 1 Differential w o brakes 2 Stub axle w washer and nut 2 Axle flange bolt on Jag CBC1784 pin drive E R A 2 Bearings and seals hub See page 135 carrier HE Half shafts and U joints See page 42 Brake caliper 38 ASSEMBLY AXLE ASSEMBLY The stock
144. rd bell housing on the stock T 5 you can use a pull type clutch release system If you are using an aftermarket blow shield See page 24 we recommend that you change to a push type clutch release system Please specify before the kit is delivered TREMEC 3550 TKO AND 500 600 See gearing details on page 13 Some Tremec transmissions require a Chevy splined driven disc some use a Ford spline The pressure plate can be standard Ford Some bell housings require a spacer so that the input shaft doesn t bottom out in the crankshaft In addition except for the 500 and 600 series the rear mount requires an adapter plate used with a Chevy mount See page 24 for part numbers We recommend a concentric type clutch release bearing with all Tremec transmissions Inquire for details Before you install the speedometer driven gear check that its spiral meshes properly with the drive gear Transmissions have come through with both the LH and RH drive gears See page 14 for calculations and page 23 for part numbers SECTION A PARTS NEEDED We trim the Lakewood bottom flange so that is does BELLHOUSING not extend below the chassis See page 32 for Since the clutch and pressure plate are in line with your calves E R A recommends a forged steel blow shield bellhousing such as made by Lakewood or Quicktime TRANSMISSION GEARING All based on 26 OD tire TREMEC 3550 TKO 500 5 SPEED 4 SPEED TOP LOADER WIDE RATIO 2nd
145. rds the front of the car slip its trailing edge up and under the glove box opening lip of the dash Be sure that the edge goes under the glove box door mounting screws Raise the rear of the glove box into place and install the final dashboard screw Tighten all the dash screws to hold the glove box in place while you attach its rear flange with the self tapping screws provided A ratchet and a long extension makes this job easier Attach the leading edge of the glove box with the two 4 trim screws at the sides of the glove box opening SPEEDOMETER CABLE AND OTHERS e spcable Feed the other end towards the rear over the bellhousing and down the right side of the transmission From inside the car pull the small end through the grommet Align the square end of the cable and its receptacle in the gauge and tighten the retaining nut If the transmission drive is on the right side run the cable through the hole in the hand brake lever ENGNE FIREWALL FROM FRONT The holes are used differently with Comp and mounting bracket If the drive is on the left side the Street dashboards Hole B is drilled when an cable must be kept from interfering with the MSD ignition box is mounted behind the dash shifting mechanism by attaching the cable to the side of the floor with clamps 103 SECTION G BODY II Secure the cable to one of the bellhousing top bolts Some cables or right angle drives have been known to have too
146. res for For the obsessive compulsive The backside of the the back up light switch connections exit the main mirror and the clamp on the original cars was black harness on the passenger compartment side of the wrinkle finish paint firewall Assemble the mirror as shown The upper and MIRRORS lower clamps hold the rim against the reflector Note that the stainless steel reflector is only polished on one side gt o I COMPETITION STYLE Mount the rearview mirror on top of the dash in the pre drilled holes using chrome 8 oval head Attach the bracket to the dashboard with the Phillips tapping screws See below for mirror hole included 8 screws The bottom mirror nut should locations hang over the edge only minimally Typically the mirror is placed just to the left of the center tonneau SIDE iic COMPETITION STYLE ON DOOR The Raydot style mirror is attached through the front side curtain ferrule as shown Drill and safety wire the long nut after tightening it only enough to keep the mirror in place but not so much as to crush the body g racemir 114 SECTION G BODY II G racemiro COMPETITION STYLE ON WINDSHIELD The left side mirror is shown below The right side bracket has a slight bend to tilt the mirror toward the driver El 115 STREET STYLE Follow the instructions included with the mirrors for disassembly You may have to drill the holes in the base larger to fit the included screw
147. rips to the inside of the front bow channels to seal the top of the windshield frame REMOVE AND REPLACE after fitting Cold temperatures make top installation difficult Install the top bows with the hinged frame toward the rear See above Lay the top in position across the top bows Install the header channels on the windshield by engaging the header tang into the slot in the top of the windshield Engage the outside windshield clamps to the header but don t cinch them down Working toward the center from each side press the lift a dot fasteners onto the body studs It helps to rock the fastener back and forth a bit When all lift a dots are secure cinch down the windshield clamps and adjust the height of the bows at the sides If the top is too loose unscrew the knurled ends of the top bows to raise everything Remove in the reverse order SIDE CURTAINS If your top has not already been fit the windshield angle may be matched to fit the front edge of the side curtain If you intend to install side curtains in the future E R A can supply a template to determine the angle Once the windshield angle has been determined the top may installed to fit If the top has been fit the windshield angle may effect the fit of the side curtain front glazing The front edge of the curtain may have to be trimmed See below The door must be open wide to install the side curtain mounting pins into the door ferrules Tri
148. rn us if you aren t coming with extra people too Don t tie down the dolly wheels to secure the kit Tie to the chassis or suspension In the absence of suspension pieces to tie to wrap soft tie straps around the front crossmember and the upper mounting bolts for the rear subframe TIE DOWNS You or your shipping agent will require ratchet tie downs come alongs and or strong straps We recommend either 4 diagonal connections or 2 longitudinal and 4 lateral ones for a total of 6 Don t forget that the trailer must have anchor points for the straps to tie to To avoid scratching the paint on the chassis use 2 wide loops or double 1 wide loops or ratchet straps 5000 Ib minimum rating Make sure that your trailer has places to tie to If you use chains or a come along bring padding or nylon straps for intermediate connections to the chassis SECTION A PARTS NEEDED INCLEMENT WEATHER A plastic cover will quickly shred at highway speeds A high quality cloth car cover can be used to cover up the plastic but it must be held down with rope all over Looseness will allow any cover to quickly beat itself and your paint job to death SPECIAL NOTES Be careful when selecting and building your components The information on the following pages shows the recommended parts for many possible drive train combinations The ERA 289FIA chassis and body follow the dimensions of the original Shelby 289 competition car very closely For your convenie
149. rom inside the grille opening The hood hinges are marked L and R The trunk hinges are similar but cannot be exchanged for the hood hinges and are marked with a T Fit any shims found earlier 89 SECTION G BODY II ebod HOODHNDL The hood is held off the body flange with 7 rubber bumpers held with sheet metal screws Extra engine compartment ventilation is gained by leaving gaps If you lose the holes during the body preparation process position the bumpers as shown in the diagram on page 90 Hoodgask Lay the hood carefully onto the body centering with cardboard or wooden shims inserted between the sides of the hood and hood opening Leave a gap at the front edge so that the hood doesn t chip the paint when opened From inside the grill opening or engine compartment lift the hinges assemblies into place Align and bolt to the body and hood with the shims used earlier Tighten all bolts Carefully lift the hood checking the front edge clearance Adjust and or change shims if needed Adjust the hood strikers on the firewall so that the hood is flush with the body The hood seal will be compressed slightly eliminating rattles 90 HOOD STAY The upper and lower hood stay brackets are factory attached as shown fiat man e Hoodprop If you removed the keyhole receptacle from the hood inner panel when it was painted install as shown The plastic rod retainer fits into a square hole in the wheelhouse panel It
150. ry to have the large spline input shaft with a small block The small spline transmissions were fine when used in such a light car even with a FE engine We recommend a short tail shaft case 24 from the mounting flange to the end of the tail shaft housing This will enable a longer drive shaft Make sure that the transmission tailshaft has the mounting boss located as shown above SPECIFICATIONS AND APPLICATIONS Ford used the Top loader was used in many cars from 1964 to 1973 However in 1964 and 1965 the transmission had a four hole mounting face and a 25 spline output shaft This early transmission should be avoided Driveshaft parts are unobtainable From mid 1965 to 1973 Ford changed to a universal eight hole front mounting pattern Also during this time the output shaft was upgraded to a larger 28 spline output shaft for the 200 to 390 cubic inch engines and 31 spline shaft for the 427 428 and 429 engines Because the E R A 289FIA is very light stress on the transmission is low We have found that the small input and output shafts are fine for street use Input shafts were also upgraded to 1 s diameter for use with 200 to 390 cubic inch engines and 1 diameter for HD 427 428 and 429 engines The larger spline size was only available with close ratio gears The Top loader gearbox was built in three case lengths measured from the mounting flange to the end of the tail shaft housing 24 25 5 and 27 If at
151. s Have a friend help you locate the mirror on the fender Use wide masking tape to protect the fender where the mirror is to be mounted Use the plastic gasket to mark the outline of the gasket and the mounting holes onto the tape Make sure the gasket is facing in the right direction The Street mirror is assembled as shown Postioning the mirror typical ebodNoutmirl Position mirror pedestal on the fender over the hole markings and within the gasket outline SECTION G BODY II Holding the pedestal in position drill two s holes where marked making sure to hold the drill at the proper angle Be very careful when puting in the screws If they are too tight in the hole adjust the hole size with the drill See the illustration on page 116 ebod sidemir GRAB HANDLE Attach the handle to the dash with chrome finishing screws 10 x 3 4 L if the dash is 1 2 thick at that point If the dash is thinner at the attachment points sometimes we use a 10 24 screw with a nut TOP SNAPS The top snaps were trial fit before paint If the screw holes have paint in them they should be chased with a drill bit Use a fiber or plastic washer under each snap Do not over torque The studs are plated brass and break easily 116 DOOR TRIM STEP MOLDING Anodized aluminum doorstep moldings come with the optional street interior only They are pre drilled but must be shaped to the door opening Note that
152. s show misalignment material will have to be removed from the flange on the body the flange on the door or lid or both Use care not to remove too much material from the flanges on the doors or lids A barrel sander works best for this job When disassembling parts record the shims between the hinges and body panels Remove the transmission tunnel and the filler at the base of the pedals Remove the inner rocker panels beneath the doors Remove the wheelhouse panels front and rear the trunk filler panels at each rear corner Remove the radiator oil cooler and shrouding Remove the quick jacks or bumpers Remove the battery closing panel and battery tray Remove the fuel cap and fuel reciever from the tank Tape over the hole Remove the rear fender stays Remove all the screws holding the body to the rear crossmember cowl and front support tube With the assistance of three others raise the rear of the body first spreading the sides of the body slide the body up and forward over the cowl Remove the fuel tank and reinstall the fiberglass rear wheelhouse panels Drill rivet holes through the footboxes into the cowl and chassis rails through the floors into chassis and portion of wheelhouse panels that run under floors Remove everything from the chassis The body must be removed to paint the chassis but is not necessary to remove the body from the chassis to paint the body E R A turn key cars are painted with
153. s only of the threads in the filter Trim the threads if necessary A 90 degree adapter Ford M 6880 A50 may allow a larger filter but we have not had a chance to check fit If you decide to build your own system the specifications below may be helpful but should not substitute for good design practices e Oil cooler approximately 14 x 3 or 6 h with AN 10 male fittings 10 stainless braided hose IGNITION NOTES MSD SYSTEMS Neither the Stewart Warner nor our current Smith tachometer Caebont can be driven by the MSD tachometer output port No adapter is required Some other brands may Inquire See the separate wiring instructions for special wiring routing notes and the wiring instructions for hookup instructions UNILITE DISTRIBUTOR Always use a ballast resistor 1 2 1 6 ohm with the Unilite system Also disconnect and tape the wire at the I terminal of the starter solenoid When combined with an MSD ignition system a special resistor is required Call Unilite for details TRANSMISSION Transmission Differential tables are on page 13 The original racing 289 Cobra used the Borg Warner 4 speed but was frequently replaced by the much stronger Ford Top Loader transmission For street the Top Loader is available in both Nascar close ratio and street wide ratio configurations The T 5 and Tremec are very good street alternatives with the overdrive fifth allowing excellent highway cruising They
154. sary See the rug diagram and page 110 12 After gluing on the tunnel carpeting cut holes for the dash tube grommets and install the grommets Install the dead pedal over the carpet as shown on page 83 Attach the tunnel carpet 12 with about 1 extending past the front edge allowing the carpet to be folded over to the backside and glued Cut out for the shifter ashtray and hand brake lever Screw the tunnel into place 108 To make cleaning easier the front of 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 to go Drill holes and screw the snap bases into place Remove carpets to fit seats fiaNnanNeMoorrug1 DOOR STRIKER ADJUSTMENT Replace the door strikers as described on page 89 The added thickness of the carpet should make the rear edge of the door flush with the body If not add or subtract shims The door should latch on the second catch without being slammed If it doesn t shut all the way with a solid chunk check for latch striker misalignment or interference between the two parts To check for misalignment hold the latch lever in the open position and shut the door without putting any pressure on it up or down The door latch should seat into the striker without resistance or sharp contact sounds Re align vertically if necessary Open and shut the door several times then check the striker receptacle of the l
155. sh Republic 12292 Pinion seal most AAU3381A H E T Bearing outer hub Timken 18620 18690 B B R 1 Subframe bottom mt nergy Susp 9 9107 STEERING COLUMN Bushing early column housing with rubber insulators Bushing late column Joint universal MISC ELECTRICAL Door hinge bushing Boston FB58 5 Gages Nylon bush 1 OD x x I L McMaster Carr 6389K226 Lucas 209423 Triumph Spitfire Borgeson U15N ie x Ae part of E R A assembly Stewart Warner D550 BP Stewart Warner 82170 S W 82323 S W 82327 60 S W 82326 60 S W 82311 S W 82303 SENDERS RELAYS SWITCHES Standard fuel tank Foam filled tank Relay Horn and radiator fan Switch fan thermo Relay tail light Switch brake light BULBS Headlight Frt signal parking light Rr signal parking light Instrument lighting Warning lights License plate 2 rqd SW F 385 B 2300 Centroid 10 12V Bosch Tyco V23234 A001 X032 or VW 321 919 505 VW 823 959 431 75 Standard Ign TC 52 Ford 100810B GM 403936 Wagner FC5106 6014 1157 1157 Smith GE Osram 159 S W short socket 1893 S W long socket 57 Osram 3898 Wagner 11009 BA7S base 12V 2W Used on Honda VW 57 STEERING COLUMN RELAYS FLASHERS ETC E R A Column Signal Dimmer Switch VW 141 953 517F VW 111 935 227 D H Flasher E R A Triumph Buss 180 136 SECTIONH REFERENCE JACKING F
156. sleeves can be easily polished with very fine steel wool and or car polish fiat man e bumpers INSTALLATION Install the front and rear bumper mounts onto the chassis Front mounts should have locating marks that were made when you disassembled the kit Leave the mounting bolts slightly loose Fit the rubber grommets to the body Be sure the lip is seated on both side of the fiberglass SECTION G BODY II Fit the studs and spacers onto the bumper uprights or jackpads Note that the upper spacers and studs LIGHTS are longer than the lower ones on both front and rear of the car Leave the nuts loose if the nudge HEADLIGHTS bars hoops are to be fitted i Extra bright Lights Insert the bumper jackpad assembly through the body grommets and secure onto the frame bracket with a lock washer and nut The stock E R A headlight wiring harness is adequate for up to 65W bulbs 100W bulbs require auxiliary relays to carry the extra current If you have a rear nudge bar the bar and uprights must be installed as a unit The front nudge bar All holes for mounting the lights are pre drilled at can be fitted separately or in unit with the uprights the factory The headlights can only be installed Align and tighten nuts and bolts with the correct orientation RETROFITTING THE FRONT NUDGE BAR Tape the sides of the front uprights to prevent scratching and facilitate marking With the front uprights installed as shown above h
157. so don t tighten the bolts yet Tighten in sequence the top differential bolts the fia man d rsasblyt bolts between the top and bottom subframe pieces If the clearance between the differential and the bottom section of the subframe is greater than Insert the thrust washers and inner bushings into the hub carrier assembly Lightly lubricate the inside with heavy grease silicone or moly base is best 040 insert shims to fill the gap Use a medium Install the hub carrier onto the front radius arm grade threadlocker on the bolts Loosely install the second bush half washer and Install the bushings and side brackets on the front castle nut mount tube Tighten one castle nut to 5 Ib ft and back off so that the slot aligns with the nearest hole the same manner Slide the other inside end into in the shaft Tighten the second nut to 15 lb ft and the bracket on the subframe and temporarily secure back off to the nearest hole with a bolt Insert the 16 x L bolts through the connecting plates Tighten each castle nut to 15 Ib ft and back off to the nearest hole Secure with a cotter pin Install the rear radius arm onto the hub carrier in SHIM BETWEEN BRACKET AND CHASSIS IF NECESSARY b rsasblyf 40 SECTION B PARTS PREPARATION EMERGENCY BRAKE CABLE Route the long cables through the hole in the subframe as shown above Pass it through the internal holes the holes above the front mount page 40 and into th
158. st Drive 133 Battery and cables 104 Recommended service 134 Steering column and wheel 104 Fues 134 Shiftlever 105 135 Tunnel 106 Inspection and registration 139 Carpets 107 140 Hand Brake Lever Cover 109 Driving your E R A 289FIA 141 Shift boot 110 Shiftpatterns J 141 Seat mounting 110 Index 1242 Seat belt shoulder harness 110 Gril Bumpers Jack pads J 1 SECTION A PARTS NEEDED READ ME FIRST Congratulations on your selection of the E R A 289FIA We at E R A hope that assembling your kit will be a pleasant experience We share your goal of creating a great automobile Our objective when we started on the design and production of this kit was to create a Cobra replica better than all the rest To keep quality consistently high we have designed in almost everything making this kit one of the easiest to build Even though the E R A 289FIA kit is extremely complete we realized that it is your labor that puts the final quality into the product that bears our name If you have problems E R A will help you as much as possible to complete your kit After all you are really an extension of our production line And please feel free to offer suggestions that might improve the end product or the process of construction Many of our production changes come from cu
159. stomers requests Remember the E R A 289FIA Cobra replica is usually a very good investment Of course you are free 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 details of the 289FIA We would love to hear from you but Please if you have a problem read the manual first We have tried to include all the information necessary for you to complete this project in a timely fashion Information on the parts required starts on page 8 parts preparation on page 29 and the actual process of assembling the components begins on page 67 Please insert any addenda before you start Some of our electrical equipment may vary depending upon the supplier Therefore the wiring instructions are included with the wiring harness not in this manual This manual is organized in assembly sequence not by subject Use the index to find a specific topic Have fun The Legal Stuff Information in this manual is correct to the fullest extent of our abilities Era Replica Automobiles assumes no liability for any direct indirect incidental or consequential damage resulting from the information within SECTION A PARTS NEEDED SECTION A PARTS NEEDED In this section we describe the components necessary to complete your E R A 289FIA together with part numbers and sources Normal wear
160. tal line between the block and the gage INSTALLATION Remove the tape wrapping the fresh air cables and let the cables lay on the floor 102 SECTION G BODY II GLOVE BOX OPTIONAL Hole For theft prevention you may want to put a kill Dash A B C D switch in the glove box See the wiring instructions for electrical details Drill a hole for the switch in Comp Speedo MSD Water Oil the upper corner of the vertical section of the box cable temp Temp BONO Street Water MSD Speedo Oil Use contact cement to line the bottom and sides of temp Temp the glove box with the fuzzy material included There are several possible speedometer cable and with the carpet set drive location on the transmission See page 12 for Also glue a strip of material on the underside of the the right cable for your application rear box edge where it meets the dash to prevent it from rattling against the transverse dash support If you are using a counter rotating speedometer with a Top loader transmission a cable reverser must be installed on the speedometer cable With the Richmond gear transmission the reverser is integrated into the right angle drive adapter at the transmission INSTALLATION From the engine compartment side slip the smaller speedometer end of the cable through the rubber grommet in the footbox g glovebox Holding the glove box with its forward edge tilted down and towa
161. tch door 89 Latch trunk usss 9 Lever Shift See Shift Lever Lever parts emergency brake 22 License ecrit 117 License plate light 113 Lights Back up Installation 114 106 Headlights 112 License 113 Limited Slip Differential 16 19 143 Linkage Transmission shift 24 Linkage throttle 80 Lubricants transmission and differential 138 Master cylinder Brake Installation 68 PariS aie eie 135 Master cylinder Clutch Installation 124 Mirror Dash mount 114 Side Comp style 114 Street Driver s side 115 Molding door step 116 Mount Engine esce ene 22 Transmission See Transmission MSD Tachometer compatibility 10 Nuts 67 Oil Eneilie e hei 131 Oil COOler zn 93 CL filter nux 10 CL pan 22 33 Oil temperature 9 Overheating 132 Oversteer sese 130 Paint cene 62 Chip guard 62 Painting 63 Painting chassis See Chassis
162. tch the door pocket into place with its forward edge even or slightly past the front edge of the door frame and of the way up from the hinge bottom mounting holes Hold the top of the pocket in place with masking tape Attach the hinge loosely with the two upper bolts Mark and punch holes for the two lower bolts through the door pocket Attach the bottom of the hinge and snug the bolts 87 Gently and evenly pull the bottom edge of the door pocket down over the bottom edge of the door Stretch only enough to eliminate any wrinkles Hold in place with several pieces of tape With a temporary marker trace the profile of the lower edge of the attaching plate onto the pocket Also mark where both ends of the plate fall SECTION G BODY II DOOR WEATHERSEALS Lay the doors outer surfaces down on a soft surface Glue the door weatherseal provided onto door lip about from the door edge Use contact cement or weather strip adhesive Don t stretch the weather stripping It will eventually shrink to its original shape pulling away from the corners It s better to compress it slightly around corners Trim the ends of the weather stripping as shown d doorpnl3 Remove the door pocket from the door and trim the edge of the door pocket approximately 1 outside the marked line Cut wedges out of the edge of the material almost up to the marked line DOORGASK SIDE CURTAIN FERRULES g doorpnll Re install the pocket onto the doo
163. te of Origin for the kit from E R A at the time of delivery 139 SECTION REFERENCE INSURANCE Many insurance companies will allow you to add the 289FIA to your present policy If not there are a number of insurance agencies specializing in replicas Look in issues of Kit Car Illustrated Specialty Cars and related magazines for the latest offerings When dealing with an insurance agent say replica not kit car Some of them can t translate If you use a specialty insurer there may be some restrictions to your use and the yearly mileage allowed The cost however is usually quite reasonable Below is a short but not necessarily current list A list of kit car clubs that may have more local information starts on page 140 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 Automobile Club of Southern California Cardiff Insurance Rich Dunham Tel 818 980 8941 Classic Automobile Insurance www classicins com Tel 800 397 0765 Fax 317 576 1899 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 Currently 19 states CollectorGuard Heacock Insurance Grp Lakeland FL Tel 800 678 5173 2500mi year max Great American Insurance Classic Collectors program 800 252 5233 Grundy Insurance
164. ted slip differential and you must use the spare on the back fix the tire as soon as possible Driving with 2 different size tires on the back will put extra stress on the LSD WHEELS SLABSIDE The original early cars used 5 5 wide Dunlop wire wheels which were quickly superceded by 6 x 15 wheels E R A offers both original Dunlop wheels which require hub machining and Dayton wheels which come with a bolt on adapter A spare would be the same size as the others Specifications for both wheels are posted at http www erareplicas com ssman index htm RADIATOR HOSES Pre trimmed hoses are available from E R A The 289FIA requires some standard molded hoses depending on your equipment Hoses are listed on page 22 In some configurations the hoses must be trimmed to length See page 34 EXPANSION TANK FIA A Harrison tank 3155416 can be used on the optional E R A front tower mount The tank with mounts clamps and isolators is available from E R A See page 34 and 100 for installation details SLABSIDE We re still looking for a good substitute for the original tank JACK ETC A Honda Acord scissors jack available new from E R A works well for wheel changing etc With pin drive wheels use a lead or plastic dead blow hammer to remove the aluminum knock off wing nuts Removing them with a steel hammer will mar the wing nuts Hydraulic jacks knock off hammers safety wire pliers and ot
165. ter fitting packed with the auxiliary instrument pieces onto the left side STARTER Because Ford ringears have several offsets the starter must be matched correctly Measure the distance from the plane of the rear face of the engine to the near edge of the ring gear teeth varies from 14 to so you might have to visit your jobber for the correct unit SECTION B PARTS PREPARATION RADIATOR HOSES LOWER A single hose hose can be cut to function as the two connectors used between the radiator and water pump Cut and trim the hoses as shown as appropriate for the exit side of your water pump See page 93 for installation of the hoses Note the electrical connection for the fan thermo switch on the aluminum connector A startoff THERMOSTAT If you are using a heater with the configuration shown on page 100 you must drill a small bypass hole in the thermostat next to the bulb so that a small amount of water bypasses constantly The hole also allows easier bleeding when filling the system EXPANSION TANK FIA A Harrison unit part number 3155416 is recommended An assembly consisting of tank Left exit water pump brackets and original style clamps is available from E R A FOR LEFT EXIT WATER PUMP 1 Con tube radiator DISCARD Hose Gates 20390 FOR RIGHT EXIT WATER PUMP Con tube radiator Dvexptank End piece from end section of upper hose may fit better SLABSIDE fia man LWATHOSE Come
166. tersunk the holes in the rear edge of floor where brake access panel sits the fuel tank compartment floor into the chassis the spare tire well thru the rear crossmember and aluminum trunk panels the aluminum trunk panels to chassis and the front trunk panel to the trunk lower side panels and steel flange on the 1 steel cross tube Reinstall the aluminum rear wheelhouse trunk closing panels and drill holes into the trunk side panel flanges DETAIL UNDERCOATING Because our fenders are lined with coremat it isn t necessary to protect the fender areas around the tires but you may wish to undercoat or paint flat black the inside of the fender wells for cosmetic reasons Use spray or brush on undercoating to cover all the weather seals From inside the front and rear wheel wells brush on a coat of undercoating to seal the seams and the pores in the Reattach the rear inner splash panels by riveting weather stripping Silicone will also seal the seams and fiberglassing as shown If there is a large gap very effectively along the non glassed sections fill the gap with foam You can used either foam strips or fill with DAPTex insulation See page 25 If you use spray foam be sure to back up behind the area first Silicone is then used to do the final sealing between the upper edge and the outside shell e caulk Check the body and chassis seams from underneath and seal openings with either the brush on undercoating or the c
167. th the ratio you want you can have your gear set changed at a reasonable cost Dampers coil over shocks All E R A Jaguar rear suspensions require 4 dampers and coil springs coil over shock absorbers Specifications are the same as for stock Series I and II Jaguar XKE XJ dampers cannot be used See page 23 for part numbers and page 48 for length specifications Dampers with adjustable spring seats and externally adjustable damping are available from E R A The E R A subframe requires lower control arm brackets from an XJ Sedan The control arms and half shafts will be exchanged for shortened pieces when you buy the subframe from us mounting bushings and hardware are included with the E R A subframe STEERING GEAR The ERA uses a Flaming River Musting II style gear that s 3 shorter than standard ERA modifies the unit for different tie rod ends Part numbers are listed on page 24 and modifications are described on page 43 New outer tie rods are supplied with the kit part numbers on page 135 and the parts necessary for the gear modifications are available from ERA FRONT ROTORS AND CALIPERS E R A stocks standard rotors and rebuilt calipers WITH BOLT ON 5 PIN OR DAYTON WIRE WHEELS Most mid sized GM cars from 1970 1978 used the correct pieces with 2 piston calipers Station wagons may use incorrect parts Chevrolet lists the same rotor and calipers for all sedans Before purchasing the rotors
168. the body already bonded to the chassis but without mechanicals installed This requires careful masking to minimize overspray but guarantees good body panel fit Installation of all the mechanical components is easy with the body on the chassis It is in fact much harder to install the body over the mechanical components e Remove hinges and metal closing panels behind door hinges e Remove latching hardware from the main body e Remove the aluminum interior panels that are below the door openings RADIATOR SHROUDING Remove shrouding 3 pcs from inside grill opening Remove the upper radiator support and support straps from inside the engine compartment See page 92 Gently lay the radiator back against the chassis DASHBOARD AND GLOVE BOX e Remove steering column if fit page 104 e Remove the 5 chrome screws and trim washers securing the dash panel If the dashboard wiring is already connected to the main harness disconnect the multi plug connectors Remove the dashboard and store on a soft surface e Ifthe caris already assembled you must also disconnect the air control cables the water and temperature bulbs and the oil pressure line going to the cngine For simpler operations you can pull the dash rearward without disconnecting those things Street Option Remove the screws securing the glove box to the firewall DOORS ETC e Remove the door hinge covers e Remove the doors hood and trunk
169. the same process with the left front caliper e Repeat the sequence with the rear calipers doing the right one first then the left The feed for the clutch is midway up the reservoir Don t let the level fall below the feed hole when you flush the clutch fluid Have someone depress the clutch while you open the bleeder Close the bleeder before they release the pedal Repeat until the fluid is fresh SECTIONH FINAL OPERATIONS JACKING THE CAR FRONT The car can also be jacked up on the lower control arms at the ball joint be careful not to damage the grease fitting or the front crossmember as shown The jack will barely fit by going in diagonally just in front of a front wheel avoiding the oil cooler Scoop HNjack REAR Jack up by the differential or the crossmember just in front of the differential The Jaguar suspension can be jacked on the outer end of the control arm or the hub carrier the ERA suspension just under the hub carrier BOLT ON WHEEL NOTES The standard thread of the front GM lug nuts is h 20 The thread for the rear Jaguar are 20 If you have a space saver spare be sure to have lug nuts sized for both When using the E R A rear suspension some bolt on wheels that use a cone type lug nut will have to be converted to shoulder lug nuts Call us for details PIN DRIVE WHEEL NOTES Some pin drive wheel castings have been porous especially with the real magnesium wheels We reco
170. the short lip side of the molding is to the inside of the door opening Carefully pre shape the molding by hand as closely as possible to match the door opening Form the molding by starting at the rear edge lining up the radiused edge as shown below Drill a 2 hole into the door opening flange through the top hole above the door latch striker Attach the molding at the top with one of the screws provided Enlarge the hole slightly by running the drill in and out if the screw does not go in easily Press the molding tightly against the sill and carpet Drill the next hole and insert the screw 4 x 2 L countersunk Continue for the entire length of the molding EMBLEMS The nose and trunk emblems are optional and only legal for a street style car NOSE Lay out a centerline by projecting the line of the hood forward and measuring across the headlights Use masking tape to protect the paint during marking and drilling of the hole locations SECTION G BODY II Follow the dimensions in the diagram below for the SIDE location of the original type Cobra emblems Drill holes for the emblem studs Access holes are already in the inner panel x Project a line directly up from the 4th louver Secure the emblems with the press on speed nuts provided Alternately some use double sided tape after removing the pins gvemble side LICENSE PLATE S FRONT E R A offers a tilting bracket to mount the front plat
171. traightest front to rear paths The diagram above is typical but may not be ideal for your setup To remove the pedal from the pivot box remove the setscrew through the access hole in the casting Remove the bellcrank and slide the shaft out Important Do NOT trim the engine end of the cross shaft excessively When the engine torques over under load the support can move quite a bit Leave at least 2 of shaft past the supporting rod end ADJUSTING THE LINKAGE Wire the carburetor linkage fully open Install the cross shaft support onto the engine ENGINE AND TRANSMISSION orienting it so that the shaft is as parallel to the INSTALLATION firewall as possible and fairly horizontal Refer to page 29 for engine and transmission preparation To check compatibility trial fit the transmission to the engine before any attempt to install either into the chassis Note that the engine Install the link from the carb to the cross shaft adjusting the length so that the cross shaft bellcrank is angled back about 30 degrees toward the firewall 2 and transmission are offset toward the Adjust the bellcrank on the pedal shaft so that it is passenger side of the car by one inch to balance angled back toward the firewall about 20 degrees the driver s weight and to give more legroom for when the pedal is bottomed out on the floor the driver 80 SECTION F MECHANICAL COMPONENTS If you are using a blow shield check the conce
172. ts in the outer mounting hole in INTAKE MANIFOLD the head as shown below Some aftermarket heads require a threaded insert Ford FAZZ 6E086 A to If you are going to have a heater you ll need two s E reduce threads to 1s USS The adjusting bracket tapped holes in the intake manifold or a T that will accept both fittings between the alternator and the upper right water pump bolt is included in the kit If you use both 289 302 Engine Most intake manifolds except the spacers an external brace should be put between very tallest will fit under the hood If you have a the outside end of the alternator mounting bolt and question please call the water pump Because there are so many possible combinations of water pump pulley and heads this brace is not included in the kit Use a straight edge to figure what combination of spacers BASIC PREPARATION and possibly washers will be required for all the Siete pulleys to line up 351 Series Use only medium height intake manifolds Remove cooling fan from engine water pump pulley Install the fitting for the water temperature gage in the intake manifold adjacent to the distributor Some Smiths temperature gages require a NPT hole If space permits you may adapt with a Weatherhead fitting 3200 x 8 x 6 Otherwise drill and tap the manifold to NPT You may remove the heater fitting in the manifold too Plug the hole If necessarey install aa NPT fitting
173. ttle a bit after driving The spring specifications below have worked for us consistently but they may need minor adjustments for lighter or heavier components or your non standard chassis height preference DAMPERS The ERA Jag subframe requires XKE series I or II dampers or their dimensional equivalent SPECIFICATIONS Damper Compressed Un Spring Eye size Extended Length with compressed Rate Top Bottom Length rubber Spring Ibs inch eye to eye compr sed Length on Spax Front Vel Ya Rear Jag hub carriers 10 Nhe 1s Spax w o height adj 10 VAT Spax with height adj 8 he ls Rear E R A carriers 9 2 25 ID Va Va The spring rate is either on a tag 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 FRONT SPRINGS x PRELOAD Because of small variations in the free length of new springs the installed height in the damper may vary slightly Use the preloads below to calculate the spring installed height Measure each spring and subtract the values below for the installed height in a fully extended damper Drive the car for a short distance to settle the suspension and re adust as necessary See page 127 ENGINE LEFT RIGHT 0 260 289302 250Ibs in 351C 351W 275 Ibs in Dimensions above apply to dampers with the above extended length only 48 SECTION B PARTS PREPARATION
174. u are using the outboard braked E R A rear suspension the rear wheel lug nut holes must be enlarged to 0 687 and the shank of the non tapered lug nuts McGard 61000 shortened by 0 10 A 16 Halibrand wheel in the same style of the Torq Thrust is also available but in 7 width only Definitions BACKSPACING The distance from the inside edge of the wheel to the mounting face OFFSET The distance from the centerline of the wheel to the mounting face Positive offset is where the wheel centerline is inside the mounting face Negative offset moves the wheel out away from the center of the car Some wheel companies may define the offset differently Check PIN DRIVE The E R A pin drive hubs require original style pin drive wheels using 6 pin on a 4 circle Original FIA cast aluminum 15 wheels 7 and 9 wide are available from PS Engineering 427 style wheels are available from E R A Trigo and Vintage These wheels require special machining to change the backspacing Inquire for specifications PS Engineering and Dr Dix also make 17 wheels that are up to 9 wide front 11 5 rear Specifications available on the 427man section of the ERA web site See page 126 for special installation notes PS ENGINEERING WHEEL SPECIFICA TIONS Width x Diam Offset Th x 15 8 x 17 9 17 9 1 x 15 9 10 x 17 11 177 Front 1 3 1 0 0 85 TIRES
175. ugh the fiberglass with a drill and hold the assembly in place with the Allen screws provided Carefully drill through the rear flange of the side plate and the radiator tray taking care not to damage the radiator if installed Fit the front fillers against the front flange of the side plate Trim the bottom edge to match the body fiaNnanNeNoilcooler2 contour Fit the rubber grommets onto the lines first Then Remove the assembly and match the outside baffles pass the lines through the shrouding tweeking the to the side plate Drill through the outside baffle grommets into the holes with a blunt screwdriver and the side plate with a bit etc Drill through the front filler and side plate with a The longer oil cooler line runs from the right side 30 bit Redrill through the front filler afterward of the cooler alongside the radiator and is tie with a bit wrapped to the bottom of the upper control arm Reinstall the assembly holding the pieces together inner pivot then through a clamp on the front of the with 8 sheet metal screws oil pan to the right fitting on the adapter housing Place the top curved shroud between the top side The shorter line runs along the left side of the of the bottom edge of the body opening and the slot radiator is tied to the control arm pivot goes below in the front of the radiator tray the steering shaft and to the left fitting fiat man e oilcooler1 94 SECTION G BODY II
176. ut the holes before starting Install using the diagram below WINDWINGS Loosen the sunvisor mounting block set screws Remove the bottom and third screws holding the the blocks onto the angle brackets and tighten windshield frame to the windshield SSI SOTEWS sunvisor e windwing Compare the length of the two new screws provided with the original screws by inserting into the mounting blocks on the windwing mounting brackets Grind off any excess length If the screw hits the glass the windshield will be cracked Double Check Install the screws with medium strength thread locking compound 99 SECTION G BODY II HEATER DEFROSTER Close the water shut off valve when the heater is not required The heater will radiate some heat even if the fan is off and the doors shut Definitely not necessary during those hot and hazy days When ordered with the E R A kit the optional heater defroster system is already mounted behind the dash as shown below eMieater See thermostat note on page 34 E R A 289FIA uses what would have been the original heater switch for the radiator fan over ride function You may install another toggle switch at either end of the row of toggles or drill a hole in the bottom of the heater case and mount the two speed switch supplied with the heater there the wires must be re routed but this makes a very clean installation Hose routing is dependent on the several different intak
177. vals through the following panels and the chassis and rivet body to the chassis e Front inner wheelhouse panels s rivets and the triangulated sections at the rear of these panels e Drill holes but don t rivet yet in the rocker panel attachment flanges e firewall where it mounts onto the steel crossmember e The overlapping joint between the upper and lower trunk panels e The lower trunk panel where it rests on top of the rear crossmember and along the slopped frame rails on each side holes Countersink the rivet holes See above 57 Section D Body Chassis assembly ATTACH ROCKER PANELS Reattach the rockers at the front middle and rear tabs using the original shims etc For street use seal the bottom of the rocker with upholstery foam or spray latex i e DAPTex foam insulation Once the foam has hardened trim off the excess Note that the upholstery foam should be sealed with undercoating or silicone afterward EI d rockseal SEAL ENGINE COMPARTMENT TO BODY Before the footboxes are installed install the fillers between the chassis side boxes and the inside surface of the body side Once the foam is in place you can enhance the seal with a little spray undercoating along the front face You can also seal any other possible passages with spray latex foam available from a building supply house Urethane foam is not recommended It can distort the fiberglass when it expands
178. veland Canton 15 710 pan 15 711 pickup Oil Filter See the note on page 9 Oil Pan Extra Capacity E R A E R A Exhaust System Under car complete Competition style pipes w primaries Fuel Filter In line between tank and steel line on chassis Hand Brake Lever Or Hand Brake Lever Cable Jaguar XKE Series I II 1961 1970 E R A Reproduction Lever Custom for E R A subframe Jaguar Dealer E R A E R A Emergency brake linkage Custom by E R A ERA rear suspension See http www erareplicas com fiaman cooling hose_interchange htm for part number applications Water neck thermostat Ford Motorsport M8592 B302 angled 30deg up housing Cooling system parts Hoses Upper Gates 21178 or equivalent requires trimming Local auto parts store Lower w L or R outlet Gates 20390 or equivalent See page 34 for trim Bypass Gates 28466 7 x 28474 34 x 34 or 20662 CA X 34 Heater Gates 28472 to thermostat housing 5 ID straigth hose 50 to water pump Radiator expansion tank Harrison 3155416 E R A 22 SECTION A PARTS NEEDED Rear suspension Jaguar based or Custom ERA design with outboard brakes FIA only Jaguar Rear Suspension 1964 1974 Jaguar XKE Series 1 or 2 Wrecking yard or E R A Assembly Core 1965 1987 Jaguar XJ 6 All rear suspension with inboard brakes and tubular lower control arms Sub frame Custom E R A for Jag based or ERA outboard E R A
179. ver 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 use a drill on an extra long distributor drive shaft to turn the oil pump Once the pressure is up you may need to add more oil See page 137 for Capacities COOLING SYSTEM SETUP See page 138 for your optimum proportion of antifreeze With a 15 psi pressure cap the boiling point of water or water antifreeze mixture will be raised to florkbal about 240 F In some installations air may be trapped in the intake manifold or cylinder heads To remove the trapped air e 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 valve Actually we usually fill the system with water first and pressure test for leaks then drain half the water out e With the expansion tank full loosen the water temperature fitting on the intake manifold Air will be expelled When nothing comes out but fluid tighten the fitting e Repeat the bleeding process after the car is run More air will usually come out e Check the hoses and retighten all the hose clamps HEATER With the system pressurized loosen the higher heater hose at the heater fitting to remove any air 131 SECTIONH FINAL OPERATIONS After starting and running the car up to operating OVERH
180. vice Tel 1 716 342 5769 P O Box 17325 Rochester NY 14617 Florida Fast Title Service car titles com MotoTech Tel 1 800 528 5108 P O Box 1131 Belmont NH 03220 registration And they may revolk your registration Check before you use them and or post a question on clubcobra com P O Box 9816 Birmingham AL 35220 EZ Auto Registration Tel 1 562 982 1342 California specialists Martinia Int l Title Service Tel 1 800 543 8626 Joe Holmes Las Vegas NV 89121 POSSIBLE PROBLEM AREAS Exhaust system Some states require a heat shield over the side pipes Call us Some states will put a local identification plate on your car If possible have them put it on the firewall above the driver s footbox BE PREPARED 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 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 origin of your parts Be sure that you have bills of sale for your engine transmission wheels etc You will get a Certifica
181. wiper motor illustrations on page Error Bookmark not defined to help you identify the parts Separate left and right straps are required for dual strap shoulder harnesses The length of an off the shelf shoulder harness strap may need changing Many times the wheel boxes available are not correct Measure across the teeth of your gear to the theoretical center of the cable Some of the gears are flat some are concave If your dimension A is FRONT SHOCK ABSORBERS 1 45 not 1 25 the wiper drive must be modified to compensate See page Error Bookmark not defined for details E R A offers custom made Spax dampers with springs Konis are available on special order 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 48 and part numbers on page 23 Both Koni and Spax are adjustable for damping The Spax is externally adjustable for combined jounce and rebound damping The Koni has separate external damping adjustments for jounce and rebound SECTION A PARTS NEEDED FRONT COIL SPRINGS Front Spax and Koni dampers require 12 long by 250 Ib inch 260 302CID to 275 Ib inch 351 400CID springs for most engines If you have aluminum heads on the larger engine the lighter spring will suffice Other dampers may require a different spring length Some spring shock combinations may require spacers Chec
182. zontal flange and e doorwire the body with caulking or foam rubber INTERIOR PANELS The inner door sills and the rear bulkhead panels behind the seats are attached with rivets and sealant If you had E R A bond the body these panels are already attached permanently If not leave the temporary fasteners in place while you drill through the holes in the panels with a bit REAR BULKHEAD PANEL Blind rivet the panel as shown using the factory locating holes and drilling new holes in the chassis where needed Some urethane or silicone sealer will prevent any possible buzzing between the bulkhead and main frame If you wish to mount a battery cut off switch see page 68 for the recommended position fiat man d rbulk 86 SECTION G BODY II DOORS DRILL HOLES FOR SNAP FASTENERS Use the Street interior only aluminum banana strips note that the left and right are different as a template to drill 4 holes into the fiberglass door inner panel INSTALLING POCKETS Lay the doors on a soft surface outside surface down Snap the foam covered metal door pocket attachment plates into the holes along the lower edge of the door The plates are marked left L and right R Position each door pocket on the door with the rear corner completely under the door latch with to of the pocket showing at the top and rear sides of the latch Locate the screw holes with an awl and screw down the latch g doorpnl2 Stre

E.R.A. 289FIA/USRRC 289 Slabside

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