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427 ROADSTER - Era Replica Automobiles

1. 74 Rocker ein 67 E bets ceopteveneveantes 88 Installation Removal ccescceseeeeeeeeeseeeeeeeeeee 71 Rust 77 Safety strap 102 Scoop HoOOd 74 Seat allele 17 122 Seats Tnistallaton 122 Mounting 0 2 enr a n a 122 Sequence Assembly cee eeceseceseceecesecsseeneeeneeees 5 Service Periodic 147 Shelby sions 36 Shift 15 113 Placement 48 Preparation 47 Shift lk age 15 Shipping 7 Shock absorbers See Dampers Shrouding Radiator 56 89 Side 85 107 135 Side PIPES domination nahn 130 See Lights Slave cylinder Clutch ais 35 37 Snaps top tonneau 128 SE
2. See Steering wheel Wheels Back spacing 2 08 ni dssttsavene ies nner A cients 19 Bolt on Special 138 Parts and specifications 19 PIN ALIVE i 19 26 Sealing air leaks 138 Wit DUS sein 138 Whoopee a 145 Windshield 107 58 amp amp 106 Wine ec saa igs ain 138 Wiper Arm installation and 139 Linkage wheelbox installation 77 Modifications 50 Parts ee ees 18 26 Relay 109 WIENS think sneer asa 80 Ballast resistor 80 109 Firewall a 80 Front harne S 80 Parking Tights 81 rear harnesses eerie 82
3. 97 141 Latch adjustment door 123 69 Lever parts emergency 23 Levers Shift ihc ee naa 47 casita seria nn anial enue 26 iene 130 License plate 11 2 127 Lights Back up Installation 127 SWILCH 3 sed 113 Head 125 License 1 127 Signal Fronte eden 126 126 Limited slip 16 Linkage Carburettor ssi anrasinen a n 86 Emergency brake ciais ni enii aeiee 41 Transmission 1 26 Lubrication 150 SCHECUIEs 147 Hecke 19 Manual updates and 2 Master cylinder Brake Parts 148 Master cylinder Clutch 148 Mirror Dashimount e 128 Benne tics se tens 128 Molding door step ceceseeccesecreesecneeeecnseeeeeaeaee 118 Motor mount modifications 32 Mount Engine Installation 32 INDEX 156 Modif
4. See Hood striker Stipes 75 Subframe Rear SUSPENSION siess nieni e 16 Supplies and materials 29 Suspension Al nent oes stiaees cies teats nal s 140 96 Part nUMDbETS Re 148 REAM eoret sees yscsaptosieasvasssss easddveesvsassenssaiects 23 ERA teens antes dated ee 43 eet eects eaten eee esi re 45 Trailing 101 Hub Carrier anette denen 43 Rebuilding spenni renne 40 Selectii eena wn etal Mie wee 16 Urethane bushing ceceeecssecseeeecnereeeeeeees 40 TUNING aie aie ek eh 140 SWay Dar ass rah sili ae isle MA eis Switch Thermostatic 00 ccccccccsssceceesseceensseeeeenees 144 beige baled ast 126 Tank Expansion oi eae 38 Fuel ce esssstoieucsnsioticaaentanaussuistnieds 92 Drain deine 92 Radiator expansion 20 Thermostat 9 144 Modifications ss 5sccccsstaasgisctseastateetands cssevceasestieeeee 38 Tires 142 20 20 Sp ren a pre E 20 140 Tonneau cover bait catia e eiea RE e EA scone 135 Snap installation 79 Tools Nee
5. box wrenches 1 e Screwdrivers Phillips and flat bladed 3 or 4 sizes of each e Jack preferably a hydraulic floor type e Small needle nose pliers e Engine hoist or chain fall e Oxy acetylene or small MIG welder for side pipe brackets e Rubber mallet e Saber saw if you are fitting side pipes e Socket head Allen wrenches e Jack stands 4 e Special wrench for exhaust headers see picture at left SHIPPING COMPANIES PARTIAL LIST Horseless Carriage Phone 800 631 7796 Intercity Lines www intercitylines com Phone 800 343 0802 Fax 413 436 9422 SECTION A PARTS NEEDED SUPPLIES NEEDED The following list covers most of the materials you will need to complete your kit Not necessary with bonded body option Caulking to seal body to Urethane or Silicone 5 For caulking gun 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 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 200 dia long Aluminum panels to chassis button head Aluminum t
6. eee 131 Side PIPES 130 INDEX 155 WINGO Cal i 132 Expansion 20 24 38 Balas ees 88 Ferrule Side Curtain ceecccecessceceesececesseeeeenees 85 Filler Cap See Fuel Filter 23 Olly Ba ea 17 Fire exting isheT roster ereire s reiris 153 Firewall components s sseseeeeeereeeereeeersrsrrerererrererse 80 Finin orderne ne ane e 130 Floors 8 61 Fork throw OUt ccccccccccccecsesssseceeeeeeeenees See Clutch Fresh air vent Body Mleta 125 109 121 Front SUSPENSION 96 Fuel Filler cap ner Cap sss sceesescscssacseussssessbssancsspeesisasesssassncscets 149 Installation 0 eecceeceesceesceeeceseceseceneceeenseeneeenes 93 Removals civsceciuscbintetucccnieaeurtetvtnpevannbesssvboes ones 58 PUMP secession enn eee ees 10 Tank a R a 92 amp nace es 86 GIOVE DOK 109 amp einni ie awed ai aides 90 Grommets Firewall 80 Ground Clearance 139 Ground Engines 82 Handbrake
7. 86 Removal aceat sores e e e eee aed 56 Step molding 2 118 8 85 Doug See Richmond Gear Drive shaft cccccccccscccssccceessececessseceenseeeeeenaes 49 84 Electrical Components eccesesecesesseesecneeeeeneeneeeee 80 Emblems Installation T 113 129 SOULE 23 Emergency Drakes 41 Adj stment 100 101 ERA rear SUSPENSION 102 Lever parts 23 121 EMISSIONS 9 Engine B90 fictive shiv iA cian athena ae ath 10 427 Center OET ieee 10 427 Side Oilein nnn aiaa 10 ADS FOr RATRE E sisaveeusastesteest 9 29 60 11 Availability eni nese Eo e eaa 23 CHEVIOlEb e e E E EEEN 11 Finne 1 eani see eR AN y 130 Identifying casting numbers 153 Installation 83 ib erostali E E E 23 Preparation 32 SOHC yikes Oe ali de apa 10 Exhaust a Tae 132 Exhaust systemi s sshssssvstesessnocsenioessaessseastness 18 23 Gaskets and 132 Heat shield installation ccescesseeseeeteeeeeeseeeee 87 Leaks diene eames 132
8. Solenoid 24 Source eae ae 27 Spacer Transmission 13 Spare eda bees 20 SPAR ssi ide apache Geiessdyeyess 141 Speedometer INDEX 157 90 degree cable 110 Cable Drive gear E 25 Installation 283 110 Richmond Gear 13 Top Loader i 2 222 25 Drive gear Calculations 14 Splitter Grills 2 90 eh avs 18 22 Height adjustment 00 eee eeeseeeeceeeeeesseeeeeeenees 53 E E E ooeeke 41 Starter ise 24 37 Starter Solenoid 24 Starting with a carburetor 147 Steering column Bushing R amp R nateni ninini nenas 49 Cancelling CaM neisiet arieni ih 50 Installation Upper 112 17 24 Preparation 50 Steering gear Installation lees 97 Part number R E 23 Prepatation a a 49 Steering KnUCKE 97 Steering wheel Center Cap wena cicteh Sees Aste erat 113 vests Hite ies 112 PAIS 1823 hs 17 24 StOVer 60 95 151 Striker
9. Headlight J 6 j 4 To Radiator ebod fwire DASHBOARD HARNESS Wire the dashboard off the car See the separate wiring instructions for individual connections Make the final connections to the dash and steering column after everything is installed in the car SECTION E BODY PREPARATION GROUNDING THE ENGINE FRONT MOUNTED BATTERY Run the cable directly from the cylinder head to the negative battery terminal Don t forget to also run the harness kit ground wire from the cylinder head to the firewall REAR MOUNTED BATTERY It s usually easiest to ground the transmission to the X member REAR HARNESS The multi connector block for the front end of the harness is with the dashboard module Don t install it until after the rear harness has been passed through the hole in the side of the footbox The rear harness is installed at the factory The following shows the technique we use 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 Before the door sill aluminum is installed pass the harness under the door sill and secure the harness to the fiberglass under the door sill 82 SECTION E BODY PREPARATION REAR BULKHEAD PANELS Blind rivet the top and side panels as shown using the factory locating holes and drilling new holes in the chassis where n
10. 144 PUlley fen Sie 27 Rack and Pinion See Steering gear Radiator Fan Automatic 145 Optional 89 Standardia 88 88 SHrOUGING deg oats 56 Upper connecting tube cee eeeeeeseeeeseereeeeenees 24 Radiator hoses Layout and Partsi eise riei 38 S 24 Read First ne i i 8 Rear aX lessan ae ERTE RES RS 40 Rear suspension Jaguar part numbers seseseeeseeseseeesesrereerreeeeesreeees 42 Rebuilding 40 16 Trailing arms ei eee aie eA 40 Reflector REAT 127 Registrato aa 152 Regulator Voltage 80 Relay Wiper ens 109 Removal 56 Replacement 148 Requited e SR cupeeen 8 Reservoir 2 See Brakes Richmond Gear 5 13 RallOS aki hehatcks teenie R 12 Richmond Gear transmission Shift linkages 15 Ride height Speciications 139 Raed 18 Ring gear FE 3 10 E E 29 Rivets
11. 13 Ibft Shis 28 is 46 The 75 115 GRADE 5 GRADE 8 ENGLISH 54 225 Metric Grade 10 9 Grade 12 9 METRIC 25 lbft 29 Ibft 47 83 95 SECTION F SUSPENSION ASSEMBLY FRONT SUSPENSION LOWER CONTROL ARM Lubricate the chassis receptacles and the sides of the control arm bushings with silicone or petroleum jelly Use a gentle oscillating motion when inserting the control arm into the mounts Sometimes a plastic dead blow mallet helps Insert the 5 bolt with a heavy washer through the front bushing into the chassis Use a flat washer under the locknut Use the 3 x bolt through the rear mount with flat washers and locknut Torque to 50 ft lb UPPER CONTROL ARM d fsusp The upper control 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 Install the upper ball joint as shown sandwiching the control arm between the ball joint and the dust shield boot retainer Torque to 16 Ibft Install the arms with 3 shims front and rear for a preliminary camber setting Leave the pivot shaft end nuts slightly loose Tighten to 60 after the suspension is at normal ride height COIL OVER DAMPER Spacers for the lower mounts are provided with the dampers Use a washer on either side of the top mount Secure the top with a 2 long bolt in from the back A 2 2 bolt is supplied for the
12. Before the Triumph steering column is installed check that the signal canceling cam on the steering column shaft is oriented correctly See page 50 ASSEMBLY Also ground the engine or transmission directly to the chassis with at least a 2 gage cable The TKO 600 is illustrated on page Error Bookmark not defined The most convenient ground is usually from the transmission to the threaded insert in front of the X member where the transmission adapter is used with some transmissions Clamp the cable along the inside of the right frame rail g stcol Lower steering column installation is described on page Error Bookmark not defined Insert the upper column and housing through the hole in the dashboard engaging the lower column as the upper one is slid in Align the flat of the lower column with the notch in the upper tube and fit the clamp over the column tube Snug the bolts slightly but don t tighten Fit the bottom half non threaded of the upper column clamp between the column and the mounting tabs on the transverse dash support With the top half of the upper clamp in place insert the bolts from the bottom through the relay bracket E R A column Install the switch onto the column housing Original orientation was toward the passenger side of the car but you may install it on the conventional side at your preference Bolt the steering wheel to the hub The pattern is asymmetric the part
13. E Remove the front wheelhouse panel It s attached with screws or rivets to the main chassis rail as shown below to the vertical support fiberglass inner panel top and where it meets the middle panel The following panels are held in place with screws standard kit or are bonded and riveted with the Bonded body option 57 SECTION CHASSIS PREPARATION DASHBOARD AND GLOVE Remove steering column if fit page 112 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 and the connection at the ammeter Remove the dashboard and store on a soft surface If the car is already assembled 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 Remove the screws securing the glove box to the firewall 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 anyway See page 107 for details Before removing windshield mark the location of the center windshield bracket on the body with a sharpened piece of stiff wire or a scribe Remove the two small screws f
14. shims supplied with the seat tracks under the SEAT BELT SHOULDER HARNESS right front holes over the tunnel Put 3 shims under the left front holes Place the seats so that the studs in the tracks go through the holes in the floor Note that large washers are used under the floor on three studs and a small washer is used on the inside front E R A offers reproductions of the original competition belts Inquire If the seat does not slide freely loosen all four bolts slide the seat back and forth to align the tracks and re tighten WITHOUT ADJUSTING TRACKS If seat adjusting tracks are not used follow the previous instructions using the spacers and bolts provided to raise the seat base EINT SEATBELT Screw the seat belt anchors into the captive nuts provided on the lower chassis If necessary clean the threads with a hs 20 tap to remove any coating build up If you have shoulder harnesses cut holes in the carpet and if necessary chase those threads also Slip the ends of the belts in the clip to the eyelets of the anchors already in place 122 SECTION BODY INTERIOR DOOR INSTALLATION Generally the hinge assembly won t have to be disassembled If the bushings have to be renewed with the hinge off the car loosen the retaining set screws and drive out the pin The bushing number is listed on page 148 Lubricate with light grease on assembly Bolt the door hinges onto the chassis with the si
15. FUEL PUMP We use a heavy duty mechanical fuel pumps Carter M6905 on both 427 and 428 engines with no problems If you don t need the extra capacity of an electric pump avoid the complication and noise Wiring for an electric pump is built into the standard wiring harness OIL FILTER Any standard block mounted oil filter equivalent to the Motorcraft FL1 HP may be used The same Ford part can be used on the remote filter supplied with the oil cooler with remote filter The optional remote filter mount usually integrated with an oil cooler uses a Transdapt 1015 block adapter OIL PAN There is a limited distance between the engine and the ground Use a pan with a maximum depth of 6 5 inches For more oil capacity there are pans available that are wider Canton and Aviaid make good designs E R A normally stocks Canton pans both in a high capacity street design and the Road Race design Part numbers are on page 23 Some Aviaid pans have two additional fittings at the right front A large tube that s intended to connect to a breather tank and a smaller tube that can be used for a dipstick Plug them with metal if not used ALTERNATOR AND PULLEYS ERA supplies the alternator mounting bracket to shift the alternator up and in from the original location An adjusting bracket to replace the stock one is optional You may use a single groove pulley system for the crank water pump and alternator Aluminum pulleys from March P
16. Use two Gates 28472 hoses or their equivalent to connect the heater inlet to the shutoff valve Connect the upper to the engine The length must be trimmed heater tube outlet to the fitting on the water pump When ordered with the E R A kit the optional Connect the blower motor wire to the dashboard harness heater defroster system is already mounted as shown as indicated in the wiring instructions See the wiring below hints above to use the two speed switch e eater1 The E R A 427SC 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 wiring heat2sp TO RETROFIT Use the template included with the heater to drill holes in the firewall 108 SECTION BODY INTERIOR DASHBOARD Note that the rotary knobs for the wiper and dash lights Note With a heater installed the oil temperature gage similar but not necessarily the same The retaining pin and ammeter are interchanged hole position must match the proper hole in the switch GLOVE BOX For theft prevention you may want to put a kill switch in the glove box See the wiring instructions for electrical details Drill a hole for the switch in the upper corner o
17. ee eee See Emergency brake Handling 141 142 Headlights E E 125 Adj stment RE 145 Heat shield side 87 a e E EE E T 108 OSES prie n E EEE E E Ri 23 esi pannat See Chassis height Chassis adjusting osisssa eeter geesi 139 Hinge Door COVEI See er E ETE E ES 125 Hood pornea EREE EENET 67 Installat O 67 eran ae araa a E E 67 Prop Stay zean a a S 68 Scoop Ford FE small 74 Stiker nra e E E E i REE 68 I ma KOS E o AEREE RA 6l Hoses radiator sekn reei ea 20 Installation iee E 144 Layout and parts 38 Modifications senesini ii eiai 39 Parts esain e E A E E ES 24 H b TEAL eenn a S 41 47 ID plate 63 Inspection ein eee 152 Insulation Material A 29 TSU AN COs 153 Intake 1 10 Interior panels iiss diated ible 83 TntrodUcti om 5 JACK 20 bse aen eaae a alain aie 151 Jack pads eine 124 Keep it simple 8 Killswitch 109 Knob wiper dash light 1 109 Knuckle
18. firewall where it mounts onto the steel crossmember e 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 only See above 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 either with shims or by bending the steel attaching flange on the chassis Use a block of wood and a hammer to bend the flange Don t strike the fiberglass directly If necessary bend the flange in further than necessary with a block and bend or shim back the necessary amount When the doors fit well permanently attach the rocker panels Run a bead of sealant in between the flange and the rocker edge with a caulking gun Rivet the rocker panels to the chassis Use one or two clamps as you move along riveting to insure a tight fit If the car is already painted and the rocker attaching flange is painted semigloss black touch up the rivets with the semigloss black 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 Cla holes for rivets into the chassis tubes The closing panel should not contact t
19. BMW 21521104269 SECTION REFERENCE SUSPENSION FRONT Ball joint lower Ball joint upper Bushing lower inner pivot Tie rod end outer Tie rod end inner Sway bar link Bushing and bracket inner outer Seal inner F hub Bushing upper inner pivot Upper control arm shaft w bushes Bushings only Steering gear Bearing F hub Moog 6145 Rep 10277 Moog 5208 Rep 10268 TCI 9952 ERA Republic ES 425R Moog ES425RL E R A part Republic SL18060 Suspension Techniques PB 93 A 2 Bower BCA A 6 Bower BCA National 8871 TRW 12310 MOOG K6148 MOOG K6108 Flaming River FR1502 3X3 SUSPENSION JAGUAR REAR Inner pivot bearing lower wishbone Outer fulcrum bearing lower wishbone Seal inner fulcrum Seal outer fulcrum Bearing inner hub Bearing outer hub Hub seal inner Hub seal outer Sway bar link clamp and bushing Universal joint Subframe pivot bush Pinion seal most Door hinge bushing 148 Tor B146 Timken 03062 03162 Jaguar C17168 National 471652 Timken 18520 18590 Timken 18620 18690 Beck Arnley 052 0221 BeckArnley 052 0643 large Republic SL18050 Suspension Techniques PA 75 Spicer 5 160X Moog K8169 or Republic 12292 AAU3381A Boston FB58 5 SECTION H SUSPENSION REAR OUTBOARD BRAKES Outer fulcrum bearing lower wishbone Upper trailing arm Frnt Rear Upper radius rod inner Upper rad rod outer Lower rad rod Rr in r Lower rad
20. PAINTING The E R A body requires only the standard techniques for fiberglass preparation nothing special Because of our methodical production rates bodies are seasoned fairly well right from the factory You may use one part color for economy or a 2 or 3 part clear coat system for a show quality job Paint all panels including the inner portions of the doors hood and trunk lid COLORS For reference some of the more popular color schemes and contemporary equivalents are listed below Visit us or your local paint supplier to look at color chips Colors are also available subject to the limitations of your monitor at autocolorlibrary com Guardsman Blue B7 Equivalent Evening Blue Met Deltron DBU3344 Night Watch Blue non metallic 1987 Chrysler DB9 Red slight orange tint like original Equivalent Honda R51 British Racing Green 1971 Lincoln code G R amp M A2426 Twilight Blue Poly Non original but nice From 1990 Lincoln PPG 4246 STRIPES The official competition stripe layout and dimensions are shown on page 76 Extend the stripes around the edges of the body openings where indicated CHIP GUARD Your painter can add a special material to the front of the rear fenders to prevent paint chipping from stones thrown from the front tires Alternately a clear plastic film like 3M 84911 from your local body shop supply can be added after the car is painted SECTION BODY PREPARATION
21. Turn the subframe differential upside down on a padded surface with the differential mounting plate down 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 40 If there is a gap between the top of the differential and the mounting plate shim to zero clearance Tighten the top bolts On both the Jaguar and 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 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 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 b jagcage 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 screws in from the inside of the brackets On
22. and the clutch still seems to be dragging the disk may be sticking to the flywheel or pressure plate Try turning the engine over with the clutch depressed and the car in 4 gear taking care not to crash into the garage wall The process may disengage the stick 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 reservoir 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 ATE type 400 Both are DOT 3 or 4 Don t use DOT 5 i
23. switch to manually turn the radiator fan on The temperature should stabilize somewhat under 210 F depending on your ambient temperature Shut the over ride switch off and allow the fan to come on automatically This should happen about 200 F 210 F If the fan does not start even at 220 F check the electrical circuits involved Once the temperature drops the fan will automatically cycle off The fan will run even with the ignition off but will normally stop within 5 minutes This feature helps prevent hot soak fuel percolation in the carburetor e Check for exhaust leaks e Re torque the exhaust manifold bolts e 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 152 for hints on inspection insurance and registration 145 SERVICE MAINTENANCE PARTS DRIVING CONTROLS The dash switches are arranged as follows All the toggle switches are oriented with off down Note that the fresh air is on when the dash knobs are pushed in If you have a heater the positions of the oil temperature gage and ammeter may differ from the diagram below Warning lights Blue U High beam Green G Signal Red R Ignition Alternator There are also two fast blow 4A fuses under the steering
24. En EEE E EE E ase 96 Cooling system Expansion tank seseeeeeeseseseseeeereeseersrsrrrerrerrersesreee 38 eraon aE E E E RRE 88 SEUD a r 144 snee See Thermostat Dampers oret 139 Fine tuning ceccccessceseconscrssenscenseescessestseesess 141 BLOM bs E 22 Installation 96 Reb erea irn ee ede eee 22 140 Specifications front and reaf 53 Dash tubes 120 DaShDO ard a 109 Controle 146 58 S Witch 109 ahem Gee hee 81 104 121 108 Differential 150 16 Differential Sears 23 Differential problems With 6 150 DiStriDUtors i tact avestiedees 11 Dolly Wheel Sirenene aa EA mses 7 Door Adjustmentin ren 121 Installation 123 Latch 123 Pocket installation 84 Pull strap
25. Reproduction or Triumph Spitfire GT 6 1972 E R A wrecking yard mid 1977 Steering column Bushings Triumph E R A dealer Moss Motors Steering wheel Moto Lita E R A Wheel hub Triumph Moto Lita E R A column E R A column Comes with E R A column Steering wheel Center Reproduction of original either AC or Cobra motif button 24 Speedometer Cable Ford Top Loader Richmond Gear Cable drive gears etc Top Loader T 5 Tremec Speedo drive gear Speedo driven gears Retaining clip Cable drive Richmond Gear Spare Wheel Tire Transmission Transmission mounts Ford Top loader 2 holes along centerline or 2 transverse holes 5 6 apart Ford Top loader w holes 6 25 apart Ford C 6 Automatic Richmond Gear 5 speed and Tremec TKO 3550 II TKO 500 600 standard input 500 600 with short input Throw out fork Big spline T L Richmond Gear 5sp Small spline T L Tremec TKO including 500 600 Pivot bracket for above SECTION A PARTS NEEDED AC 11589234 1967 Mustang Champ 400020 See page 13 for other parts C4DZ 17285A LH 7 tooth black C8AZ 17285A RH 7 tooth yellow See parts and selection notes on page 14 C1DZ 17292A See parts on page 13 and 14 Space Saver w 4 bolt circle Non 6 pin only Pin Drive Ford Top Loader Richmond Gear 5 spd for FE Ford Tremec TKO 5 speed See notes on page 13 Ford C8ZZ 6068A or Republic 31 2258 Ford C9AZ 606
26. SECTION BODY INTERIOR FINAL INSTALLATION HINTS EXHAUST SYSTEM UNDER CAR Use gaskets coated with high temperature silicone such as Permatex Ultra Copper 81878 on both sides Special pase I exhaust tolerant silicone is available at most automotive INSTALLATION supply stores Loosely bolt the primary pipes to the Install insulation on the underside of both the floors to engine Sanaa minimize heat transfer into the passenger compartment Spread a small amount of silicone or Walker Acousti seal on the inside of the collector pipes and install the side pipes over the primaries With the rear of the side pipes propped up slip the end of the side pipe through the body Hold the side pipes up against the ends of the primaries and start the primaries into the side pipes one by one Once all are inserted push all the way on A rubber hammer sometimes helps to get the pipes fully seated Stainless steel side pipes may benefit from Walker Acoustic seal exhaust sealant between the primary pipes and the side pipes Loosely bolt the front brackets together and the rear brackets to the rubber hanger Tighten the bolts holding the primary pipes to the cylinder heads A modified wrench see special tools on page 28 will make tightening the rear drivers side flange much easier Re torque the bolts after the engine is run and periodically thereafter See page 131 for instructions on welding the tabs between the
27. Tel 800 274 1804 www parishheacock com Sneed Robinson amp Gerber 901 372 4580 State Farm Insurance has been known to insure replicas as a Classic 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 153 ACGCONEUBES a N A N 113 Ain CLEAN Or E E 74 VESTR OEA E E E 79 Alignment SUSpensSion eseeeseeeerereerrerrerereererrrse 140 AORN AOR EERE Ea de Renae SSES 21 Mounting ees 33 Mounting Small block 33 Part NUMDETS 21 Selection 11 Ane E a Reach Aide 150 Anti sway bar Bronte 97 46 101 113 Assembly 5 Automatic transmission cccccccscecessceceesseeeeeeseees 84 Back up light 0 ccccesecesecsceeseeeseeeeeeeeeeeeeeerensrensees 127 Ballast resistor 80 Part n nR 21 Battery RE P T
28. 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 ratio The Richmond Gear 5 speed is much more flexible allowing a changes looong 2 88 1 differential The T 5 and Tremec have an Ford T5 Rated at only 300 lbft this is only useful with a overdrive 5th and can coexist with a 3 31 1 and numerically mild 302 engine Overdrive 5 gear higher ratio Tremec 3550 TKO and TKO The 3550 is good for tweaked 302s and mild 351 engines The TKO can be used with mild 427s and 428s Gear spread is very wide making it a marginal performance box The 3550 and TKO have a deep overdrive 5 gear the TKO II has a tighter 82 1 5 gear TRANSMISSION GEARING WITH 26 OD TIRE 4 SPEED TOP LOADER WIDE RATIO TREMEC 3550 TKO 500 5 SPEED 2nd 3rd Ratios 2 78 1 1 93 1 1 361 1 1 Dif Speed 1000RPM sd Ast 2nd 3rd 4th 3 27 1 1 98 1 1 34 1 1 1 Ratios Dif Speed 10008 O 7 1 11 8 17 4 23 4 34 4 6 7 11 0 16 3 21 8 32 1 TREMEC TKO Il 5 SPEED 9 1 13 1 18 5 25 2 8 4 12 1 17 2 23 4 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 3 07 1 7 7 12 7 18 8 25 2 30 4 94 12 9 16 9 218 3 54 1 6 7 11 0 16 3 21 8 26 3 Ratios 2 32 1 1 69 1 1 29 1 1 1 Speed 1000RPM Some T 5 s are geared like the Tremec 3550 Ratios 2 87 1 89 128 11 821 DIF Speed 1000RPM 3 07 1 8 8 13 3 19 7 252 30 7 39 4 3
29. front mount Trunk mount optional C6AZ 10145 B Comes with kit Gates 7450 XL most Bendix 141040 PART NUMBER Delco 321 147 rebuilt or any 70 s Ford with separate regulator A 100A unit is not necessary but will fit Delco 334 2000 83 Ford Crown Vic Commercial Police Lucas A8806 85 89 Chev Sprint Chevy w integral regulator Same as Ford SOHC Gates 7445 XL most pulleys Nieh FF 109 Borg RU 6 SMP 4 Wells GM 18002421 18003761 Rebuilts Bendix L55001 L55002 Includes pads Bendix 0525 or equivalent Semi metallic for BMW 3432 1 112 399 Bower BCA 6 or Timken LM11910 LM11949 Bower BCA A 2 or Timken LM67010 LM67048 GM 3966202 National 8871 Group 47 Must have hold downs on both ends Optima SC34 See erareplicas com 427man for installation details 21 SOURCE Most Fords 1971 1980 GM aftermarket Aftermarket GM dealer or many Front GM cars 1970 78 see page 16 GM dealer Local parts place E R A BMW dealer GM local auto parts SECTION A PARTS NEEDED Bell housing FE 390 427 428 Lakewood 15210 for Ford small block Lakewood 15200 Top loader Richmond Gear TKO with short input shaft Various E R A Lakewood 15202 Tremec May need spacer See page 13 Lakewood 15203 5 See mod s necessary on page 35 Clutch arm pivot FE Ford 8 7 7522 Small spline T L part must be custom Dealer E R A
30. onto the transverse link and bolt to the bracket D Note This linkage can be adapted to most engines If yours requires something different please call us The FE dual quad setup requires an additional linkage assembly SECTION E BODY PREPARATION ADJUSTING THE LINKAGE Wire the carburetor linkage fully open Install the cross shaft engine support bracket so that the shaft will end up as parallel to the firewall as possible and fairly horizontal Install the link from the carb to the cross shaft adjusting the length to have the cross shaft bellcrank angled about 30 degrees back toward the firewall Adjust the bellcrank on the pedal shaft so that it is angled back toward the firewall about 20 degrees when the pedal is bottomed out on the floor Install the link from the pedal to the cross shaft so that the pedal just hits the floor Remove the wire holding the carburetor linkage open and check whether the pedal is at a convenient height 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 as shown below and confirm that 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 87 EXH
31. page 102 Connect the brake hose to the caliper Cob nan caliper jpg After the suspension assembly is installed fill the differential as described on page 149 SECTION PARTS PREPARATION REAR HUBS BOLT ON 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 See page 140 for alignment specifications and procedure 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 SHIFT LEVER FORD E R A has complete reproduction shift levers and linkage for those who don t want to do the modifications described below To duplicate the original Cobra s reversed shift lever the Ford shift lever listed in Section A must be modified as shown below SHIFTI Remove the knob and rubber mounting grommets from the lever Use an oxy acetylene torch to apply as little heat as possible to melt the braze or silver solder attaching the actuating cable to the lock out dog When the braze or solder melts a spring will pop the dog out 47 Cob man b shift2 Save the dog spring and washer Push the cable back up into the lever about 4 inches but
32. valve Actually we usually fill the system with water first and pressure test for leaks then drain half the water out We can also tell the condition of the cleanliness of the cooling system by the drain water 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 If you have a heater it may be necessary to bleed air from the system by disconnecting a hose at the heater nipple e Repeat the bleeding process after the car is run More air will usually come out Standard one piece upper hose e Check the hoses and retighten all the hose clamps OVERHEATING Use a 165 F 180 F thermostat for street use Leaving the thermostat out will cause overheating The boiling point of a water anti freeze mixture with a 15 psi cap is over 230 It is not harmful and normal for the water temperature to rise to 210 F 220 F with the car not moving We do NOT recommend using an underdrive waterpump pulley on the street AT SPEED The E R A 427SC uses an oversized radiator made by Griffin rated for 600 bhp Overheating at speed is almost always the result of incorrect engine settings usually retarded ignition timing Check your dynamic timing at idle and 3000 3500rpm or as recommended by your engine builder Sometimes an extremely tight new engine can cause overheating With upper connecting tube 144 SEC
33. you can use this preload to automatically keep the clutch adjustment at zero clearance This will however reduce the life of the throwout bearing Since clutch wear will be most seen when the driven disc is being broken in you may want to keep the automatic mode during the first couple hundred miles and then install a return spring See page 104 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 adusting rod so that there is about movement when you push the transmission arm toward the front of the car With Tilton Master Cylinder Check the tightness of all fittings before bleeding BLEEDING With BMW Master Cylinder The car must be level or with the front end slightly higher for this operation felichadj Fill the brake clutch reservoir with DOT 3 or DOT 4 fluid Silicone fluid is not recommended 137 SECTION H WITH SPRING Remove the spring Adjust as above but leave just 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 after the first 500 miles and about every 6000 miles thereafter If the stroke of the arm is at least 34
34. 23 44 20 29 49 30 34 92 9 40 40 For optimum cooling it s best to use the smallest proportion of anti freeze commensurate with your local temperatures Pure water has the best heat transfer rate of all but you must always use coolant or additive that prevents aluminum corrosion We ve had good results by adding Red Line Water Wetter too REFERENCE JACKING BOLT TORQUE SPECIFICATIONS FRONT x 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 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 a light oil Metric Grade 10 9 Grade 12 9 M8 25 Ib ft 29 Ib ft M10 47 58 M12 83 100 US Bolt size Grade 5 Grade 8 HYjack 9 Ib ft 13 Ib ft i6 18 28 REAR 31 46 Jack by the differential the crossmember just in front The 50 5 of the differential The Jaguar suspension can be jacked on 1 75 115 the outer end of the control arm or the hub carrier ERA 150 225 suspension just under hub carrier 151 REFERENCE INSPECTION AND REGISTRATION Without researching and writi
35. 31 1 81 12 4 18 3 234 28 5 36 5 3 54 1 7 6 11 6 17 1 218 26 6 34 1 RICHMOND GEAR 5 SPEED RATIOS 2nd Ratios 3 27 1 2 13 1 1 57 1 1 23 1 1 1 DIF Speed 1000RPM Ratios 2 95 1 1 94 1 1 341 1 1 63 1 Dif Speed 1000RPM 11 3 16 3 21 8 34 7 2 88 1 8 2 12 6 17 1 21 8 26 9 3 07 1 7 7 11 8 16 0 20 5 25 2 3 31 1 7 1 11 0 14 9 19 0 23 4 12 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 with large and small splined input and output shafts Unless you expect to subject the drive train to extremely severe loads drag racing tires it is not necessary to use the large spline input shaft 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 SPECIFICATIONS AND APPLICATIONS Most Ford cars from 1964 to 1973 used the Top loader 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 Drive shaft 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 t
36. 50 miles COIL OVER ADJUSTMENT Front When you raise both sides of the coil spring collar by X thereby compressing the spring more the chassis height will change by roughly 1 4 x X In other words to raise the ride height by 1 Check the sweep of the wiper and adjust if necessary move the spring collar up by 0 7 Rear with Jag For small changes you can adjust only one spring per side The ride height will change roughly 1 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 FRONT The specifications for the standard front spring preload are on page 53 This will result in about 7 from the ground to the bottom of the front crossmember 5 to the front of the main rails The specifications shown below are predicated on the standard tire sizes 235 60 and 295 50 15 You may change the front height to suit personal taste but be aware that the oil cooler scoop will be the first to contact pavement if the car is too low Press the arm onto the post so that the blade falls at the base of the windshield just above the frame See above Removal Use a screwdriver to pry between the post base and the edge of the arm opposite to the blade Once the height is correct tighten the front upper control arm pivot bolts See page 96 Jf ch_hite REAR If you have adjustable spring col
37. 7 16 14 from the transmission side IRON FE BLOCK Note 2 Most clutch pressure plates won t require the spacer shown below Some however have tall fingers that move the fork connection forward The spacer moves the slave assembly forward and inward correcting the alignment If the alignment is still off the corner of the aluminum block can be ground so that the slave bracket can be rotated slightly 429 460 FORD The slave cylinder is mounted on the bell housing as shown e b clslv460 SECTION PARTS PREPARATION CLUTCH THROWOUT ROD Permantly install all the clutch components onto the E R A supplies two threaded rods between the clutch flywheel using an alignment tool for the driven disc slave cylinder and 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 137 for assembly Install the correct link either by shortening the adjustment or loosening the adapter bracket from the block A return spring is optional 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 Itis very sensitive to proper setup Install the bell housing Place a straight edge across the bell housing opening to m
38. Cables Battery Front Mount Engine ground to battery 16 long eye terminal clamp E R A parts supplier Battery to starter solenoid 32 long eye terminal clamp Starter solenoid to starter 24 long eye eye Rear Battery Cables Engine Trans ground Battery ground Battery to starter solenoid With cutoff switch Battery to switch Switch to starter solenoid Cooling system See Radiator Hoses on page 24 Po Dampers Springs Front Coil Spring 12 x 250 Ibs in For Spax E R A AFFCO Eibach Damper Spax G135 PAS 200 E R A Koni 8212 1126SPA1 Double external damping adjustment Special order only w aluminum body Dampers Springs Jag rear Coil Spring 10 x 350 Ibs in E R A AFFCO with ht adjst Spax 8 x 350 Ibs in Eibach Damper w o ht adjst 5200 415 Externally adjustable damping E R A Std XKE w height adjustment G640 5200 Ser 2 ERA rear Coil spring 9 x 400 Ibs in Must be 2 25 ID Damper w height adj G297 Drive Shaft Components see page 49 for parts reference Po 22 ENGINES AND ENGINE PARTS Mounts 429 460 Ford 427 428 Ford 260 289 302 351 Oil Pan Extra Capacity 289 302 351 Cleveland Exhaust System Fuel Filter Hand Brake Lever or Hand Brake Lever Cable Horn Button dash mounted SUSPENSION REAR Jaguar Rear Suspension Assembly Sub frame Rebuilding Parts for rear suspension Differential LSD rebu
39. ERA Rear Suspension The E R A 427SC is designed to use either the Jaguar rear suspension in an E R A subframe or a custom E R A suspension unit with outboard brakes The E R A unit is available as a kit with with all our conversion parts ready for your differential and brake parts or as a complete assembly See page 43 for details JAG PARTS SELECTION See page 23 for application list The Jaguar differential is the same Salisbury unit that 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 Gears wear is not normally a problem even in well used assemblies but always replace seals The vintage of the Jaguar differential is punched in the casting at the lower right corner of the cover The top number is 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 and buying a used rear end look for e Completeness You don t need the Jag trailing arms but you do need everything else e Limited Slip Differential Many XJ differentials were open A new limited slip may be retrofitted for about 700 e Brakes Try to get serviceable hydraulic and emergency brakes There were no major chan
40. INTERIOR CARPETS INTERIOR REAR PANEL After masking the body spray or brush contact cement on the panel areas and the back sides of the vinyl and carpet Install the side carpets starting by lining up the corner s as shown Install the vinyl on the central aluminum side panels Trim even with the vertical edges and leave a short amount at along the floor Carefully form the carpet over the wheelhouse bulge and push into the side and top areas Trim off the excess material 115 SECTION BODY INTERIOR FOOTBOXES Layout of pieces Spray contact cement on the front and sides Note where the dead pedal mounting holes are Corner Detail Glue in the front panel first When gluing in 2 use the corner below the door hinge area and the front vertical edge for reference 116 SECTION BODY INTERIOR UNDER DOOR Trim around the top socket and locate the holes for the Before you glue in the rug take note of the location of door striker mounting bracket the seat belt hole at the rear bottom corner Remove the door strikers mounting brackets and any shims 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 the front and rear bound edges to line up the raw piece wrapping the material around the front edge underneath the door hinge area Trim the material even with the door sill opening an
41. Note that the basice kit is shipped with short pieces of half round rubber taped to the door openings This is put there to prevent rattles and wear when the car is shipped You may discard the rubber etc Lengths of new gasket are included in the parts boxes shipped with the kit Remove the door hinges and metal closing panels behind door hinges Remove the hood and trunk hinges noting their location L and R are stamped into the hood hinges The trunk hinges are the same from left to right and are stamped with BUMPERS BUMPER BRACKETS Front If you have the optional nudge bar s detach them from the overriders Remove both fresh air inlet ducts and screen from the front body Remove each bumper tube assembly from its mounting point The upper nut is accessible from inside the nose The lower nut is accessed through a hole in the inner splash panel Rear Unbolt the bumpers from their mounting brackets upper bolt and chassis lower bolt The nuts on lower bolt are reached through the access holes on the bottom of the rear chassis cross member If nudge bar is fitted remove as a unit 56 CHASSIS PREPARATION ROLL BAR Remove the center access panel from the rear bulkhead See page 83 Remove the bolts from roll bar brace one at each leg and at the top and bottom end of the rear brace Remove the shim washers from the lower end of the brace and slide the brace down to disengage the upper sl
42. STEERING GEAR See page 24 for part numbers The E R A supplied steering gear does not require the preparation below It is modified from a Flaming River gear Parts to complete the modification are available from E R A Remove the tie rod boots Cut off the threaded end Weld MIG is preferred the ERA adapter to the remaining inner tie rod Paint Replace the boot and fasten with tie wraps b fr_gear_mod STEERING COLUMN UPPER You may use the E R A reproduction column or the Triumph column listed on page 17 BUSHING REPLACEMENT The bushing consists of two parts an outer rubber steel 49 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 When inserting the column through the assembly be very careful that you don t push the sleeve out SECTION PARTS PREPARATION E R A COLUMN The E R A column is ready for installation No preparation is necessary TRIUMPH COLUMN Astcoltri 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
43. SUNVISORS 106 REAR HUBS BOLT ON WHEELS 53 WINDSHIELD HEATER DEFROSTER SECTION A PARTS NEEDED SECTION A PARTS NEEDED READ ME FIRST Congratulations on your selection of the E R A 427SC 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 427SC 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 Remember the E R A 427SC 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 427SC We would love to hear from you but Please if you have a problem use the
44. 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 28 for names DIMENSIONS AND WEIGHTS Weight 800 Ib bare kit 200 Ib of boxes 600 Ib for roller m 26 5 33 5 aa 27 9 13 7 5 0 N A 02 9 7 kot 20 9 7 4 7 DILINI 5 83 50 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 a comfortable height during construction The track of the Cobra dolly wheels is only about 20 Your trailer may require additional boards to support the dolly wheels Without tires or dolly wheels you can put tires as buffer between the chassis and the trailer The kit will have to be lifted on and off the trailer manually Have 3 strong friends to unload If you re coming on a weekend to pick up your kit please warn us if you aren t coming with extra people too Don t tie down the dolly wheels to secure the kit Tie to the chassis or suspension In the absence of su
45. WHEN YOU BUY PARTS KEEP THE RECIEPTS They are frequently necessary for inspection and or registration The following items are critical to the proper assembly of the E R A 427SC Details for selecting each component are listed in this section Any special component preparations are detailed in Section B Engine Front brake rotors and calipers Engine accessories Front coil over shock absorbers Oil cooler system optional Exhaust system side or under car Transmission Ford 4 speed or automatic Richmond Gear Speedometer cable 5 Wheels and tires Transmission shift linkage and lever Radiator expansion tank and hoses Drive shaft Windshield wiper motor and drive components Jaguar XKE or XJ Sedan rear drive suspension unit Hand brake lever and cable Rack and pinion steering gear Emblems Spare tire Jack and lug wrench or knock off hammer 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 FORD FE SERIES Bore Stroke BHP Torque Remember All piston engines have a limited torque spread If you decide to build a fire breathing monster expect to suffer at the lower RPMs Because the E R A 427SC is light every hiccup is felt Very high octane gas
46. are threaded into the casting and retained by a setscrew and Loctite Differential w o brakes 2 Stub axle w washer and nut 43 SECTION PARTS PREPARATION Bolt on cob man2 b rerahbbo Pin drive cob nan2 b rerahbpd 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 to 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 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 Technique One Insert the hub with outer bearing 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
47. arm Loosely install the washer and castle nut Install the rear radius arm onto the hub carrier in the same manner Slide the other inside end into the bracket on the subframe and temporarily secure with a bolt Insert the USS L bolts through the connecting plates Tighten each castle nut to 15 lb ft and back off to the nearest hole Secure with a cotter pin 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 fia nan d hsaxiflg Install the coil over damper onto the upper mount using a 1 x 2 L bolt with flat washers and stover nut Connect the lower end of the damper to the front radius arm with x 2 L bolt Use spacers on either side of the damper if necessary Install the anti sway bar onto the rear of the subframe with is USS nuts flat and lock washers as illustrated above Install the brake calipers using M12 x 30mm Allen cap screws and wave washers Bolt on wheel hubs require spacers between the caliper and the upright Pin drive hubs need no spacer Attach the emergency brake cable as shown You may have to make a slot in the bracket in which to insert the cable See page 46 The cable is routed through the internal holes in the subframe and out the front to the balance bar assembly
48. belts in the clip to the eyelets of the anchors already in place SHOULDER HARNESSES Locate the mounting holes in the chassis with an awl and cut holes in the carpet See page 83 The optional four point shoulder harness are installed with the Ch 20 attaching bolts above the belt loops Ebod bumpers INSTALLATION The lower spacer nut is accessed through a plug in the inner splash panel The upper nut is access from the inside of the nose opening Fit the rubber grommets to the body Be sure the lip is seated on both side of the fiberglass Fit the studs and spacers onto the bumper uprights or jackpads Note that the upper spacers and studs are longer than the lower ones on both front and rear of the car Leave the nuts loose if the nudge bars hoops are to be fitted Insert the bumper jackpad assembly through the body grommets and secure onto the frame bracket with a lock washer and nut If you have the rear nudge bar the bar and uprights must be installed as a unit The front nudge bar can be fitted separately or in unit with the uprights Align and tighten nuts and bolts RETROFITTING THE FRONT NUDGE BAR Tape the sides of the front uprights to prevent scratching and facilitate marking 124 SECTION With the front uprights installed as shown above hold the nudge bar between them aligned with the body opening and with about clearance between it and the body Transfer the hole locations from t
49. bottom attachment Again slide the bolt in from the back The damping adjusting screw on the Spax unit goes toward the centerline of the car LOWER STEERING COLUMN INSTALLATION ERA STEERING GEAR MODIFIED MUSTANG Because the connection is splined the intermediate column will fit no matter what the shaft orientation SECTION F SUSPENSION ASSEMBLY STEERING GEAR 12 BRAKES HUB AND ROTOR MOUNTING FYfifq ANTI SWAY BAR Prepare the rack and pinion assembly for as described on a a page 49 Studs are already on the chassis Clean any paint off the threads before installing the washers and nuts The front bar is mounted under the front frame extensions just behind the radiator e Bolt the bar in place with the rubber urethane bushes and clamps The link holes slant up toward The assembly is held in place with 5 8 18 x 4 5 L bolts Degrease the threads on the bolt and in the chassis Use a small amount of low strength thread locker i e Locktite Blue on the threads Torque the bolts to 50 Ibft the outside e 15 41 the connecting links between the tab on the STEERING KNUCKLE lower control arm and the pads on the ends of the See the illustration on page 96 sway ber e Tighten the link bolts so that the rubber bush Install the knuckle on the lower ball joint with a washer if expands to the diameter of the cupped washer Do needed to space nut for the cotter pin and nut Torque to not over tighten 6
50. column that protect the rear signal brake lights individually 1 Radiator fan heater 2 Horns 3 Wipers Heater sho Gh MUNG 4 Voltage regulator Fan relay Signal lights 5 Brake backup lights Fuel pump PTGWA OTS 6 Parking panel lights wry Atay MTS SW 7 Headlights high beams 2 8 Headlights low beams FUSE BLOCKS VIEWED FROM FRONT 146 SERVICE MAINTENANCE PARTS RECOMMENDED PERIODIC SERVICE Fluids and capacities are listed on page 143 EVERY GASOLINE FILL UP EVERY 12 000 MILES e Check engine oil and water e Check transmission oil FIRST 1000 MILES e Grease rear axle and driveshaft universal joints e Check the tightness on all chassis bolts e Grease the inner and outer pivots on the rear lower Change engine oil and filter control arm Jaguar only EVERY 3000 MILES e Grease front upper and lower ball joints and outer tie rod ends EVERY 24 MONTHS OR 2 YEARS e Change antifreeze Change engine oil and filter Check engine drive belts for wear and tension Adjust clutch play if using a return spring Check beak eck rear brakes Grease the lower spherical joint of the front shock EVERY 3 YEARS EVERY 6000 MILES e Flush and replace brake fluid See page 138 Inspect front brakes STARTING A CARBURETOR CAR Most of our preferred engine builders use a carburetor Hot start Crack open the throttle pedal just a bit while without a built in choke This is for sim
51. designs that are currently available The shaft end play of the second design can be adjusted by bending the tang on the cover 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 from the wiper motor to the right wheelbox through the grommet E wiper2 Fit the cable tubes to the wheelboxes so that the flared cable tube ends lock into the slots on the wheelbox housing and back plates Leave the retaining plates slightly loose so that the tube orientation may be adjusted The short tube on the left gearbox is to support the surplus cable outside the left wheelbox SECTION BODY PREPARATION If necessary gently bend the tubes to create a 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 51 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 insulat
52. fit the Top Loader with stock or Hurst linkages or TOP LOADER Richmond gear transmissions with the Long shifter SHIFT LINKAGE TOP LOADER Originally AC modified the 1965 66 Mustang shift lever by turning the handle about 180 degrees on its mount This placed the lever forward While it looked a bit strange it worked quite well Both the original Ford 4 speed shift linkage and Hurst linkage 391 3180 work well Some modifications to the rod link lengths will be necessary to move the lever back to the original position If your transmission does not have the shifter mounting bosses in the correct position adapters are available from E R A See page 48 for shift lever placement On the short tail shaft transmission the shifter mounting bracket should be mounted within the last couple of inches of the tailstock end This places the shift lever in the same spot as on the original Cobra If your transmission locates the bracket further forward an E R A adapter plate can be used to move the shifter back RICHMOND GEAR E R A modifies a Long shifter and rods for the 5 speed using the Ford reversed lever for control The lockout T handle is there but no longer is functional Inquire about available parts TREMEC The lever bolts to the transmission s stub Ask about available original look levers 15 SECTION A PARTS NEEDED REAR DRIVE SUSPENSION ASSEMBLY Jaguar based Suspension EI Custom
53. genesis427 com March Performance Pulleys marchperformance com Mustangs Unlimited mustangsunlimited com PS Engineering Reider Racing reiderracing com Richmond Gear richmondgear com Summit Racing Equipment summitracing com Trigo Inc trigowheels com TrueChoice truechoice com Vintage Wheels vintagewheels com SPECIALTY ADDRESS Speedo reducers angle 235 E O Connor Drive Elkhorn WI 53121 drives 800 683 500 Oil pans and pickups 10041 Canoga Ave Chatsworth CA 818 988 899 1 1434 Pleasant Valley Blvd Altoona PA 16602 814 942 1869 Oil pans and pickups 9 Tipping La Branford CT 06405 203 481 9460 Engines parts 19021 S Figueroa St Gardena CA 90248 310 538 2914 Reproduction Cobra 3099 Carter Circle Kennesaw GA 30144 770 427 0020 hardware Transmissions and 205 E Dogwood Dr Franklin NC 828 524 9085 shifter parts Top Loader San Antonio TX 210 967 4161 transmissions parts Clinton Twp 48036 810 468 1356 376 Cambridge St Burlington MA 781 273 9900 Engines and parts P O Box 19449 Indianapolis IN 46219 317 357 8767 Engine pulleys 32413 Park Lane Garden City MI 48135 888 729 9070 Shelby Mustang parts 185 Adams St Manchester CT 06040 800 243 7278 15 and 17 Pin drive 2675 Skypark Dr 102 Torrance 90506 310 534 4477 wheels Jag differential 12351 Universal Dr Taylor MI 48180 800 522 2707 rebuilding 1208 Old Norris Rd Liberty SC 29657 864 843
54. hacksaw To prevent scratching mask off the Plexiglas Saw the excess material from the top edge of the frame 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 135 FITTING THE TONNEAU COVER Stretch the cover over the snaps Starting in the middle snap in the front mark and install the snaps as described above for the top SECTION FINAL OPERATIONS 136 SECTION FINAL OPERATIONS Attach a small hose to the slave cylinder bleeder nipple CLUTCH HYDRAULICS emersing the other end of the hose in a small cup of fluid PRESSURE HOSE INSTALLATION See page 35 for an illustration of the slave cylinder Loosen the nipple about turn with 2 or 7 mm wrench Work the arm on the clutch pedal shaft instead of pushing on the clutch pedal itself until only clear fluid comes out of the hose 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 The slave cylinder has an internal spring that keeps a small amount of pressure to extend the piston at all times Most throw out bearings will operate with the small constant pressure involved Those that cannotmust use a return spring and be adjusted periodically If you wish
55. hard at any time Stress can break the windshield Make sure the top material is centered on the front bows and 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 134 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
56. hood strikers on the firewall so that the hood is flush with the body The hood seal will be compressed slightly eliminating rattles HOOD PROP Pre installed The upper and lower stay brackets are factory attached as shown HOODPROP Note the orientation of the keyhole slot and the bend in the rod TRUNK LID Tape the gasket to the main body as shown on page 78 for bodywork alignment prior to painting 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 on the inner panel Tighten bolts and recheck fit TRUNK STAY Pre installed 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 68 ebod trnkstay SECTION D BODY CHASSIS ASSEMBLY TRUNK LATCH Pre installed 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 Adjust the striker o
57. index 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 32 and the actual process of assembling the kit begins on page 54 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 the assembly sequence that E R A normally uses with their turnkey cars not by subject You may change the sequence to your own preference within reason We prefer to install all the mechanical parts after the car is painted That way the mechanical bits stay clean and it is easier for the painter to get any hidden areas Please use the index to find a specific topic Have fun SECTION A PARTS NEEDED SECTION A PARTS NEEDED This section describes the components necessary to complete your E R A 427 SC together with part numbers and sources Normal wearing parts that may need replacement after use are also listed on page 148 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 PARTS NEEDED PICKING UP YOUR KIT The kit can be transported from our factory in an enclosed trailer standard automobile trailer or rampback hauler
58. installation through the holes in the panels with bit or removal of the engine or transmission e Remove the hood and hood prop e Wrap rags or towels around the front X brace and over the transmission tunnel to prevent paint scratches e With the engine on a hoist and tilted down at the clutch end carefully lower it onto the engine mounts engaging the studs on the engine mounts into the slots in the mounting perches 83 SECTION BODY PREPARATION e Loosely install the washers and nuts onto the engine mount studs e Raise the back of the engine either by changing the tilt of the adjustable engine lift or with a jack underneath the rear of the engine e Install the clutch and bell housing on the engine See notes on page 35 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 Top Loader Front holes of trans adapter e Borg Warner Front holes of adapter 5 3550 Rear holes of adapter e TKO Series including the 500 and 600 All require an aluminum adapter available from ERA Depending upon whether you have a standard length transm
59. number of teeth on the speedometer drive gears part s on page 25 using the formula Dif Ratio Tire revs mile 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 13 for gear selection DRIVEN GEAR SELECTION AND PART NUMBERS Ford Top loader T 5 and Tremec Richmond Gear 5 Speed Diff App Toploader T 5 Tremec Diff App Part Number Ratio Teeth Left hand Right hand Ratio Teeth Orange tip Burgundy 3 07 1 3987919 White 17 C2DZ 17271G C3DZ 17271C 3 31 1 20 3987920 Blue 1 C2DZ 17271K CODD 17271B 3 54 1 22 3987922 Gray Green tip Yellow 6 8 3 54 1 C4DZ 17271A CODZ 17271B Pink tip Pink 0 3 77 1 2 107 17271 Black C8SZ 17271A Orange Retainer for all C1DZ 17292A 14 SECTION A PARTS NEEDED SHIFT LINKAGE i If you don t want to modify the Mustang lever yourself see All shift linkage modified Hurst is available from E R A page 47 E R A manufactures a duplicate the original shift lever to
60. or track use These require modifications to the steering knuckle DRIVE SHAFT E R A has drive shafts for most applications in stock This is a project for a shop specializing in power transmission equipment or shafting See page 49 for design details OIL COOLER SYSTEM The optional E R A oil cooler and adapter system comes with or without a remote oil filter Layouts for both configurations are shown on page 90 The remote oil filter is a reproduction of the original race option and mounts on the front of the block If you decide to build your own system the specifications below may be helpful but should not substitute for good design practices Oil cooler approximately 13 x 4 h or 6 h with AN 10 male fittings The 6 h unit requires a special aluminum housing included the ERA option 10 stainless braided hose Oil cooler adapter or block off plate bolts to the block or oil filter housing STEERING COLUMN UPPER You may use a Triumph unit see page 50 as described below or the custom E R A reproduction column The E R A column includes the hub and requires no preparation TRIUMPH COLUMN The preferred parts are from a Spitfire or GT 6 vintage 1972 to mid 1977 Get the upper column and housing upper and lower clamps and both switches See page 50 for bushing remove and replacement preparation and rebuilding of the Triumph column 7 STEERING WHEEL The original Cobra used a 16 l
61. 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 b canclcam E R A has wiper assemblies that can be purchased outright or if necessary will modify your pieces on an exchange basis OVERVIEW The original style Lucas wiper motor and drive uses a spiral wound drive cable that engages gears at each wiper arm By driving the cable back and forth in a rigid housing the gears and wiper arms rotate The amount of rotation is determined by the stroke of the drive cable and the diameter of the wheelbox gears A switch in the motor that remains closed during 350 degrees of the rotation of the drive gear automatically parks the wiper arms on the right side of the windshield after the dash switch is shut off Some motors have the switch cam oriented incorrectly Check the Stroke Changes section below for the correct orientation Unfortunately the best wheel boxes listed on page 26 are rarely available If your wheelboxes do not match the specifications on page 18 the crankshaft in the wiper motor may be modified to compensate See Stroke Changes below For electrical testing see the electrical troubleshooting guide SECTION PARTS PREPARATION CONNECTING TUBES b wiper3 Undo the large nut and remove the cable tube wheelbox assembly from the motor Remove the wheelbox bac
62. sockets Windshield frame support Bumper Door hinge and latch to chassis Integrated throttle brake and clutch pedal assembly mounts Aluminum fuel tank Fresh air vents for footboxes Bumper mounts Not shown Aluminum floors and wheelhousings Standard front battery mount Fiberglass footboxes 55 SECTION Body pre mounted on chassis option Most of the time consuming items listed in this section are already done although it couldn t hurt to check critical fasteners You can skip all the Section C items except removing the windshield bumpers lights and fuel filler cap in preparation for paint BODY REMOVAL The body must be removed to paint the chassis but is not necessary to remove the body from the chassis to paint the body All E R A turn key cars are painted with 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 When doing any disassembly note any adjusting shims and their location Mark each for reassembly DOORS HOOD AND TRUNK LID Note the location of the hinges and the number of shims for all pieces Remove the door hinge covers Remove the doors hood and trunk lid from their hinges
63. the small slits Install the snap backing plate to the underside of the material bending the prongs to secure the snap 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 SECTION BODY INTERIOR 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 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
64. the center of the windshield to 44 degrees above horizontal assuming the car is level of course 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 that fits 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 See illustrations that follow 133 ENopfitl Install a snap on each rear flap as close as possible to the outside corner e Punch 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 e From the outside insert the prongs through
65. the lower trailing arm bushing end to the lower holes on the chassis brackets Note the slight angle of the bushing Tighten upper bolts See page 99 for trailing arm installation ANTI SWAY BAR Set the slider about 1 5 from the end of the bar as a prelimary adjustment D rerasbmt 102 EMERGENCY BRAKE Attach the emergency brake cables and balance bracket as shown The front cable is attached to the handle as shown on page 100 feraeblay SAFETY STRAP d drvhoop Install the strap into the holes on the chassis support below the driveshaft and bolt into place If you have the ERA rear suspension and are using the emergency brake see the diagram on page 102 SECTION F SUSPENSION ASSEMBLY BRAKE AND CLUTCH PEDAL brpedal INSTALLATION If necessary clean and grease the needle bearings in the chassis and in the brake pedal Slide the pivot shaft through the chassis bearings with the splined end toward the inside If the engine is installed the shaft must be installed from the outside of the chassis Install the thrust washer s brake pedal and clutch pedal onto the shaft Secure the clutch pedal with the shoulder screw Install the clutch throw out arm onto the splined end of the shaft Orient the throw out arm approximately opposite the pedal See the illustration on page 137 To adjust the orientation of the clutch arm change the length of the connecting rod between the clutch pedal throw out arm a
66. the support tubes Use a hole saw to make the 1 holes as shown Paint the tubes gloss black and install after the dashboard is in place Ein tunltube The optional ashtray location is marked on the tunnel Cut the hole slightly smaller than marked file to fit A snug fit is all that holds the ashtray in place INSTALLATION 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 drill two holes one on either side through the vertical surfaces at the front of the tunnel near the top Enlarge the holes in the tunnel to so that the hold down screws will drop through SECTION BODY INTERIOR Insulate the inside of the tunnel Use contact cement to fasten aluminum foil backed jute foam or high temperature material see page 29 on all surfaces except for the areas of overlap at the front edge and the bottom flanges Check for adequate clearance along the left side of the tunnel adjacent to the shift linkage Glue low density foam weather stripping the same type used on edge of the wheelhouses onto the bottom of the tunnel flanges Install carpet page 120 Removal after car is completed Remove shift lever boot and bezel Remove seats Remove dash support tubes Remove the rear bulkhead access panel Remove screws along floor flange and lift the tunnel out eint tunnel 114 SECTION BODY
67. 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 Certificate of Origin for the kit from E R A at the time of delivery 152 REFERENCE INSURANCE Many insurance companies will allow you to add the 427SC to your present policy If they won t 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 I try to keep an updated listing at http www erareplicas com 427man insurance too 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 usu
68. top over the exposed rivets on the backside of the front channel Glue thick foam strips to the inside of the front bow channels to seal the top of the windshield frame E topfit3 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 SECTION BODY INTERIOR 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 Once the windshield angle has been determined the top may installed to fit If you intend to install side curtains in the future E R A can supply a template to duplicate the correct angle or use an angle gage to set the glass angle at the center of the windshield to 43 degrees above horizontal assuming the ca
69. 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 within a steel and rubber collar They 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 metal tabs holding it in place The plate may be discarded if you are going to use the dash mounted horn button e Remove the nylon washer and aluminum cap from the lower end of the column housing Slide the column up and out of the upper steering wheel end of the housing as far as it will go e Trim most of the old upper and lower bushing nubs off with a razor or utility knife Work the lower bushing out with a screwdriver by pushing in and down on the locking nubs in the side of the housing e Remove the column from the housing e Using a dowel just small enough to fit inside 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 e Slide the column back in place e Replace the lower bushing e Replace the horn plate if necessary Canceling cam 50 Before the Triumph steering column can be permanently installed check that the signal canceling cam on the steering column shaft
70. 0 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 washer if needed to space nut for the cotter pin and nuts torque to 40 lb ft 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 Ib ft minimum Install the cotter pin If you have trouble greasing the ball joint loosen the Zerk fitting one turn e fswayb 97 SECTION F SUSPENSION ASSEMBLY ROTOR HUB GENERAL INSTALLATION Parts are listed on page 21 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 lb ft If you ever need to remove the pins they will have to be heated to 300 deg to weaken the bond Excessive heat will weaken the pins Always grind the rotor after installing the wheel bearing races If you don t have a special driver for the races let the auto machine shop install them Clean off the grinding dust thoroughly before putting grease in the hub and installing the bearings and inner GM based Upright through chassis 2086 seals ahubash Install the dust shields onto the steering knuckles if GM assembly desired Install the hub onto the stub axle with a special tanged washer and castle nut With new wh
71. 21 Bell housing Modifications 35 11 Belts 21 Blind rivets 29 Blow shield 11 Body Paintings aA 75 E ERa 71 75 Removal essa nt atin estes 56 Sid pipe Holes 72 67 Books engine 153 Brakes Bedding in the 138 Bleeding 138 Drake COVER ov cad seescones dese 81 BAR 103 Fluid reservoir Part 21 Front inlet 125 Front rotors Installation snra 98 126 Master cylinder installation 61 Part 148 16 21 148 Pedal 5 103 Pedal seen alae el 103 er Re en nee 16 Bulkhead Rear cacsiscckiiesasrtienteetemawies 83 BUMPETS coeaeas 124 INDEX 154 Remova a rer eaaa ee ie 56 Cable 22 Emergency Drake tes nenn 100 Speedometer Inst
72. 8E or Republic 31 2242 Ford C9AZ 6068H or Republic 31 2345 Pioneer 622378 72 73 Camaro w MT Pioneer 622378 plus an adapter from ERA Pioneer 622378 Requires straight spacer Same as above with offset spacer Note Both forks listed below Ford 807 7515 May be hard to find As a substitute ERA widens the small spline The edge must still be modified per page 34 DOTZ 7515A or Pioneer CF 101 Hole added Must be modified per page 34 Ford C8AZ 7522B NLA from Ford 25 E R A dealer auto parts store E R A Dan Williams Ent Ford dealer RH driven gear G M cars Trigo Dan Williams GT Performance David Kee E R A Richmond Gear E R A Summit Fortes Ford dealer E R A auto parts supplier Auto parts supplier David Kee E R A Tony Branda David Kee E R A Tony Branda David Kee E R A T Branda SECTION A PARTS NEEDED Shift Linkage Mid sixties Ford 4 spd Top loader Modified Hurst 391 3180 recommended The rod lengths must be modified when the shifter is moved to the correct location See page 15 Inquire about a plate that may be necessary Richmond Gear 5 speed Long shifter Shift Lever Curved Ford See page 47 for modifying the Mustang lever or contact E R A 1965 67 Mustang unit to duplicate original ERA for finished units and other period Fords Cobra Voltage Regulator Ford Regulator D4TZ 10316A D9PZ 10316A or Ford dealer E R A aft
73. 9231 Misc parts at low 580 Kennedy Rd Akron OH 44305 800 230 3030 prices Pin drive wheels 3933 Foothill Blvd La Cresenta CA 91011 818 248 7446 Racing parts fire 40 Industrial Park Place Powell OH 43026 800 388 8783 extinguisher systems Pin drive and bolt on 14805 Fisher Cove Del Mar CA 92014 619 952 4717 wheels 27 SECTION A PARTS NEEDED TOOLS NEEDED Most of the tools required for assembly of the E R A 427SC 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 the engine and transmission may not be a good time for your first project but assembly of the rest of the kit is very straightforward 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 Heat and bend a wrench for the left upper exhaust header flange bolt HEAT AND BEND WRENCH SIZE TO MATCH YOUR HEADER BOLTS HEAT AND BEND Tool List Body Installation e rivet gun with adapters for and 1s rivets e Electric drill with bit assortment e Utility razor knife e Paintbrush 1 1 5 buy a cheap natural bristle brush e Shears or large scissors e Caulking gun cartridge type Mechanical Bits e Ratchet wrench and sockets e
74. ASSEMBLY AND SERVICE MANUAL FOR THE Era Replica Automobiles 427 ROADSTER Chassis 758 on Revision 10b 6 08 Copyright 2008 Era Replica Automobiles Updates Addenda We try to keep the manual current with the state of the kit but there may be kit changes not already noted If the error is significant please drop me a note Thanks for your patience Significant updates corrections and supplements to the manual will be sent to you if required Lesser partial updates and helpful hints will be posted to our web site at www erareplicas com 427man The latest entire manual in PDF format is posted on the web Use the e mail below for the location Thanks Bob Putnam ERA e mail eracars sbcglobal net Please direct your parts inquiries to eraparts sbcglobal net The Manual The text and layout of this manual was done with MSWord 2000 Some of the illustrations were hand drawn and scanned and some were done in DesignCad 2D and 3D Images were translated to GIF and JPEG format and linked to this file The Legal Stuff Contents SECTION C CHASSIS SPEEDOMETER CABLE 110 BATTERY AND CABLES 111 54 STEERING COLUMN AND WHEEL 112 This manual is arranged by SHFTL 113 i BODY 56 assembly sequence not topic 58 113 For
75. AUST HEAT SHIELDS offers a set of heat shields that help to contain heat of the primary exhaust pipes where they are close to the foot boxes They can be fit before the engine is in place and are easily removed for primary pipe installation LEFT SIDE INSTALLATION Right and left pieces are marked L and R dhtshld2 Hold the vertical shield against the bottom of the tube at the front of the footbox e Left the inner edge about from the main frame rail e Right the inner edge about 2 from the frame rail Mark and drill for the Tek screws supplied Attach the top to the vertical shield Mark and drill the wheel house for the sheet metal screws provided SECTION BODY PREPARATION RIGHT SIDE INSTALLATION RADIATOR AND FANS These shields are only used when the battery is moved to the rear Install like the left side Install the upper shroud on the bottom side of the cowl inner panel as shown E upradmt Insert the rubber radiator grommets into the holes in the radiator support tray and install the tray onto the studs in ROLL BAR the chassis Insert the 3 roll bar grommets into the rear body cut outs All pieces are pre installed on every Kit Lubricate the inside of the grommets with silicone spray or Armor All and install the roll bar hoop and support brace as described on page 71 Drop the radiator into place from inside the engine compartment Fit the rubber grommet to the upper radia
76. AZ 6080E Republic 31 2250 or equivalent 13 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 First and second gears are shorter than the Ford 4 speed so you may numerically lower your differential ratio without fear of bogging down in first gear See the chart of speed in gears on page 12 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 Bulletproof for competition but very noisy for street use Rear Mount GM 3870184 Republic 31 2224 Pressure plate Standard Ford Clutch disc Ram 4148 11 x 1 26 spl Clutch throw out bearing arm Same as small spline top loader Speedometer drive parts see page 14 for gear e Cable Champ 400020 Gear Holder Bullet GM 345215 e Retainer 3708148 e ORing GM 10054241 e 090 deg adapter AA1052 Gear 39879XX XX No of Teeth See driven gear part numbers on page 14 FORD MUSTANG T 5 This 5 speed transmission and its Tremec variations can be used with the smaller Ford engines
77. D in inches Some people like the look of the Goodyear Sports Car Specials which are a vintage race tire The proper sizes are 26 5 x 8 0 15 and 26 5 x 10 15 front and rear These tires are not legal for street use in many states They also tend to pick up and throw rocks and flat spot after being parked Their sidewalls are also very thin and intolerant of curb parking We don t recommend them Avon CR66ZZ tires are available in 15 sizes now and have gotten rave reviews They are the only streetable 15 tires that are V speed rated For 17 wheels tires in 35 and 40 series will fit Ask for current recommendations Before mounting on pin drive wheels see page 138 SPARE With 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 This unit gives an increase in trunk room and mounts very nicely on the upper trunk shelf between the hinges RADIATOR HOSES The 427SC requires several standard molded hoses depending on your equipment FE and small block hoses are listed on page 24 In some configurations the hoses must be trimmed to length See page 39 Installation layout is on page 144 If you are using the steel upper connecting tube your radiator must have a special top fitting Specify when you order your kit Hhose kits are available from E R A EXPANSION TANK FE ENGINE New reproduct
78. E R A are designed to use an old style Ford alternator with an external voltage regulator 50 60 amps capacity is adequate See page 21 for part numbers Use the alternator as listed for the FE block page 21 Install the alternator as shown 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 33 OIL PAN Maximim oil pan depth with the small block is 8 The sump should not extend past the front mounting flange OIL FILTER If you are using an oil cooler and sandwich adapter with block mounted filter you must use a Fram PH16 Equivalent filters may not work The Fram s shape is slightly different A 90 degree adapter Ford M 6880 A50 may allow a larger filter but we have not had a chance to check fit FORD 429 460 CID E R A has engine mount pedestals special foot boxes and a steering column for the Wedge and Boss engines This engine even with the narrow heads is considerably wider and somewhat taller than the FE Consequently the foot boxes are made narrower leaving you with reduced leg room The primary pipes to fit this engine currently must be custom made although we will try to have them for the Ford Power Products 460 soon The standard hood scoop may have to be changed Use the lowest intake manifold available to eliminate the need for an extra large hood scoop The hemi headed Boss 429 is not rec
79. ETUP The optimal operating temperature for most FE engines is WATER HOSE LAYOUT FE about 185F 85C This will keep water condensation in the oil to a minimum and allow adequate oil flow We do not recommend using a restrictor plate in place of a thermostat unless the car is used exclusively for track use Install the radiator hoses and optional top tube connector and lower hose connector The hose part numbers and instructions for modifying the front lower hose are covered on page 39 See page 150 for your best mix of water and anti freeze With a 15psi pressure cap the boiling point will be raised The radiator cooling fan thermostatic switch is in the lower to about 240 F hose connector Connect the harness wires as shown on page 81 and detailed in the wiring instructions There is Fill the system through the expansion tank leaving about also an over ride switch on the dashboard 1 of expansion space above the coolant level See the diagrams below for the cooling system circuits With some engines especially the FE Ford air tends to be trapped in the intake manifold and cylinder heads To Do NOT remove the spring from inside the long lower remove the trapped air hose It prevents the hose from collapsing at speed e Drill the thermostat as shown on page 38 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
80. Its overdrive 5th gear gives excellent highway cruising even with a 3 77 1 differential ratio Don t expect high top speeds in Sth 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 duplicate the original orientation A special clutch release system is required TREMEC 3550 TKO AND 500 600 Some Tremec transmissions require a Chevy splined driven disc some use a Ford spline The pressure plate can be standard Ford A McLeod spacer 8607 between the bell housing and transmission may be required with FE engines unless the transmission is equipped with a special short input shaft available from Fortes Parts Connection A portion of the case must be removed for clearance See page 34 The TKO mount requires an adapter plate used with a Chevy mount See page 25 for part numbers SECTION A PARTS NEEDED Before you install the speedometer driven gear check that drive gears See page 14 for calculations and page 14 for its spiral meshes properly with the drive gear part numbers Transmissions have come through with both the LH and RH 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
81. JA tralarm SECTION F SUSPENSION ASSEMBLY XKE COMPENSATOR Modify the Jaguar handbrake compensator linkage on the differential as described on page 41 ERA COMPENSATOR Attach the front end of the cable to the handle by slipping the cable up into the slot in the protruding boss and attaching the bracket on the end to the bottom of the operating lever with a clevis and cotter pin Bolt the handbrake lever to the bracket on the chassis Attach the other end of the cable to the compensator lever on the suspension cage Slip the cable into the 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 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 SECTION F SUSPENSION ASSE
82. MBLY The cable passes through the right block and connects to lever Sce 41 REAR SUSPENSION E R A DESIGN Adjustment Fully release the handbrake lever Adjust the cable length by screwing the threaded end out of the block to a point just short of where the handbrake operating levers on the calipers begin to move If the handbrake lever movement is excessive adjust the cable at the right block fitting ANTI SWAY BAR The rear anti sway bar mounts on the rear face of the crossmember just in front of the rear subframe See the other assembly information starting on page 43 for more diagrams INSTALLATION Adjust the upper trailing arm length to 10 3 between rod end centers leaving on of the jam nuts loose Insert a x 2 HCS from the outside of each vertical chassis rail through the lock and flat washer and left hand threaded rod end For extra safety use a medium strength i e blue Locktite thread locker The chassis sleeve is internally threaded Tighten to approximately 60 lb ft dvswayb The chassis is threaded for USS bolts If you meet resistance when installing the bolts chase the threads in the chassis A broken bolt inside the frame is difficult to fix Bolt the anti sway bar to the chassis crossmember using the rubber bushings and clamps If there is a jog in the bar the center offset is to the rear and down with the arms extended under the suspension control arms C
83. ON AND PAINT 71 CONVERTIBLE 133 REAR DRIVE SUSPENSION ASSEMBLY FOOD 74 SIDE CURTAINS 135 DETAIL UNDERCOATING FITTING THE TONNEAU COVER 135 STEERING GEAR ale E Tl H N L FRONT ROTORS AND CALIPERS 16 TRUNK 78 SECTION H A DRIVE SHAFT ssssssssssssssssssssssssssssssee 17 Se pene S 5 136 FRESH AIR gt ae TONNEAU SNAPS 79 CLUTCH HYDRAULICS 137 T BERING COLUMN PPER WIRING AND ELECTRICAL 80 BRAKE HYDRAULICS 138 STEERING WHEEL 3 S Ser B 138 SEAT BELTS WIRING AND ELECTRICAL 80 OLT ON WHEEL NOTES NOTE WIPER MOTOR AND COMPONENTS 18 REAR HARNESS ccceeeessseeeeeeeeseenee 82 INTERIOR 8 6 83 INSTALL WIPER 139 FRONT SHOCK ABSORBERS 18 ENGINE AND TRANSMISSION 83 SUSPENSION ADJUSTMENTS 139 FRONT COIL SPRINGS 18 DRIVE 84 BRAKE BALANCE 142 EXHAUST 18 ADD FEUDS 143 WHEELS 1 19 DOORS er a 84 ADD PLUIS nsssssssssssssssss
84. TION FINAL OPERATIONS AT LOW SPEEDS HEADLIGHT ADJUSTMENT Our standard fan is adequate for practically any small block engine under normal conditions and OK for mild FE Most service stations have a standard set of headlight engines under 90 F ambient conditions If you expect high adjusters If you have a flat area at least 40 ft long you temperature city driving or you have a large displacement can do the job yourself and or highly tweaked engine consider ordering our heavy e Remove the screw at the bottom of the trim ring and duty fan Alternately the effectiveness of the heavy duty fan is approximated by the combination of the standard rear fan plus the optional dual front fans See page 89 pry off the ring with a flat screwdriver e Change the vertical horizontal orientation with the adjusting screws at the top and side of the headlight The fan only effects water temperature when the car is below retaining ring See the diagram below 15 e Replace trim ring and screw Test the fan function The fan thermo switch is in the aluminum connector x 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 After starting and running the car up to operating temperature 180 F min use the dash manual over ride
85. 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 reversed shift lever can be purchased from E R A or modified from Mustang parts See page 47 113 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 Handles that bolt onto the linkage stub are available for the Tremec transmissions TUNNEL If you are using a backup light mount a switch on transmission actuated by the reverse gear lever The wires can be attached to either terminal SHIFT LEVER HOLE See page 15 and 48 for shift linkage details When the transmission is installed in the car measure from the side and back to the base of the shift lever Temporarily remove the lever and mount the tunnel in the car Mark the shift lever location on the tunnel Cut the hole for the shift lever a little undersize and refit the tunnel to check the location ACCENT TUBE HOLES These non structural tubes duplicate the look of the dash support tubes that were used on the original Cobra Our tubes are held at the top by bolts at the bottom by the grommets in the tunnel Locate and cut holes in the tunnel for
86. UM CONNECTOR along outsio CUT HERE GATES 21178 The long leg of the aluminum connecting tube goes toward the radiator Lower Hose Ford small block Connecting hose for aluminum water pump This substitutes for the 21047 shown above SMALL BLOCK FORD Use the center portion from the radiator to the lower connecting tube You must tell us that you re using a small block when you order Upper hose 429 460 FORD Lower hoses are the same as the FE Ford You must use an in line filler cap i e Moroso or an expansion tank If you are using an in line filler only you must use an overflow system that replenishes the system automatically Pad the X member if the upper hose touches it 39 SECTION PARTS PREPARATION REAR SUSPENSION JAGUAR DISASSEMBLY See the exploded view of the lower control arm on page 42 The following Jaguar core parts should 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 148 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
87. a scrap of material to hide the fuel filler pipe Secure with e A thick piece of vinyl to line the glovebox also installed with contact cement SPECIAL NOTES The tunnel is upholstered before fastening to the floor After gluing on the tunnel carpeting cut holes for the dash tube grommets and install the grommets Glue in and cut the two seat belt mounting holes under sections I C and 8 C See page 124 for hole locations Use an awl to locate the mounting holes for the dead pedal Cut small holes for the screws Locate the holes in the carpet for the lap and shoulder belts if necessary See the rug diagram and page 124 20 SECTION BODY INTERIOR eint doorrug Replace the door strikers as described on page 123 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 an interference fit 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 latch for shiny
88. adjustable dampers are available from E R A DAMPERS SPECIFICATIONS Damper Compressed Spring Extended Length with Rate Length rubber Ibs inch eye to eye compr sed Rear Jag Stock XKE Spax w o height adj Spax with height adj Rear ERA Design Spax with height adj 14 5 10 5 9 x 2 25 ID 450 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 PRELOAD Because of small variations in the free length of new APPLICATION LEFT RIGHT springs the installed height in the damper may vary Big Block slightly Use the preloads at the right to calculate the 275lbs in spring installed height 250 lbs in Small Block 250 lbs in 225 lbs in Dimensions above apply to Spax dampers only Because component weight may vary from car to car final adjustments to determine the correct ride height should be made after the car has been driven a short distance to settle the springs See page 139 Dspring REAR HUBS BOLT ON WHEELS Measure each spring and subtract the values below for the To accept bolt on wheels Jaguar XJ hubs must be used installed height in a fully extended damper They have a flange with 5 2 20 studs 53 SECTION CHASSIS PREPARATION Assembling the chassis and preparation for paint 54 Roll bar attaches to main chassis rails bow
89. allation rreren ricis 110 eienen E E EO EE E 25 Camberg SE TE 140 AGjUSHIG ta ipaa 46 Fuel filler ss ccc See Fuel Capacities Lubricants XE Lubrication Capacity Type and COONS ic Lee aS E TA 150 Carburetor linkage 86 Car bDuretor s 10 Carburetor starting 147 Carpet Installation 122 Chassis Height 53 139 oh eek 58 Chassis NUMDET 64 Chip tassios 75 Closing panel 67 Clutch ACIUSEMENE ys 137 Bleeding 137 Concentric slave 37 Hydraulic parts 148 Master cylinder keaient eeose oesie rra 61 11 13 138 Slave Cylinder ena eae 35 Throw out fork 34 11 25 Throw out fork 37 Colors original DOdY ee ceeeccseeeceseeeceseeeeeseeneeeee 75 Column See Steering Column Compression ratio 9 Control arms BONG 96
90. ally quite reasonable Some insurers will grant you a significant discount if your car has an on board fire extinguisher in the engine compartment See the TrueChoice listing on page 27 Call E R A for the latest system specifications Below is a short but not necessarily current list A list of kit car clubs that may have more local information starts on page 153 Aidukas Insurance Agency Palm Springs CA Tel 619 327 3889 California Only American Collector 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 Div Modern Home Ins Tel 800 397 0765 44 states limited mileage Condon and Skelly Maple Shade NJ Tel 800 257 9496 in NJ 800 624 4688 Currently 19 states Great American Insurance Classic Collectors program 800 252 5233 Grundy Insurance grundy com Horsham PA 800 338 4005 Hagerty Classic Auto Insurance 800 922 4050 Heacock Ins Grp Lakeland FL Tel 800 678 5173 Insurance Alternatives Agency Bridget Scherb Forked River NJ 609 693 3943 J C Taylor Modified Auto Ins Agency Upper Darby PA 215 748 0567 610 853 1300 John Young 310 254 7355 K amp K Insurance Fort Wayne IN Tel 800 540 0858 Metro Agency 313 522 3900 Northeast Classic Auto Insurance Div Steeves Smith amp Assoc Monroe CT Tel 203 261 8474 ext 20 Parrish Insurance Nashville TN
91. aminated wood rimmed aluminum framed steering wheel We have found that a 15 wheel allows more knuckle room between the wheel and the cowl while still offering reasonable steering effort 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 original cars Inquire Standard seat belts can be installed in the threaded chassis bosses Separate left and right straps are required for dual shoulder harnesses The length of an off the shelf shoulder harness strap may need changing SECTION A PARTS NEEDED WIPER MOTOR AND COMPONENTS FRONT SHOCK ABSORBERS Modified and rebuilt wiper motors and hardware are E R A offers custom made Spax dampers with springs Konis available from E R A are available on special order Also available are spring collar wrenches to adjust your ride height The best wiper components are found in the 1969 1976 Triumph Spitfire GT 6 or TR 6 Get the entire set up The coil over dampers should be adjustable for ride height including wiper motor wheel boxes spacers gaskets See the length specifications on page 53 and part numbers chrome bezels and the connecting tube between the wiper on page 23 motor and right wheel box See the wiper m
92. and enlarge the holes Install the grommets and reinstall bar for a final check Silicone will make installing the tubes through the grommets easier The rear support grommet is a piece of rubber hose slit lengthwise Its ends should butt tightly together 71 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 a very reliable and competent local company that does all our turn key cars at a fair price Inquire GENERAL HINTS The body is easier to prepare if it is on the chassis We always permanently attached 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 The kit is designed so that the engine and transmission can be easily installed later If the body is painted on the chassis carefully mask so that overspray is kept off the chassis and mechanical parts Remove any clay that remains on the mold break lines Be very thorough The clay has an oil base Wash the body with soap and water to remove any mold release still pr
93. apters The subframe is mounted to the chassis at the top and at the bottom cross member through urethane bushings 2 Axle flange bolt on Jag CBC1784 6 pin drive E R A 2 Replacement parts are listed on page 148 You will need the following parts for a complete assembly Qt E R A conversion assembly with subframe lower radius arms upper and lower trailing arms hub carrier all bushings ASSEMBLY axle spacers and all rod AXLE ASSEMBLY ends and fasteners Also included brake hat Bearings and seals hub See page 148 carrier Half shafts and U joints Brake caliper The stock Jaguar XJ inner axle must be shortened to XKE Series VII length Alternately you may build the axle from scratch Specifications are available from us Complete assemblies and parts are available from E R A Optional Emergency brake cables with balance assembly Clean and deburr the axle splines Coil over dampers Carrera 3356 or Carrera requires coil 3257 conversion kit Koni Ask 14 5 extended length Spax G452 Hub Carrier 10 5 compressed length AS200 2 Springs 9 L x 450lb in aluminum casting It may be removed by heating the 2 25 ID only assembly or less preferably by using a press Generally Assemble the stub and inner axle together replacing the universal joints with genuine Spicer units 5 160 Some of the lower pivot shafts are a shrink fit into the removal is not necessary Later pins
94. arting have all tools and materials ready and read the text below All the aluminum splash and trunk panels must be removed before the body shell is installed Once the body is bonded at the areas indicated except for the nose opening the front inner panels must be installed in the pre drilled holes to locate the nose support bar Clean and rough the tops of the chassis at the areas indicated Remove the front body mount With assistance raise the body over the chassis Lower the front so that the bottom lip goes over the front chassis horns Carefully spread the body sides while slipping the lower body edges over the cowl support side tubes Lower the body down over the cowl supports and onto the chassis Use small blocks of wood etc to keep the body at least 2 above the bonding strips and chassis Loosely install the front body mount Attach the aluminum front wheelhouse panels to the body tube either with several Clecos rivets or small screws When the body is lowered the bottom holes in the aluminum must line up with the holes in the chassis Mix a trial batch of bonding adhesive see Supplies and Materials on page 29 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 66 Use a caulking gun to apply body sealant also used on the flo
95. between transient and final balance although slightly less initial understeer will increase responsiveness TIRE PRESSURES Use initial settings cold of 28psi 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 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 opposite axle for a better ride Generally it is the difference in front and rear tire pressure that determines handling balance If the car does not behave the same cornering right and left check that the anti sway bar links are not preloaded and that the spring preload follows the preload specifications on page 53 142 FINAL OPERATIONS BRAKE BALANCE ADJUSTMENT Do not change the brake bias until after the brakes have been thoroughly bedded in The factor set bias will be fine for most applications Changes may be necessary because of strange pad material and or different ca
96. bolts are found on page 151 Good reference books for Ford engines are listed on page 153 BASIC PREPARATION Remove cooling fan from engine water pump pulley Install the fitting for the water temperature gage in the intake manifold adjacent to the distributor Note that some manifolds must be tapped NPT If your manifold is tapped NPT you may be able to adapt with a Weatherhead fitting 3200 x 8 x 6 available at your local Ford FE Engine B engmt jobber Note If you have excessive engine motion or a very high Install the mounts onto the Ford small block as shown torque engine eo below www erareplicas com 427man engine mountmod for mount modification details Ford Small Block b sbengmt The FE mounts look similar but they cannot be exchanged from side to side Note that the stud surface is angled slightly from the engine side Install the engine mounts onto the FE block as shown below 32 SECTION PARTS PREPARATION ALTERNATOR MOUNTING ALTERNATOR MOUNTING FE BLOCK FORD SMALL BLOCK Serpentine belt engines must change to the following components 1980 lower pulley modify by removing the outside groove 1980 upper pulley 1979 water pump The alternator pivots in the outer Mounting hole in the head Some aftermarket heads require a threaded insert to reduce threads to s USS Ford F4ZZ 6E086 A An adjusting strap between the alternator and the upper right water pump bolt i
97. ck the alignment of the pulley grooves with a straight and stud D on the water pump edge Add washers or shorten the spacer as needed Tighten the reinforcing strap bolt 33 SECTION PARTS PREPARATION CLUTCH Install the clutch pilot bearing driven disk and pressure plate CLUTCH THROW OUT FORK Forks for small and large spline transmissions are available from E R A The standard Ford small spline fork see page 25 for part number can be left stock or bored through for easier adjustment Drill remember that the part is hardened the indentation to id Install the spacer between the mount and the mounting boss The offset standard length input shaft goes toward the rear Fork installed in TKO 600 TRANSMISSION TREMEC The Tremec TKO series has a boss on the right side that must be trimmed back flush in order to clear the chassis X brace Note that the TKO 600 is metric threaded 10 x 1 5 on the inner holes 12 13 on the outer holes TKO 3550 TKO II 34 SECTION PARTS PREPARATION BELL HOUSING CLUTCH SLAVE CYLINDER EXTERNAL 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 SMALL BLOCK housing flange This dimension applies to_all engines although the trimming operation may not be necessary for some See page 137 for hose installation The bracket and s
98. cks up in the back you can go to limited 8 7 depth NOTE STARTER McLeod recommends that you remove any centrifigul Any standard or aftermarket starter may be used weights on the clutch pressure plate when you use a concentric throwout bearing ADJUSTMENTS 37 SECTION PARTS PREPARATION THERMOSTAT RADIATOR HOSES We recommend that you drill 3 16 bleed hole in the thermostat as shown below This will allow a small The installation layout is also shown on page 144 amount of water to pass all the time plus facilitate air FE 390 427 428 ENGINE bleeding Install into the manifold with the hole up x E Used Ford tanks can be reversed so that the outlet exits on EXPANSION TANK FE BLOCK the left side as shown Unfortunately our experience has shown that most original tanks 20 years old by now have corrosion and fatigue problems even after close scrutiny and careful rebuilding Fortunately new expansion tanks are now available from E R A 62107 Some aluminum water pumps with 2 inlet STANDARD UPPER HOSE 21047 Standard cast iron water pump others with 2 inlet If you don t wish to do this job yourself any radiator shop 21258 Ford Small block WITH OPTIONAL CONNECTING TUBE B HEADTANK 38 SECTION PARTS PREPARATION HOSE TRIMMING INSTRUCTIONS FOR 4BBL MANIFOLD The two lower radiator hoses must be modified to fit After checking fit cut and trim the hoses as shown ALUMIN
99. collector and privary pipes d undercarex Glue or rivet aluminum or stainless faced insulation onto the bottom of the floors Alternately you may wrap the exhaust pipes and mufflers Add jute or foam insulation underneath the rugs Install both sets of primary pipes as described in the side pipe section The flange bolts on 8 cylinder may require the special wrench shown on page 28 Also see the Final Installation Hints for the side pipes Fit the collector pipe onto the primary pipes The exhaust hanger mounting holes are on the floor transverse supports One in the front support two in the rear Mount the muffler with the inlet offset to the outside Install the intermediate and tail pipe Position the entire system to leave clearance between it and the frame Tighten all bolts and clamps 132 SECTION BODY INTERIOR CONVERTIBLE TOP FITTING THE TOP KIT More pictures at www erareplicas com 427man top index htm While it is possible for an individual to fit the top E R A recommends that you have the top 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 party If you intend to install side curtains in the future E R A can supply a template to duplicate the correct windshield angle or use an angle gage to set the glass angle at
100. compromise can be made using common sense and a screwdriver The bump rebound ratio is designed for the ERA 427SC 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 front and rear 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 rebound 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 Drive the car again over unev
101. crew 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 windshield rake to match the front edge of the curtains e windshld WITH SIDE CURTAINS See curtain installation on page 135 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 107 Tighten the outside mounting bolts and fasten the center bracket with two 8 self tapping screws Trim the bottom channel gasket at both ends as shown 107 SECTION BODY INTERIOR HEATER DEFROSTER 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 Close the water shut off valve when the heater is not required The heater will radiate some heat even if the fan 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 is off and the doors shut definitely not necessary during those hot and hazy days Cut the heater hoses to length Connect the lower tube on
102. d along the floor Details around the front hinge area 117 SECTION BODY INTERIOR TUNNEL Locate the holes for the dash tube in the aluminum and trim the carpet back Use the rubber grommets supplied to line the holes After locating where the carpet goes on the top apply contact cement to the top of the tunnel and the carpet Glue only the top section first Apply contact cement to the right passenger s side of the aluminum let it tack off and carefully work the carpet down starting at the crease in front of the emergency brake handle cutout Do the same process on the driver s side Cut the hole for the shifter and install grommets for the tunnel tubes FRONT TOP PANEL Install the aluminum between the footbox flanges The carpet is secured with Velcro STEP MOLDING Anodized aluminum doorstep moldings are supplied with the kit They are pre drilled but must be shaped to the door opening Note that the short lip side of the molding is to the inside of the door opening Hand form the molding to the door profile The top edge of the sill should extend about 2 2 past the center of the latch Installing the door sill molding Apply masking tape to the door opening edge marking the position of the rivets To install hand form the molding approximately matching its curve to the door opening Once close form it directly on the sill Watch out for several rivets holding the sill flange to the b
103. d 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 Mount the pump in the dashboard The location is shown on page 109 Pass the plastic tubing from the fluid container cap through the hole in the firewall 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 106 SECTION BODY INTERIOR SUNVISORS Pre installed With a small stiff wire clean out the holes tapped in the upper windshield frame Push the wire to the bottom of the hole and mark where it is flush with the windshield frame surface 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 Loosen the sunvisor mounting block set screws Slip the blocks onto the angle brackets and tighten the set screws e sunvisor WINDSHIELD Slip the aluminum trim plates onto the windshield posts with the convex side up and the s
104. de 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 83 Don t tighten the hinge bolts Bolt the door to the hinge lightly snugging the bolts If the car is already painted consider using masking tape along the door and body edges to prevent damage when assembling The door edge may be aligned with the body opening by loosening the bolts where the hinge attaches to the door To adjust the front edge 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 123 ebod 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 door fitting flush at the rear The latch striker must be refit when the rugs are installed SECTION BODY INTERIOR SEAT BELT SHOULDER HARNESS BUMPERS JACK PADS The bumpers or jackpads are factory fit and installed The aluminum spacer sleeves can be easily polished with very fine steel wool and or car polish E R A offers reproductions of the original competition belts Inquire EINI SEATBELT Slip the ends of the
105. ded 28 PUTIN Bos Bt 133 Remove replace 134 128 E 149 Torque Values General esceeeceeeseeceseeeeeees 95 151 Trailer shipping 7 especie oe ta 40 Transmission 13 84 Installation 84 110 13 PE Op Loader 13 ATEMEG 13 34 Transporting 7 Trunk 69 Lid 68 TAG INE a 78 68 Weatherseal innana 78 15 68 74 anii nonnii E 77 Understeei i a 142 E r S 11 Universal essea eeen 40 INDEX 158 Voltage regulator Installation soei 64 26 Washer Windshield ccccceccccesscceessececesnseees 109 Water pump 144 Weatherseals 85 67 68 Wheel bearing Installation 98 Parts tee A E Saa 21 Wheel
106. don t remove it completely Cut the lever as shown removing approximately 2 where indicated Chamfer both ends for welding The inside of the original tube was stepped for a washer that created a seat for the spring When the lever was cut that stepped section was removed To create a spring seat lt lt Extend the cable through the end of the tube and slide a washer over it Tack weld the washer in place centered on the tube Be careful not to overheat the cable D shift3 Clamp the base of the lever in a vise Holding the lever in an 11 o clock position tack weld the lever to its base Hold the lever so that it points forward as shown above Make sure the slot for the lock out dog in the base of the lever is on the right side with the lever pointing forward Weld the unit together using minimum heat Don t let the cable slip down and out of the washer SECTION PARTS PREPARATION Place the lock out dog in a vise and cut off the top portion as shown Remove any burrs in the cable hole The original spring must be replaced with one that is 1 long and approximately 8 coils per inch Find one with the same tension as the original Cut the tip of the cable off the dog so that the cable can pass through the hole Slip the spring over the cable and into the lever Insert the dog over the cable and into place in the lever Pull the cable tight through the dog With a pair of vise grips hold the do
107. duplicate an original street car There is a small horsepower penalty however A complete system for the FE engine is available from E R A The system is shown on page 132 a whlbox 18 SECTION A PARTS NEEDED WHEELS BOLT ON Bolt on wheels require a 4 bolt circle Chevrolet pattern 7 wide wheels for the front 8 or 10 rear with 3 s back spacing will result in the right look Using wider wheels on the rear requires a change in the wheel offset and may prevent use of the under car exhaust system Custom bolt on wheels will fit with the same offsets as the pin drive wheels shown here If your wheel and or tire widths are significantly different call us for advice Note The front GM hubs use 7 s 20 lug nuts the rear Jaguar hubs have 20 thread 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 outside the mounting face Negative offset moves the wheel in toward the center of the car Some wheel companies may define the offset differently Check Rear Wheel Offset WHEEL DRIV See page 138 for special notes E 5 PIN IVE Five Pin pin drive wheels are also available from E R A Six Pin as original 15 wheels 7 4 and 9 wide are Trigo and Halibrand These wheels look exact from the available from E R A Trig
108. e 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 See the illustration on page 84 eint doorpnl2 SECTION E BODY PREPARATION Stretch the door pocket into place with its forward edge even or slightly past the front edge of the door frame and 2 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 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 eint 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 ei
109. e points in the harnesses FRONT WIRING HARNESS There are 2 primary branches and a grommet about 18 inches from the two large and two smaller multi connectors These branches separate just in front of the firewall From the engine compartment pass the multi connector blocks one at a time through the large hole in the center of the firewall If you are using an MSD ignition module do not route the tachometer trigger wire next to the coil wires Cross induction may create erratic tachometer readings Typically we pass the trigger wires down the right side of the intake manifold then across the front of the engine to the left wheel well The coil wires pass down the left side of the intake to the coil Note Attach the radiator ground to the upper fan frame bolt See the picture at the right SECTION E BODY PREPARATION FRONT ENGINE COMPARTMENT Attach the branch of wires to the ballast resistor alternator and front lights to the left edge of the hood opening with the clamps provided BALLAST RESISTOR ebod engwire The brakes light switch wire passes down the corner of the wheelwell and is attached to the brake line with tie wraps and into the brake box through the notch on the inside front edge The brake cover can be re installed now Be very careful installing the sheetmetal screws into the chassis rail Don t overtorque 81 PARKING LIGHTS e fparkwir X MEMBER me Md
110. e right side run the cable through the hole in the hand brake lever mounting bracket If the drive is on the left side see page 111 the cable must be kept from interfering with the shifting mechanism by attaching the cable to the side of the floor with clamps Secure the cable to one of the bellhousing top bolts CABLE FOR REVERSE ROTATION SPEEDOMETER Some cables or right angle drives have been known to have a square drive adapter that s too long 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 freely If not either shorten the square drive where it enters the speedometer or add shims where the cable housing meets the threaded section on the speedo The illustration below shows the right angle drive for the reverse rotation speedometer A right angle drive for a clockwise read speedometer will be the mirror image RICHMOND GEAR 5 SPEED The transmission requires a right angle drive adapter installed as shown The parts required are listed on page 13 SECTION BODY INTERIOR TREMEC TKO 500 600 BATTERY AND CABLES FRONT MOUNTED BATTERY See page 22 for battery and battery cable sizes and information e The drive cable is also secured to the top of the mission case See the previous section for the cable path e batcabls At
111. e shift lever to the proper location The linkage shown is from Long Richmond Gear 5 speed 48 TREMEC TKO SERIES All Tremec transmissions keep the lever in the stock full back location to use the bent forward shift lever available from ERA SECTION PARTS PREPARATION DRIVE SHAFT b drivshft T L small spline T5 Tremec 3500 T L big spline Tremec TKO Trans gt Richmond gear Part Rr Flange 2 2 459 2 2 459 2 2 459 yoke 5 153 5 153 kit Rr Weld 2 28 437 2 28 437 2 28 437 yoke Frt Weld 2 28 1697 2 28 1697 2 28 437 yoke Frt U joint 5 213X 5 213X 5 153X kit 1330 Series 1330 Ser 1310 Ser 2 3 6041X 2 3 5981X 2 3 9131 The Tremec driveshaft is 0 8 shorter than shown above The Ford 5 is 1 8 shorter All part numbers are Spicer except as noted E R A stocks drive shafts for most Top Loader Tremec and Richmond Gear transmissions Alternately you may have a shop specializing in power transmission equipment make one to your specifications You must supply them with the appropriate 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 2 for movement note that some seals are accordion like and designed to ride against the flange of the output yoke
112. 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 SECTION PARTS PREPARATION b tralarm Reinstall the hub carrier onto the half shaft and lower control arm The trailing arms should be installed onto the rod ends when the suspension assembly is installed into the chassis See page 150 for lubricants and capacities HAND BRAKE LINKAGE XKE EMERGENCY BRAKE SYSTEM If you started with an XKE core the linkage system will be similar to the picture below Rearrange your compensator parts as shown EB_JAG Remove the clevis pins securing the brake levers a to the compensator links B D Remove the bolts securing the compensator bracket c onto the rear end cage and remove Remove the cotter pin and the washer securing the bell crank assembly e onto bracket c Reassemble the bell crank assembly upside down and onto bracket c with washer and cotter pin Install the unit onto the cage and replace the clevis and cotter pin securing the links b and d onto the levers a XJ6 OR XJ12 REAR SUSPENSION CORE If you have a block on either brake actuating lever it must be removed Pry the lever apart to remove then squeeze together again Use bolt at bolt at B EB_ERA STIFFER COIL OVER SPRINGS You may use slightly stif
113. easure 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 We typically use Weber brand and have found them to OIL PAN be reliable if properly done When you assemble your car EEEN it is essential to follow the installation guidelines Pictures There are several aftermarket pans and OEM Ford designs and procedures shown here are particular to Weber yours listed on page 23 If the pan does not have a oil may be different Always read and follow the instructions temperature bung weld the oil temperature adapter fitting for your setup packed with the auxiliary instrument pieces onto the left Weber brand cylinders and most others have no system side to keep the piston from being pushed too far out of the With a Ford small block keep the full length pan depth cylinder and puking fluid all over the floor The ERA less than 8 3 to prevent the pan from hanging below the requires a pedal stop so that the master cylinder stroke is chassis If your pan ki
114. ebod stripe 76 SECTION BODY PREPARATION DETAIL UNDERCOATING For sound supression or cosmetic reasons you may wish to undercoat or paint flat black the inside of the fender panels Use spray or brush on undercoating to cover all areas including 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 weather stripping Silicone will also seal the seams very effectively ebod caulk Check the body and chassis seams from underneath and seal openings with either the brush on undercoating or the caulking 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 If you wish to rustproof 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 WINDSHIELD WIPERS Prepare the wiper motor and other components as described on page 50 INSTALLATION Before you install the wiper wheelboxes mock up the assembly off the car to check whether the cable properly engages the drive gear Tighten the cover against the guide tubes If the fit is too loose or too tight bend the guide above the gear up or down as necessary There are two typical
115. eeded Pass the harness through the gap in the aluminum filler and up through the hole in the side of the footbox RPANELS 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 horizontal flange and the body with caulking or foam rubber ENGINE AND TRANSMISSION If you are carpeting the trunk the fuel sender wire goes under the carpet Refer to page 32 for engine and transmission preparation To check compatibility trial fit the transmission to the INTERIOR PANELS engine before any attempt to install either into the chassis It s easiest to install the engine and transmission separately If you have a stationary engine lift have the dolly wheels or the suspension installed so that the chassis can move under the engine 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 with the rear harness pre installed too If not leave the temporary fasteners in place while you drill The seats and tunnel must not be in lace for
116. eel bearings torque the axle nut to 20 Loosen the nut and re torque to 15 lb 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 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 With Wilwood or JFZ Caliper Late design with custom uprights 98 SECTION F SUSPENSION ASSEMBLY Lubricate the insides of the upper chassis brackets with REAR SUSPENSION JAGUAR BASED lithium grease so that the sides of the rubber bushing will XJ COMPONENTS IN E R A SUBFRAME slide into them Guide the suspension assembly into the ee ee ee chassis brackets Using a little light oil on the threads Thread the trailing arms onto the rod ends with jam nuts install the bolts with flat washers but don t tighten yet already installed on the lower control arms Thread on until one or two threads show Leave the jam nuts loose d eracage Note that the trailing arm bushing is angled slightly relative to the trailing arm tube See the bottom of the illustration on page 99 On one side of the car Rotate the trailing arm so that the bushing angle matches the chassis bracket H
117. en 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 smoothly with no drastic attitude changes and without leaning excessively Any increase beyond this point is unnecessary and may in fact be detrimental SECTION H 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
118. eplace the body from the chassis Gently spread the body sides out working the rocker over the sill tube and the door hinge mounts 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 already powder coated from E R A optional all the remaining parts on chassis must be removed e Brake cylinder pedal cover box and pedal assembly Cover or remove the pedal shaft needle bearings in chassis before priming or sand blasting chassis Refer to page 103 for pedal assembly details e Brake master cylinder cover floors footboxes and brake lines e Radiator lower support bracket Remove the nuts on the bottom of the front chassis extension See page 88 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 e 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 Clean all parts with wax and grease remover Etch metal with Metal Prep or by sandblasting Apply a primer coat appropriate for your paint If possible use non sanding epoxy primer Paint the chassis and other parts with epoxy or a two part polyur
119. er s side to match the engine The Turkey pan or single round air cleaner does not require inner panel modifications However if you are using an oval air cleaner the inner panel must also be trimmed whether using an integral or rivet on scoop See the notes below for the Ford 429 460 engine ENnoodriv2 Use small screws or Cleco fasteners to hold the scoop in position while drilling all the holes Wait until the parts are painted with color before final riveting Hoodriv1 To avoid panel distortion use blind rivets with aluminum mandrels only The rivets used on the original competition cars to keep the front edge of the hood from peeling back at speed are also illustrated Ford 429 460 If you use dual 4 carburetors the rivet on scoop may have to be positioned further back on the hood than shown above Cut the hole first and check clearances Optional Finish and paint the rough fiberglass inside the hood so that it looks like the original aluminum 74 SECTION E BODY PREPARATION 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 eint Doorfill Use body filler to blend the areas where the inner panel meets the front edge of the door openings as shown above CHECK DOOR FIT Check and adjust the fit of the doors as described on page 67 75
120. erformance work well For street use we don t recommend underdriving either the alternator or water pump SECTION A PARTS NEEDED FORD 289 302 351 Pre serpentine belt engines are easily adapted to the 427SC although primary exhaust pipes must be specially fabricated The chassis mounts are the same as for the FE block You may retrofit the FE engine without modification which comes in handy if you update later E R A supplies a special alternator adjusting bracket and clutch slave cylinder bracket CLUTCH No matter what engine E R A recommends using a clutch with stock pressure for street use Because the car is very light extra pressure is not necessary Be careful to match the bolt pattern of your flywheel to the pressure plate Ford has used several variations E R A has used standard pressure Brute Power replacements with good luck We have found that removing the weights from any centrifugally assisted pressure plate prevents release problems without making the clutch less efficient FE Note Small spline throw out forks for the Ford FE bell housing are no longer available from the dealer Custom forks and pivots for all Ford transmissions are available from E R A BELLHOUSING E R A recommends a blow shield type bell housing such as the Lakewood 15210 Ford FE We trim the bottom flange so that is does not extend below the chassis See page 35 ALTERNATOR To keep that original look most engines in an
121. ermarket equivalent Fits early 70s Ford with external regulator Windshield Wipers Motor and Drive Parts From 1969 1976 Triumph Spitfire GT 6 or TR 6 Arms Lucas 5201 E R A Lucas parts dealer Blades Lucas GWB 164 E R A Chrome Bezels Bush Kit Lucas 60600 429 E R A Lucas dealer Wheels Bolt on wheel Front 7 8 x 15 4 bolt circle with 3 3 3 5 backspacing Rear 8 10 x 15 4 Bolt circle 3 3 3 8 backspacing with the wider wheel having more backspacing Reproduction Halibrand 7 x 15 and 9 x 15 E R A Trigo Vintage GT40 style aluminum pin Various widths in 17 Wheels drive PS Engineering Vintage Wheels Reproduction Sunburst street 7 2 x 15 Only OEM take offs type aluminum pin drive Spare Tire Wheel Bolt on GM Camaro space saver note on page 138 Pin Drive PS Engineering or Trigo 26 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 Carroll Shelby Ent carrollshelbyent com Cobra Restorers Ltd cobrarestorers com Dan Williams Enterprises toploadertransmissions com David Kee Transmissions 4speedtoploaders com Ford Motorsport Performance Equipment Fortes Parts Connection Genesis Performance
122. es may have pigtails with female connectors Otherwise connections are made directly to the light e tailites To make the tail light connections e sure that the rear harness black ground wire is connected to the light stud or ground receptacle SECTION BODY INTERIOR e With the parking lights on the red wire should be live Touch the red wire to each pigtail or LICENSE PLATE LIGHT connector loop Connect that wire to the dimmest filament e Connect the other wire to the remaining receptacle BULB PROTECTOR REFLECTOR Optional ERA offers optional reflectors for the rectangular tail lights Be careful not to pinch the wires when the reflector is installed Install after the light is installed by using a second set of nuts and washers ebodNiclite INSTALLATION Remove the attachment screw lens and cover Insert the wires through the larger of the 3 holes in the deck lid license plate bracket optional and the back of the light gasket Connect the black wire to the case and the red wire to the loop on the bulb holder Attach the light and bracket to the deck lid and refit the lens and cover REAR REFLECTOR BOTTOM BACK UP LIGHT OPTIONAL Used only with round taillights Mount with the notch to x the bottom Some reflectors will have mounting studs the others require a sheet metal screw ebod bulite ebod Reflectr Back up lights may be required in some states The type and locatio
123. esent then 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 chase the holes with a 149 25 drill Using a drill will work sometimes but the tight fit will sometimes cause the brass shank to break SECTION BODY PREPARATION TRIM FOR 245 60 TIRES Our standard 235 50 15 tire fits well within the standard flare but you might want to trim the bottom inside of the front flare a bit to fit a 245 width tire The driver s side is tighter than the passenger s side SIDE PIPE HOLES Use the template on the following page to cut the holes in the fenders 72 SECTION BODY PREPARATION S8um Z J3ANO JO 1 UIN 10014 opis INO 112 3015 UAAOP SZ p 43 Bulusdo 1 apis JUuBIY D __ 73 SECTION BODY PREPARATION RIVET ON SCOOP Locate the hood scoop inlet hole and rivet spacing and INNER PANEL MODIFICATIONS number as shown below Note that he hole is offset to the passeng
124. esssserseeessees WHEELS PIN DRIVE 19 ACCELERATOR PEDAL AND LINKAGE 86 20 EXHAUST HEAT 05 87 RADIATOR HOSES 20 SaaS a Foe z Fo 90 RECOMMENDED PERIODIC SERVICE 147 STARTING A CARBURETOR is 147 PART NUMBERS AND SOURCES 21 OIL COOLER OPTIONAL 90 M JP 148 SOURCE MASTER TIST 27 FUEL 192 AINTENANCE PARTS POR FUEL FILLER 93 INSPECTION AND REGISTRATION 152 TOOLS NEEDED Ph Gp ee INSURANCE 153 SHIPPING COMPANIES PARTIAL LIST 28 SECTION PARTS 04 30 FRONT SUSPENSION 96 ENGINE COMPONENTS 32 LOWER STEERING COLUMN 96 ALTERNATOR MOUNTING 33 REAR SUSPENSION JAGUAR BASED REAR SUSPENSION JAGUAR 40 E E EE EE 2 REAR SUSPENSION E R A DESIGN 43 cap SUSPENSTON P ou DESIGN 1 SHIFT LEVER 47 RAKE AND CLUTCH PEDAL 03 DRIVE 49 SECTION G STEERING 49 STEERING COLUMN 49 105 WASHER 106 AMPERS OERING WINDWINGS AND
125. ethane 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 SECTION CHASSIS PREPARATION SECTION D BODY CHASSIS ASSEMBLY Assembly of the body and basic mechanical components 59 SECTION D BODY CHASSIS ASSEMBLY FASTENER NOTES Almost all the locking nuts in the kit are Stover style Stovers are re useable several times unlike the nylon locking type However you must use light oil on the threads when assembling General fastener torque specifications are listed on page 151 BODY MOUNTED PRE MOUNTED ON CHASSIS OPTION Many items listed in this section are already installed although it couldn t hurt to check critical fasteners You can skip the following items e Brake and fuel lines Horns Floors Footboxes Bonding strips Footbox components Battery mount 60 SECTION D BODY CHASSIS ASSEMBLY BRAKE AND FUEL LINES FOOT BOXES Replace the brake and fuel lines on the chassis securing Before permanently installing the footboxes into the the lines in place with the plastic clips and Tek screws chassis apply the supplied insulation as shown The edge Seal the thread holes with silicone to prevent rusting strips are not absolutely needed but make the installation neater and keep the edges from curling back over t
126. f the vertical section of the box next to the door Larger picture on page 146 Use contact cement to line the bottom and sides of the Install the wiper relay on the firewall before the dash glove box with the fuzzy material included with the carpet set ie ee ae ie pi oa ioe Fo with the dashboard resting face down on something soft Follow the separate wiring instructions for individual connections Also glue a strip of material on the underside of the rear box edge where it meets the dash to prevent it from rattling Smiths gage notes The oil pressure line requires against the transverse dash support pipe reducer at the filter housing or block adapter There is Holding the glove box with its forward edge tilted down a fiber sealing washer attached to the gage to seal the gage and towards the front of the car slip its trailing edge up end fitting and under the glove box opening lip of the dash Be sure Small block The line enters the block just in front of the that the edge goes under the glove box door mounting filter housing You can use the extension that normally Screws mounts the electric oil pressure switch or go directly into the Raise the rear of the glove box into place and install the block final dashboard screw Tighten all the dash screws to hold the glove box in place while you attach its rear flange with INSTALLATION the self tapping screws provided A ratchet w
127. fer from standard Ford practice and be numbered from the front 1 4 on the left bank 5 8 on the right The 4 longer primary pipes are for the left side E R A can optionally weld the brackets onto the side and primary pipes at the factory SECTION BODY INTERIOR WELDING THE SUPPORT BRACKETS Install the primary pipes on the engine leaving the bolts slightly loose ebod primpipe Support the pipes as shown parallel with the bottom edge of the rocker Leave about 1 2 between each side pipe Bolt together the sets of connecting brackets as shown and the rocker panel A soft faced dead blow hammer ebod spipebk helps get the pipes all the way on Position the brackets in place one end of each set on a primary pipe the other end on a side pipe Position each x set of brackets on pipes diagonally opposite each other so that they are easily reached Tack weld each set of brackets in place Complete the welding when the pipes are removed from the car REAR HANGER BRACKET ebod spipesup ebod spipebrk Bolt the rubber hanger to the chassis and the end of the bracket Mounting holes are provided on the angle support welded between the main chassis rail and the outer side rail Fit the brackets in position against the side pipes and tack weld in place Unbolt the front brackets and rear hangers and remove the side pipes and primary pipes Weld the tacked brackets in place Coat the pipes as desired
128. fer springs in the rear to decrease squat on heavy acceleration e springs listed below are 2 ID e If you have stock XKE springs on stock or their equivalent XKE dampers replace one stock spring on each side with a 10 long x 400 Ib in spring Alternately replace all 4 springs with a new 10 x 350 Ib in spring e If you have the ERA supplied Spax damper with adjustable collar use 8 x 400 Ib in springs for all four springs REAR HUBS BOLT ON 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 Six Pin hubs are available as a direct replcacement for the Jaguar hubs mentioned above They will fit Trigo Halibrand and P S Engineering wheels SECTION PARTS PREPARATION JAGUAR CONTROL ARMS REPLACEMENT PARTS LIST Jaguar OEM part numbers Lower control arm and lower hub carrier pivot parts 42 SECTION PARTS PREPARATION REAR SUSPENSION E R A DESIGN 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 from the Jaguar XJ Brake calipers are late model Camaro Rotors are Wilwood on E R A ad
129. fill Place the gasket and upper flange on top of the fender with the flange markings toward the right side at 3 O clock as viewed from above Hold everything together with the stainless steel screws provided 93 Remove excess RTV and clear the drain hole with a wire etc Install the vent and drain hoses to the lower flange as shown Run the drain hose through the hole in the bottom corner of the well at the side of the trunk Pass the vent hose through the seal plate and connect to the aluminum tube that comes through the hole in the tank s mounting flange SECTION F SUSPENSION ASSEMBLY e SECTION F 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 times 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 The torques listed are for lubricated threads or threads with liquid thread locker All stover nut threads should be lubricated with light oil The diameter stainless fasteners used to secure many of the body parts hood trunk doors etc should be torqued to a maximum of 8 Ibft Grade 5 Grade 8
130. fter 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 Stainless pipes will discolor slightly to light gold Chrome plating will turn blue only on the hottest sections of pipe The steering wheel center cap see page 113 is installed after final suspension alignment LICENSE PLATE S FRONT E R A Plate offers a tilting bracket to mount the front plate on the optional front grill surround REAR The rear plate may be mounted directly to the trunk lid using minimum plastic spacers between the plate and the body Alternately E R A offers a plain bracket that bolts underneath the license light and a special Carroll Shelby Motors frame See the illustration on page 127 We recommend that the primary pipes 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 mask the last 1 of the outside surface before coating While ERA specifies extra heavy flanges the primary pipes 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 Note Ford numbers the cylinders on the FE engine 1 4 on the right passenger s side bank 5 8 on the left side The E R A supplied primary pipes may dif
131. g in place approximately 1 below the surface of its receptacle as shown If necessary have someone hold it for you Braze or silver solder the cable to the dog Silver soldering is less likely to weaken the cable If brazing use as small a flame as possible holding the end of the brazing rod against the cable and dog Direct the flame onto the end of the brazing rod away from the cable Avoid playing the flame directly on the cable The heat necessary to melt the brazing rod will be directed onto the cable allowing the brass to adhere to the cable The lump of brass now on the cable will act as a heat shield while you now direct the flame against the dog until it is hot enough to cause the brass on the cable to flow and adhere Trim the cable close to the dog and grind down the brass and cable flush to the end of the dog Grease the mechanism when cooled and replace the rubber grommets For a more positive feel when shifting replace the rubber grommets with pressed in steel sleeves Install the lever onto the transmission linkage SHIFT LEVER PLACEMENT The shift lever should end up relative to the bell housing as shown below E R A has adapter plates to position a Hurst unit correctly on the Top Loader and the Richmond Gear 5 speed See also page 15 for linkage locations on the Top Loader trans B shiftmt RICHMOND GEAR 5 SPEED The Richmond gearbox uses an adapter and special handle available from ERA to move th
132. ges 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 e 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 12 for the best ratio for your engine transmission combination e Dampers coil over shocks All E R A rear suspensions require 4 dampers and coil springs coil over shock absorbers Specifications are the same as for stock Series Jaguar XKE XJ dampers cannot be used See page 23 for part numbers and page 53 for length specifications Dampers with adjustable spring seats and externally adjustable damping are available from E R A USING THE E R A JAG SUBFRAME The stock Jaguar XJ control arms and half shafts will be exchanged for shortened pieces when you buy the subframe from us Series XKE parts will not have to be modified although Series parts will All XKE lower control arm mounting brackets that bolt to the sides of the differential must be exchanged for XJ units All mounting bushings and hardware are included with the E R A
133. glass panel Mark the fiberglass panel through the holes in the bracket Remove the fan assembly and carefully drill the fiberglass panel first with drill then with a h drill Install the assembly with the bolts and washers provided Check that the clearance between the fan and the radiator is at least Wiring is covered in the separate instructions 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 ebod radduct The shrouding for the optional 6 oil cooler is assembled as shown See page 91 for the hose layout E oc6lay SECTION E BODY PREPARATION GRILLE AIR FOIL Using the Splitter is a personal choice It was originally on the street cars but not the competition ones When fitting the airfoil take special care not to chip or scratch the paint on the body Attach the plastic chrome molding to the airfoil after painting but before installation into the body The molding is shipped from E R A taped to a flat surface Remove any contaminants from the front edge of the airfoil Peal off the protective strip from the back side of the molding and carefully apply the molding to the f
134. he E R A 427SC 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 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 all possible use the short tail shaft transmission It allows a longer driveshaft If your differential ratio is 3 31 1 or taller consider the wide ratio transmission It will allow easier starts 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 25 MOUNTS There are 3 common bolt hole configurations for the rear transmission mount Two holes in the transmission arranged front to back Use Ford C8ZZ 6068A or its equivalents i e Republic or Parts Master 31 2284 e Two holes arranged side to side and having 5 between centers Same mount as above e Two holes arranged side to side and with 6 center to center distance This very rare transmission requires chassis modifications done on special order only Use Ford C9
135. he long Bolt the brake master cylinders in place as shown below The feed lines will be installed later EI term d mastcyl The clutch master cylinder is shown on page 137 The balance bar assembly is shown on page 143 Bolt the horns to the front side of the front X member See locations on page 96 Front Passenger Footbox FLOORS Place the floor panels in position and hold them in place with the screws used for shipping Using the holes the aluminum for a pattern drill s 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 Inner Passenger Footbox 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 61 SECTION D BODY CHASSIS ASSEMBLY Side Driver s Footbox Front Driver s Footbox D footbox Use a small amount of sealer under the areas with rivet holes Lift each footbox up a
136. he 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 HINGE COVERS The fiberglass covers are different from left to right Don t over tighten the screws E eint HINGCVR BODY INTERIOR FRESH AIR INLET DUCTS The left and right ducts will only fit one way Use the diagram below as a guide ebod fduct If you wish paint the inlet screens Slip the inlet ducts over the body flanges and secure each with 4 Phillips screws from the air intake side Secure each hose to the splash panel with clamps as shown The rear clamps have speed nuts and are fastened from inside the engine compartment FUEL FILLER CAP See the notes on disassembly page 58 Lubricate LIGHTS HEADLIGHTS All holes for mounting the lights are pre drilled at the factory The headlights can only be installed with the correct orientation eVflights1 Mount the headlight assembly and gasket with four 10 Phillips pan head tapping screws 125 SECTION BODY INTERIOR 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 SIGNAL LIGHTS e fparkwir Install the harness as shown above securing it with the clam
137. he outer body If necessary trim the edge for a to gap for the weatherseal Doo Ef Once the panel is in place smooth silicone or urethane sealant over the outer fender filler joint covering all the way to the bottom corner 67 HOOD Pre installed Bolt the hinges loosely into the body from 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 Attach the latching hardware onto the hood and firewall as shown ebo HOODHNDL The hood is held off the body flange with 5 pieces of half round weather stripping Extra engine compartment ventilation is gained by leaving gaps in the rubber Temporarily attach some pieces to locate the hood for bodywork Use contact cement to attach the strips onto the hood flange after the car is painted 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 SECTION D BODY CHASSIS ASSEMBLY From inside the grille 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
138. ications cecceeccesceesceeeceseceeeeseeneeeneeees 32 Parts oii 23 TFANSIMISSION 13 25 MSD Tachometer 11 poses cose Tikes 80 Nuts StOVED R 60 95 Oil cs wha cae 143 Oil COOl eis Scosche Ree E elas hee RES 17 89 aa 17 sien eee nae atte 10 OM Pall ess parai AEN a 10 23 37 Overheating suari ntaso n aa a e a EAE 144 OVETSICED arnee ai A conde E EEE ESER E 142 Paint Body preparation ecccccceesceeceeeceeeceeeeseeseeeeeees 71 Chip guard eeso eaor ee Tae E E EEES 75 COLOS Ci rore Ea EE EE EE E EE E 75 Painting 1 See Chassis Savy Aaa EE EEE SES See Oil pan Parts REQUITEO R 8 Pedal A CCOLETALOR 86 Brake and Clutch cecinere e 103 Picking up A E 7 Pin drive 47 Whe Gls iA echt athe eines See Wheels Pin drive wheels tightening cesseeesseeseeeenees 138 Pop Ti Vet deine heady ed 29 Pressure 142 Primary pipes 131 Prop Hood rars ennenen nose Bites ea ities 68 Pulley Water PUMP
139. ilding Steering gear SECTION A PARTS NEEDED Complete rebuilt Ford units are available from several Ask us suppliers C9LY 6038 A COLY 6038 B 69 Mercury Ford Dealer 31 3058 L 31 3059 R Republic 63 64 Ford w 390 428 cid Ford C3AZ 6038A B Republic 31 2222 right 31 2223 left 63 65 Mustang w 260 289 cid Ford C4DZ 6038A B Republic 31 2221 right 31 2220 left MityMount HD FM132 Windage trays are recommended for constant running at high rpm E R A or local parts E R A Canton Racing Products High capacity front sump Canton 15 810 pickup 15 811 doors Canton 15 820 15 821 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 pickup Road race with trap doors Canton 15 680 and pickup 15 611 Canton 15 710 pan 15 711 pickup E R A Cobra Restorers local auto parts store Side pipes w primaries Original type front rear and side In line between tank and steel line on chassis 3 8 Jaguar XKE Series I 1961 1970 E R A Reproduction Lever Custom for E R A subframe Jaguar Dealer E R A E R A Gates 28472 or equivalent must be trimmed Lucas 31872 Jag XKE 1961 64 starter button Jaguar E R A Lucas supplier 1964 1974 Jaguar XKE Series 2 1965 1983 Jaguar XJ 6 Wrecking yard or E R A Cus
140. information a specifice CARPETS cececcsesesseeesecsceesesteseeeeees 115 topic assembly or service see SECTION D HAND BRAKE LEVER COVER 121 the index B DY IC H AS S S A S S E M B LY SEAT BELT SHOULDER HARNESS 122 59 SEAT 122 EEE DOORINGTAT LATION So chen ck 123 READ ME FIRST ccscceesseceessseeessseeees 60 SEAT BELT SHOULDER HARNESS 124 SECTION A PARTS BODY MOUNTED PRE MOUNTED ON ri CHASSIS OPTION 60 FRESH AIR INLET NEEDED DRAKE AND PURT ce 61 FUEL FILLER CAP PICKING UP YOUR 7 HORNS fi oo 61 SPECIAL NOTES ccsesssessesesesesesesenees 8 REAR REFLECTOR BOTTOM rer SE EE NEEE 9 LICENSE PLATE 127 CLUTCH 11 LIGHT OPTIONAL 127 BELLHOUSING eccscsssessesssecseessesseeesees 11 IRRORS ER SECTION BODY SNAPS IGNITION NOTES 211 70 EMBLEMS gt 12 LICENSE 130 SPEEDOMETER DRIVE GEARS 14 FITTING THE ROLL 71 SIDE PIPES 35 130 SHIFT LINKAGE 15 BODY PREPARATI
141. 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 CAC38 18 12 CAC3818 14 CAC3818 16 CAC38 18 18 CAC3818 20 CAC38 18 22 CAC38 18 24 CAC38 18 26 CAC38 18 28 CAC3818 30 CAC38 18 32 CAC38 18 34 CAC38 18 36 CAC38 18 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 SECTION PARTS PREPARATION For example 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 bee
142. ion tanks are available from E R A The used expansion tanks that are commonly available see page 24 must be modified because the outlet faces the wrong way Unfortunately most of the original tanks are fatigued badly and frequently develop stress cracks and pinholes Most tanks are also too high and must be shortened If you wish to modify an old piece see below and page 38 for details FORD SMALL BLOCK A Harrison tank can be modified for use Inquire JACK ETC A screw or hydraulic scissors jack available from E R A works well for wheel changing etc Don t skimp on quality 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 nut edges Hydraulic jacks knock off hammers safety wire pliers and other tools are available from E R A 20 SECTION A PARTS NEEDED PART NUMBERS AND SOURCES Source addresses etc are found on page 27 PART Alternator Ford Small Block FE and 429 Ford SOHC Chevrolet 283 350 Chevrolet 427 454 Alternator Adjusting Bracket FE Ford Small block Ford Fan belt 289 302 Ford 351 Ford FE Ford Ballast resistor Brakes Bearings Front Brake Rotor Hub bolt on wheels Brake Calipers Front Pads Mounting pin kit Banjo bolt Brake reservoir standard Optional 3 cans Bearings Front Wheel Outer Inner Seal inner Spindle nut Spindle washer Battery
143. ip joint Pull the roll bar hoop up and out from the chassis Remove the rubber grommets from the body Doors etc Remove the filler panel below the door opening Remove latching hardware from the main body including the hood firewall latches Remove the aluminum interior panels that are below the door openings and the aluminum firewall RADIATOR AND SHROUDING Remove the optional oil cooler and shrouding See page 90 Remove the optional front fan assembly See page 89 Remove the rear fan on its bracket See page 88 Remove the side and lower shrouding 3 pcs from inside the grill opening Remove the upper radiator mounting tab and gently lay the radiator back against the chassis Soft paddling will help insure that nothing is damaged Remove the top radiator shroud See page 88 SECTION CHASSIS PREPARATION Remove any cotter pins and washers from the bottom radiator pins and carefully slide the radiator up and out of the car through the hood opening The radiator can also be removed from the bottom in unit with the bottom mounting bracket FRONT INNER PANEL REMOVAL Remove the fresh air hose from the front intake manifold Disengage the retaining clamps and pull the hose rearward into the engine compartment Remove the wheelhouse access panel at the rear Attachment points are circled Remove the screws that attach the middle panel to the chassis and the bonded tube at the hood opening return edge
144. ission with spacer or a short input shaft the spacer may offset the holes to the front or back Trim the GM mount at the rear diagonal where it comes close to the chassis X member The mount is secured to the transmission with 10mm bolts If the bosses on the tailshaft are within 1 8 of the chassis use washers or shims to raise the transmission e Richmond gear No adapter necessary e C 6 Automatic Special chassis mount no adapter necessary cob man d transmt Check that the engine is level side to side in the chassis Adjust if necessary Tighten all mounting bolts Removal is accomplished in the reverse order Special Note for Automatic Transmissions 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 front of the radiator DRIVE SHAFT The drive shaft is a special fabrication that may be purchased from E R A or built by a local driveshaft shop Driveshaft specifications for the Ford Top Loader and Richmond Gear transmissions are on page 49 INSTALLATION Use grade 8 bolts and washers and stover nuts if possible Lubricate the inside and outside of the slip yoke with a 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 DOORS INSTALLING POCKETS Lay th
145. ith a Remove the tape wrapping the fresh air cables and let the long extension makes this job easier cables lay on the floor Attach the optional windshield washer tubing to the pump Hold the dashboard in place on the body 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 109 SECTION BODY INTERIOR SPEEDOMETER CABLE There are several possible speedometer cable and drive locations on the transmission See page 13 for the right cable for your application If you are using a counter rotating speedometer with a Top loader or Tremec transmission a cable reverser must be installed on the speedometeer end of the speedometer cable When installing the 90 degree adapter to the speedometer see the notes on page 110 With the Richmond gear transmission the reverser is integrated into the right angle drive adapter at the transmission INSTALLATION TOP LOADER From the engine compartment side slip the smaller speedometer end of the cable through the rubber grommet in the footbox 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 guage and tighten the retaining nut If the transmission drive is on th
146. 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 Measure the camber To change the camber the front rod end must be disengaged from the inner bracket Jack the car up to unload the suspension and remove the inner pivot bolt For each 4 degree of camber change needed turn the rod 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 the number of turns that the rod end was changed by i e you rotated the rod end by turn rotate the tie rod by turn Too much negative camber can also be changed by adding shims between the inner axle flange and the spacer A 0 02 shim will change camber by degrees ANTI SWAY BAR ADJUSTMENT If you have the ERA outboard braked rear suspension the effective stiffness of the rear anti roll bar can be changed to effect the front rear balance Slide the adjuster see page 102 toward the front for more understeer less oversteer 141 FINAL OPERATIONS DAMPER ADJUSTMENT SPAX Spax dampers do not have separate bump and rebound controls but a reasonable performance
147. king plates and remove the tubes from the wheelboxes Using a tubing cutter or hacksaw cut off approximately 2 from one end of the original tube between the right wheelbox and the motor Save the nut and the piece of tubing Use the short tube for the guide at the end of the second wheelbox Slide the nut onto tube shorter tube supplied the one with just 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 MOTOR PREPARATION 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 the inside of the crankpin Mark the relative position of the round motor housing to the aluminum gear reduction housing Remove the two long screws holding the motor housing to the frame Separate the two with 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 Inspect the brushes for wear or s
148. lamp 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 frs2asbt Adjust both lower trailing arms to 15 3 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 101 SECTION F SUSPENSION ASSEMBLY 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 Carefully jack the assembly so that the upper mounts engage into the chassis brackets Slide the x 4 5 HCS with a flat washer through the chassis and rear subframe bushing See page 99 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 Rotate the subframe forward until the front mounts see page 46 line up horizontally with the holes in the chassis crossmember Start a couple of the allen head cap screws 4 13 x 1 to confirm the alignment If there is a gap use shims fill it Tighten the front mount bolts and the cross shaft nuts Attach
149. lar shocks the rear height can be adjusted to taste E R A recommends that the main chassis rails be raked about to from front to back 139 FINAL OPERATIONS ALIGNMENT FRONT 1 Specifications below are for street driving Competition Comber degen settings will differ e Adding a shim at each bracket bolt will increase camber by approximately deg Use standard 1975 Chevrolet Camaro shims or their equivalent See pages 96 for suspension assembly The chassis height should be within the specifications given on page 139 e All ball joints outer tie rod ends and wheel bearings are Chevrolet The upper control arm pivot shaft is an aftermarket part for the same application but is offset for more camber adjustment Replacement part numbers are on page 148 Caster4 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 o 0 1 0 2 deg side 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 i
150. lave 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 bolt of the left engine mount The left rear oil pan tapped hole clslave part 1 bNbelltrim For other engines trim the bell housings similarly using the distance from the centerline of the crankshaft to the bottom edge of the flange The optional E R A Lakewood blow shield is already trimmed on the bottom edge Note that every bell housing should be checked for alignment concentricity Use a dial indicator on the flywheel to indicate the inside diameter of the transmission hole of the bell housing Offset bushings to shift the centering are available from Lakewood and Ford 35 SECTION PARTS PREPARATION FE ENGINE SHELBY 427 BLOCK The adapter bracket and slave cylinder are installed with a The bracket for the Ford FE block must be modified to fit single bolt on the front side of the left rear engine block Remove the locating tab and drill two new holes Note the bell housing flange The slave cylinder points toward the shims under the bottom bolt to square up the bracket to the rear and the locating strip on the adapter bracket goes block face beneath the engine block machined surface Note On some aluminum blocks the hole does not go all the way through the casting You must drill through 3 8 and tap the hole
151. lipers but none of the available E R A options require major changes First check that your link length is correct See page 103 Note that the brake balance bar must be set up on an angle as shown below This is required because the front calipers require about three times the brake fluid volume as the rear 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 brake pedal lower balance bar bearing Retain the total number of the spacers shifting them from one side of the balance bar to the other Standard spacing is an equal number of washers on either side of the balance bearing 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 SECTION FINAL OPERATIONS fbrkbal 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 never been run add oil to the filter and oil cooler before starting Build up oil pressure by cranking the engine over with the spark plugs removed Alternately you may 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 149 for Capacities 143 SECTION FINAL OPERATIONS COOLING SYSTEM S
152. lways use a ballast resistor with the Unilite system Also disconnect and tape the wire at the I terminal of the starter solenoid Details are with the wiring instructions When combined with an MSD ignition system a special resistor 15 required Call Unilite for details SECTION A PARTS NEEDED Tremec 500 and 600 This is a new stouter TKO with a TRANSMISSION gear spread similar to the Richmond Gear 5 speed The original 427 Cobra used the Ford Top Loader Overdrive 5 gear The 82 1 5 gear ratio is recommended transmission in both NASCAR close ratio and street wide for engines that don t run well below 2000 rpm See further ratio configurations It was and is a great transmission notes on page 13 and 34 with excellent strength and good ratios The disadvantage Richmond Gear 5 speed A close gear spread with a 1 1 with the 4 speeds is that neither offers particularly good 5 gear that requires a numerically low differential gear turnpike cruising Because of the high first gears you are forced to use a 3 31 or 3 54 differential ratio In this modern age most of us are used to more relaxed cruising Fortunately there are now several other good 5 speed transmissions that can be used with small block and FE Ford engines all of which will fit in an ERA without chassis As rule of thumb if you do much stop and go driving 10 MPH 1000 RPM is the longest 1st gear that can be driven smoothly with a fairly mild engine
153. n 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 16 Without an air wrench you may want to wait until the car is on the ground for final torqueing berahubc Install the upper bracket onto each hub carrier and torque the bolts to 75 lb ft Note the orientation below 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 Raise the back up about with a block of wood etc Place the the top section of the subframe over the differential lining up the 4 holes 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 45 cob man d rsasblyu Turn the assembly upside down Install the bottom 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 L hex cap screws and flat washers Align the rear flanges of the upper and lower sections with the lower radius arm bol
154. n 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 wires for the back up light switch connections exit the main harness on the passenger compartment side of the firewall 127 SECTION BODY INTERIOR MIRRORS DASH Assemble the mirror as shown The upper and lower SIDE clamps hold the rim against the reflector Note that the INSTALLATION stainless steel reflector is only polished on one side Follow the instructions included with the mirrors for disassembly You may have to drill the holes in the base larger to fit the included screws 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 Mount the rearview mirror on top of the dash in the pre drilled holes using chrome 8 oval head Phillips tapping Screws ebod outmir1 Position mirror pedestal the fender over the hole markings and within the gasket outline 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 putting in the screws If they are too TOP SNAPS tight in the hole adjust the Hole size with dnl The top snap
155. n the back panel of the front inner wheelhouse panels Drape over the upper control arm Final fitting will be completed later TONNEAU SNAPS Chase the holes with a 25 drill 150 Install the tonneau snaps with the fiber washers Don t force The snap screws may twist off leaving you with a broken screw in the body For extra safety and ease you can use a 10 steel screw to chase the threads into the fiberglass before you install the snaps 79 SECTION BODY PREPARATION WIRING AND ELECTRICAL This section presents general outlook on the layout of the various harness components All_individual connections are detailed in a separate list that comes with the harness A wiring diagram is 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 the dashboard and column connections e third harness runs from the left side of the dashboard area to the rear components Install the electrical components on the firewall and foot boxes into the pre drilled holes as shown below and in the wiring instructions Install the ballast resistor if you are using one after laying out the front harness in the car See the diagram in the wiring list FIREWALL ebod fwwire Use the layout diagrams below and the wiring instructions to find referenc
156. n the bracket so that when latched the lid slightly compresses the gasket and sits flush and centered on the surrounding body e ebod trnkltch 69 SECTION BODY PREPARATION 70 SECTION E BODY PREPARATION FITTING THE ROLL BAR E ROLLBAR RETROFIT INSTALLATION MAIN HOOP If the roll bar is not already fit initially drill the holes for the hoop no bigger than the diameter of the bar Call ERA for the approximate location of the holes This will allow final adjustment of the holes to exactly fit the grommets Install the roll bar hoop into the chassis and adjust the holes in the body if necessary Leave the bar in place REAR BRACE The spacer shims are necessary at the brace s lower end to make installation possible After making a preliminary body hole the upper brace mount must be welded to the top of the main hoop Loosely bolt the lower end of the brace to the bracket on the chassis Hold the upper end against the top of the hoop you will have to experiment with the thickness of shims at the bottom and tack weld MIG is preferred in several places Remove the brace and the main hoop and finish welding the upper mount We use a TIG welder for the neatest job FINAL FITTING Reinstall the roll bar and mark the body around the tubes allowing for the grommet thickness Note Use the grommet groove diameter and not the overall grommet diameter when marking See below Remove the bar
157. n the transverse tube behind the engine usually covered by the aluminum firewall panel On the outside of the frame just inside the right rear tire The body is marked inside the hood opening on the left return lip about a foot from the front of the opening BATTERY TRAY Pre installed The standard front mounted battery is bolted in place onto the front of the right foot box and to the top of the front outrigger It s pre installed on every chassis so the holes are already in place d voltreg d battery_mount BATTERY REMOVE AND REPLACE The engine compartment mounted battery is accessed by removing an access panel at the rear of the right front wheel e Remove the hose from the fresh air valve Note that the top panel screw and the three lower screws are removed from the engine compartment side and the lower screws from inside the wheel well The bottom edge is secured to the chassis outrigger with sheet metal screws 64 SECTION D BODY CHASSIS ASSEMBLY BRAKE CLUTCH FLUID RESERVOIR Note The rubber hose supplied by E R A is compatible with brake fluid but most other types are not Use caution if you choose to replace the hose Bolt the BMW reservoir and its mounting bracket to the driver s wheelwell as shown Connect the reservoir to the hardlines with the hose supplied Use clamps to secure 65 SECTION D BODY CHASSIS ASSEMBLY BODY MOUNTING Preparation Is Everything Before st
158. nd slip in from the center of the car towards the outside Match the holes in the fiberglass to those in the chassis BONDING STRIPS Special fiberglass angles are used between the inner panels and the latteral steel tubes see above Attach with sealant and rivets The short strips attach to the upper side cowl support tubes and the longer strip to the top of the rear cowl support tube Position the short bonding strips at least back from the front cowl transverse tube leaving room for the firewall that will be bonded later Rivet through the sides of the strips only 62 SECTION D BODY CHASSIS ASSEMBLY FRESH AIR CONTROL VALVES THROTTLE LINKAGE Mount the pedal assembly onto footbox See page 86 for details ID PLATE Install the ID plate with diam L aluminum blind rivets as shown aNiftair d idplate Screw on top of the foot box after putting a bead of caulk on the bottom flange Clamp the duct hose onto the valve The actuating cable will be attached later Use a wire tie to secure the hose to the bracket on the inside top of the fender 63 SECTION D BODY CHASSIS ASSEMBLY VOLTAGE REGULATOR The regulator part number on page 26 installs with 10 sheet metal screws bolts on top of the left foot box into captive speed nuts More chassis and body ID numbers The chassis is stamped with the ID number in three places The left front X member inside the top shock mount O
159. nd 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 142 Clutch height adjustment is covered on page 104 BRAKE PEDAL HEIGHT Master cylinder installation is described on page 61 For people of average height set the distance from the rear of the pedal face to the forward part of the foot box to about 7 If you are much taller or shorter you may move the pedal up to forward or backward as needed 103 If even more adjustment is required a bore Tilton cylinder can be substituted for the BMW clutch master cylinder A new clutch hose is also required Special Order Only ADJUSTMENT dbraklink 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 There flats machined on the one side of each connecting rod end Install the rod ends on the balance bar with the flats toward the balance bar housing See above and page 143 NOTE ON THE BRAKE BALANCE ADJUSTMENT The rod length has no effect on the front rear brake bias which brakes lock first If necessary the bias can be adjusted as described on page 142 For a preliminary setting adjust the outer rod so that there of thread
160. ner std Stant 10810 Filler car inner locking Stant 10582 1980 Mustang w 3 3L 149 Must be vented SECTION H CAPACITIES LUBRICANTS Engine Oil FE engine with Canton pan 7 5 qts w oil cooler 8 qts Add for remote filter 5 qt Transmission Ford Top Loader Fill to hole with 80W 90 GL5 gear oil Richmond Gear 5 speed 2 US qts of Redline 75 90 NS Tremec TKO GM Synchro transmission fluid or Dexron II Ford T 5 Ford Automatic transmission fluid Differential The filler and drain plugs are 2 square Fill to about 2 below the bottom of the hole with Moroso climbing gear lube SAE 90 part number 34800 mixed 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 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 REFERENCE 150 Cooling system capacity Ford FE engine 4 gallons Ford small block 3 5 gallons FREEZING POINTS FOR SOLUTIONS OF ETHYLENE GLYCOL GLYCOL BY F C VOLUME 12 5 25 4 17 20 7 25 10 12 32 5 0 18 38 5 10
161. ng 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 E R A has compiled comments from several forums at http www erareplicas com statereg htm 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 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 Several companies will give you an Alabama registration by mail This registration may or may not be valid in your state Lately it seem that many states are not accepting such paperwork and in fact revolking the registration cars previously registered in this manner 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
162. nner sleeve e the is correct remove the steering wheel hub from the splines and re install so that is centered Temporarily install the large washer wave washer and nut torquing to 10 lb 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 lb ft Install the hub center cap as described on page 113 REAR JAGUAR Camber deg 4 Toe in0 0 1 e Adjust Camber by adding or removing shims from between the brake rotor and the inner drive axle flange A 0 020 shim will change camber by 4 degree Most setups will require only one shim less camber than is normally used in the original car so you will have extra ones left over New shims are available from us your local Jaguar dealer or Special Interest Car Parts e 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 140 SECTION H REAR ERA Camber deg deg Toe in 0 s 0 deg Procedure Set the trailing arm lengths as described on page 101 Set the height as described on page 139 Use the rear tie rod to bring the toe in into spec but don t tighten the
163. nt DOORPANLI Re install the pocket onto the door Apply contact cement to the edge and backside only of the attachment plate and the back side of the pocket material Let dry to a tack free condition Carefully stretch the material over and partially around the attachment plate Remove the attaching plate from the door Tape or clamp the upper edge to a flat surface and finish gluing the edge Before attaching the pocket to the door glue the rug items 7 and 15 in the rug installation diagram on page Error Bookmark not defined to the inside of the door with contact cement Install the door pocket and the latch onto each door DOOR WEATHERSEALS Lay the doors outer surfaces down on a soft surface Clean the door edge and rubber with a mild solvent Glue the door weatherseal start with about 60 trim the ends later provided onto door lip about from the door edge using 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 Trim the ends of the weather stripping as shown E DOORGASK SIDE CURTAIN FERRULES FERRULE Slip the ferrules into the holes on the top of the doors and note the length that each extends past the inner panel SECTION E BODY PREPARATION Mark each ferrule so there are no more than 2 or 3 threads i All components are pre installed on every kit showing between the mark and the door su
164. o aluminum panel 200 dia x long connections button head Aluminum panels to chassis 60 dia x long large flange aluminum or stainless steel Hood scoop 50 dia X long aluminum mandrel Chassis lubricant grease for universal and ball joints Wheel bearing grease disc brake high temp type Contact cement fast dry type Auto upholstery shop or supplier Weather strip adhesive or use contact cement Foil faced foam or insulation Frost King duct insulation Building supply heating and air conditioning supply 516 hardware store 29 SECTION PARTS PREPARATION Restrictions or modifications to the donor parts for the 427SC This section does not cover engine transmission or rear suspension rebuilding Use dedicated rebuilding manuals for your specific equipment 30 Special Note During the time you spend while building your kit you should protect the following items from moisture dirt and aging Brake and clutch master cylinders Clutch slave cylinder All brake lines and fittings Fuel lines Brake pedals and throttle linkage Front and rear shock absorber seals Spray with rubber lube silicone or cover with silicone grease 31 SECTION PARTS PREPARATION ENGINE COMPONENTS We cannot give complete rebuilding instructions here What follows are the E R A specific requirements for your engine General torque specifications for typical
165. o and Halibrand The front outside but use bolt on hubs with adapters and special lug E R A hubs require non original backspacing Several nuts to drive the wheels manufacturers PS Engineering and Vintage wheels among others make 17 wheels that are up to 9 5 wide front 11 5 rear Front Wheel Offset Note t hat if you machine the back side of the wheel for fit you must maintain the pin hole depth 19 SECTION A PARTS NEEDED TIRES rim size appropriate for tires Front 26 3 24 5 275mm The original Cobra used 8 15 x 15 tires on the Sunburst street wheels 712 wide front and rear 9 90x15 and 11 90 x 15 were used on the original Halibrand GT40 wheels 7 2 front 9 rear These were pre 50 60 and 70 series tires with a different profile than contemporary tires A spreadsheet of tire sizes is posted on the ERA web site at http www erareplicas com 427man Diameter Max Min Max Width 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 B F Goodrich radial T A s sizes 265 50 x 15 or 235 60 x 15 front and 295 50 x 15 in the rear Inquire about current tires that fit properly Revolutions y Mile 20168 For Reference Tire O
166. o the tunnel Attach the plate and cover to the tunnel eint ebtrim1 Re bolt the hand brake lever in place Fold the outer flap of the cover over the lever and attach to the inner flap with the Velcro and snap SECTION BODY INTERIOR SHOULDER HARNESSES Locate the mounting holes in the chassis with an awl and cut holes in the carpet See page 83 The optional four point shoulder harness are installed with the 7 16 20 attaching bolts above the belt loops SEAT MOUNTING Lay the floor carpets in place and locate the seat mounting holes through the carpet Mark and cut holes for the bolts in the carpet If you are not using seat adjusting rails each seat must be raised up approximately 2 with spacers WITH ADJUSTING TRACKS The lever for the seat tracks falls on the right side of both the driver s and passenger s seats eint ebtrim3 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 The seats have captive nuts for the adjusting tracks in the holes in the cover and attach with the trim screws seat bottom Install the adjustment tracks if used to the seat base first with 20 bolts Make sure they don t stick When the floor carpet is installed lay it on top of the cover up through the base and prevent the cushion from seating material extending out onto the floor Put 2
167. ody Don t allow your holes to intersect with the rivets 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 SECTION BODY INTERIOR Press the molding tightly against the sill and carpet Drill the next hole and insert the screw Continue for the entire length of the molding FLOORS The under seat pieces can be glued in or simply held in place with the seat mounting system The front pieces are held in place with snaps in the floor at the front and Velcro at the rear edge 119 SECTION BODY INTERIOR TRUNK Note that the wire to the fuel tank rear harness must be installed before the trunk carpeting Left Side Trim the diagonal piece to fit around the roll bar brace mount All the exposed carpet edges are cut and bound Unless specifically noted all pieces are glued into place Install the pieces in numerical order Rear edge with bumper mount detail A piece of fuzzy material thick is supplied with the optional trunk carpet to cover the inside of the trunk Carefully trim the piece leaving extra material around the edges and glue the center part of this on with contact Right Side cement Carefully push the excess material under the lip of the fiberglass inner panel 13 You can use
168. old the bushing against the inside of the chassis bracket and 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 Slip the aluminum spacer between the outside of the trailing arm bushing and the chassis bracket See the frearsusp illustration above Slide the x 3 bolt through the flat Raise the rear suspension assembly into position with a washer upper hole in the bracket spacer and trailing arm floor jack guiding the forward ends of both trailing arms bush engaging the locking threads in the chassis No into the brackets on the sides of the frame Don t install lock washer is necessary the bolts yet 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 Connect the brake flex line to the bracket on the chassis XKE HANDBRAKE LEVER AND CABLE You can use then entire XKE handbrake cable linkage as shown below
169. oline is becoming scarce and octane boosters can be a pain to deal with If you re going to do a lot of street driving use a conservative compression ratio E R A turnkey cars are usually built with 9 5 1 or 10 1 maximum COOLING Always use a thermostat in your system for street use If the engine fails to reach normal operating temperature it may affect driveability and lubrication In warm climates a 165 F to 180 F thermostat works the best Use a restrictor plate for racing conditions only The thermostat should be modified as shown on page 38 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 Side pipes with catalytic converters are available but we have no experience with them net net lb ft 4 05 3 78 320up 427 4 23 3 78 410 up 480 4 13 3 98 325 475 The original Cobra used the 427 CID Side Oiler engine in the first cars intended for competition The remaining cars were equipped with a mix of 427s and 428 Police Interceptor engines Both engines are logical for use in an authentic car TheE R A was designed around these engines The Ford FE series is not especially heavy with the all iron version weighing only slightly more than 600 165 We have seen complete engines with aluminum heads intake manifold w 2 x 46 carbs and water pump scale at 522 Ibs Simply adding an aluminum in
170. ommended due to its large size CHEVROLET Engine mounts that fit both small and big block Chevrolet engines are available While this seems like low dollar horsepower our experience has been that resale value is adversely affected In the long term this decision is a net financial loss The standard Ford side pipes will be work but custom primary pipes must be custom fabricated The 427 454 CID engine requires a special alternator see page 21 and bracket which mounts the alternator at the bottom right of the block 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 Generally a high amperage alternator is not necessary but if you use one its output may excede the ammeter s capacity A small shunt wire can be installed to increase the ammeter s capacity IGNITION NOTES More details are included in the separate wiring instructions and at http www erareplicas com 427man index htm Note If you are using the reproduction expansion tank you must use a small diameter distributor cap Both MSD and Unilite have appropriate setups available 11 MSD SYSTEMS Neither our current Smith tachometer Caerbont nor the Stewart Warner require an adapter but some other Smith tachs may Inquire See page 80 for special wiring routing notes and the wiring instructions for hookup instructions UNILITE DISTRIBUTOR A
171. ors provided Tighten all the wheelbox nuts and the tube nut to the motor Install the wiring harness plug Don t install the wiper arms to the splined drive spindles until the motor has been run and the park resting position has been found The wipers will park on the right passenger s side Installation and removal is described on page 139 TRUNK LID Install the trunk lid liner the fuzzy stuff that was with the 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 12 31 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 the 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 ebod TRNKSEAL 78 SECTION E BODY PREPARATION HOOD GASKET Permanently install the gaskets to the underside of the hood as described on page 67 Door gasket installation is described on page 85 FRESH AIR HOSES After putting edge protector on the aluminum carefully feed the fresh air duct hoses through the hole i
172. ors and foot boxes to the chassis and corresponding body parts labeled C including the rear most lip of the upper trunk panel except e The bonding strips e The rocker panel longitudinal mounting tubes e Edges of the upper trunk panel that the body will contact Apply the bonding adhesive between the surfaces indicated on the diagram Remove the spacer blocks between the body and chassis lining up the original screw holes used for shipping Refasten the rocker panels firewall front wheel house panels trunk floor on rear crossmember While the adhesive is still soft install the 2 front inner splash panels with a few rivets or screws to establish the front body height See page 57 for details Install the nose support to establish the left right location for front body Smooth out any excess sealant at the same time sealing gaps where water and dirt could accumulate Wipe off excess bonding material from all joints and clean up with lacquer thinner or acetone taking extra care near painted surfaces Use aluminum or stainless steel blind rivets to complete the body attachment Drill s holes through the guide holes in the following panels into the chassis and rivet body to the chassis Front inner wheel house panels 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 SECTION D BODY CHASSIS ASSEMBLY e
173. otor 6 Both Koni and Spax are adjustable for damping The Spax illustrations on page 50 to help you identify the parts is externally adjustable for combined jounce and rebound Many times the wheel boxes available are not correct damping The Koni has separate external damping Measure across the teeth of your gear to the theoretical adjustments for jounce and rebound center of the cable Some of the gears are flat some are concave If your dimension A is 1 45 not 1 25 the FRONT COIL SPRINGS wiper drive must be modified to compensate See page 50 for details Front Spax and Koni dampers require 12 long by 250 Ib inch or 275 Ib inch springs for most engines Other dampers may require a different spring length Some spring shock combinations may require spacers Check with us for details EXHAUST SYSTEM SIDE PIPES Side pipes were used on the original competition cars and are very popular on the 427SC However because we have lengthened the footboxes for more leg room exact duplicates of the primary pipes will not fit Primary pipes for the Ford FE engines are available from E R A Exact reproductions of the original side pipes and the appropriate primary pipes are available from E R A in various coatings and materials including polished stainless steel UNDER CAR EXHAUST The E R A 427SC has provisions for an original style under car system This is a mellower dual exhaust system for those wishing to
174. plicity and to you crank If the car doesn t start pump once and open increase power Starting the car when cold requires a litte the throttle half way different procedure than most even the old timers are used to Cold start Pump the accelerator pedal two or three times Take your foot off the pedal while you crank When the car starts feather the accelerator pedal 147 MAINTENANCE PARTS All pieces listed below are included in the kit but are listed here for reference and long term replacement Part numbers listed are typical but equivalent brands may be substituted unless otherwise stated Fluids and capacities are listed on page 143 Brake master cylinder front Tilton 74 875U Tilton 74 7500 Clutch master cyl Fits 72 76 2002 Rear chas to subframe Brake pad front Bendix D52S Bearing shaft clutch pedal Thrust washer Bearing balance bar Clutch slave cylinder Fits 72 76 2002 BRAKES FRONT Caliper Pads Rotor thickness max min GM 1975 Bendix D52S 1 040 caliper Camaro 0 970 Sierra 002 0114 Various Must 1 250 caliper LH fit Wilwood 1 190 XL 002 0114 Superlite 8 RH thick pad REAR Jaguar 1980 XJ Lucas Girling 0 500 6 GP97 0 470 ERA Rear 93 97 Bendix 0 810 MKD750 0 770 body MRD750 PMD750 HYDRAULICS Tilton 74 875U front 88264 Tor B1416 Tor TRA1423 Heim LSS 8
175. ps on the inner panel Two styles of front signal parking lights are used on the 427SC Both are valid duplicates of the original Cobra e SC style used on original race cars Uses a twist off lens Used with the rectangular taillight duplicating early 65 66 original 427 Cobras Street style used on the last of the production run The lens is held on with two screws Usually used in conjunction with later 66 67 original round taillights eflights2 When making 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 Connect the black ground wire with the eye terminal to one of the light mounting bolts On some twist off lights it is possible to insert the bulb two ways Ifthe signal light is dimmer than the parking light remove the bulb turn it 180 and reinsert it TAIL LIGHTS Two types of original style lights are possible e Rectangular lights were used on the competition cars and some early street cars e Round lights similar to the screw type lens front signal park lights were used on the later street cars The rectangular lights are mounted with the lettering on the lens right side up and the round lights with the notch to the bottom Taillights with round or rectangular lens
176. r is level of course 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 pins into the door ferrules Trial fit each curtain to the door If the pins do not match the sockets it may be necessary to tweak the pins 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 If bending the pins doesn t solve the problem Remove the center ferrule by removing the circlips This will make checking fit of the outside pins easier The center pin can be fit afterward Use a round file to elongate the holes in the door skin and inner panel as needed Don t make the holes uniformly larger in diameter Oval them in line with the other pins so that the curtain frame will not rock Once all 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
177. receptacle in the caliper While this is similar to some metric fittings the threads are SAE It is not possible to make these flares with a conventional flaring tool Aftermarket suppliers and Jaguar dealers have these British style lines Mount the brass junction block on the left front of the cage with the fitting for the flex hose up If your rear suspension core has the junction block pointing forward fabricate a small bracket from steel strap Install the hose mounted on the chassis originally onto the junction with a copper 0 ring ASSEMBLY The description below is a supplement to a good Jaguar manual not a substitute Refer to the Jaguar instructions for a detailed breakdown of the assembly sequence and parts E R A does not recommend that urethane bushsing be substituted for the roller bearings in the bottom of the hub carrier Their excessive flex will cause wheel hop E R A SUBFRAME Build the differential installing the brake rotors and calipers outside the subframe Note If you are using the competition 12 vented rotors and aluminum calipers the rotor and caliper must be installed after the differential is in place Find the brake hose mounting tab on the front of the subframe See page 99 Lower the subframe over the differential while rotating so that the front of the subframe goes around the pinion first Use USS bolts to loosely attach the upper mounting plate to the differential casting
178. rface on its shortest side Cut off the excess at the mark and slightly round off the edges with a file or sander Hold the ferrules in place with the retaining rings provided Seat the retaining rings against the door surface tightly DOOR PULL STRAP OPTIONAL Drill a hole 30 bit just to the rear of the side curtain ferrule Loop the strap over the latch ball and use the screw and countersunk washer at the front DOOR INSTALLATION The doors can be installed now but to make other ehrotink operations easier it s best to wait until near the end See Fit the rod end C through the footbox using a large page 123 for installation details washer on either side of the hole Install the pedal assembly A with the linkage bracket B ACCELERATOR PEDAL AND LINKAGE onto the foot box At the back secure to the fiberglass with bolts through the brace bracket and spacers At the front secure with the front steering flange bearing bolts Loosely bolt the bracket D onto the engine using the rear most intake manifold bolt The final object is to have the cross shaft as parallel to the firewall as possible so the orientation of the bracket may be changed so that the vertical and rod end support are toward the firewall Adjust the placement of the rod end in the bracket so that the cross shaft is roughly horizontal Fit the left end of the transverse link F to the rod end on bracket B Secure with a cotter pin Slide a rod end E
179. rods out r Lower rad rod F in r Lower trailing arm F Lower trailing arm Rr Subframe top mt Subframe bottom mt BEARINGS and SEALS Bearing inner hub Bearing outer hub Hub seal inner Hub seal outer Sway bar link clamp and bushing Universal joint Subframe pivot bush Pinion seal most BODY Timken 03062 03 162 HMR 8 HML 8 HMR 8 HML 8 HFR 8 Energy Susp 9 9105 HMR 8 Energy Susp 9 9105 HMR 8 Same as Jaguar 1 Energy Susp 9 9107 All from 1976 Jag XJ Timken 18520 18590 Timken 18620 18690 Beck Arnley 052 0221 Beck Arnley 052 0643 Republic SL18050 Suspension Techniques PA 75 Spicer 5 160X Republic 12292 AAU3381A or inquire for non leather replacement Bushing Door hinge FB58 5 Oilite REFERENCE STEERING COLUMN Bushing column Lucas 209423 housing RELAYS SWITCHES Relay Horn and radiator fan ERA Column Signal Dimmer Switch Dimmer relay E R A and Trumph Flasher Bulbs Headlight Frt signal parking light Rr signal parking light Instrument lighting License plate 2 rqd Fuel system Bosch 36 081 0 332 204 150 or 0 332 202 125 or VW 321 919 505 Switch fan thermo VW 823 959 431 75 Relay tail light Switch Brake light Standard Ign TC 52 Ford 100810B GM 403936 Cole Hersey 8626 Wagner FC5106 VW 766 67 Bug 141 953 517F VW 111 941 583 NAPA ECHAR284 Buss 180 6014 1157 1157 Varies match bulb 57 Filler cap in
180. rom the windshield post trim plates on both sides of the windshield From under the cowl remove the 4 bolts holding the windshield to the car make note of any shims Slide the windshield up and out Store it in a protected place For installation see page 107 GAS CAP FILLER PIPE See page 93 for diagram Loosen the hose clamps on the rubber connector between the tank and the filler flange Remove the hose Unscrew the cap from its mounting flange Keep the shims and or gaskets found between cap and 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 Slip the lower ends of the vent and drain hoses attached to the mounting adapter out of the holes in the lower trunk fender closing panel Remove the screws holding the cap and mounting adapter on the underside of the fender Remove the flange and hoses Final fastener removal Locate and remove the screws save them please holding the body to the chassis from the e Bottom edge of the rocker panel e The interior side of the firewall where the firewall attaches to the steel cross member 58 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 LIFTING THE BODY OFF Two people per side are required to remove or r
181. ront edge of the airfoil Once on it cannot be removed without damage ebod splitter OIL COOLER OPTIONAL See below for shrouding hole locations and sizes to retrofit an E R A oil cooler to your car If you buy the oil cooler with the kit the holes will be pre drilled If you use your own oil cooler your hole pattern may be different ALWAYS flush and 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 ebod fradfill 90 SECTION E BODY PREPARATION 4 COOLER WITHOUT REMOTE FILTER The longer oil cooler line runs from the right side of the cooler alongside the radiator and is tie wrapped to the See page 90 fe or 6 Cooler shr oud layout bottom of the upper control arm inner pivot then through Hose connections are the described below a clamp on the front of the oil pan to the right fitting on the adapter housing Mount the cooler on the shroud ebod oilclr4 The shorter line runs along the left side of the radiator Since the fitting is quite large pass it initially by the bottom corner of the radiator then slide it up a bit Tie wrap it to the control arm pivot shaft then back below the steering shaft and to the left fitting Connect the hoses to the adapter and cooler as shown Use Teflon tape or pipe joint compound on
182. s optional Also included is a reinforcing bracket from the water pump to the outer end of the pivot bolt Ford FE Engine Alternator Mounting DMltbrk2 If you have a pressed in pin at D replace it with a threaded in stud Use bolt to secure the bracket to the block at A Use a bolt at If there is no hole at b slide the short strap to the base of stud E Connect the other end to the water pump bolt C We frequently use the strap in lieu of the second bolt Two different length spacers plus washers are provided to shim the alternator for aligning the pulleys Slide the oe longer of the two spacers onto the stud Install the long bolt through the reinforcing bracket Slide the alternator on the stud and then install the long alternator and spacer tube strap to the water pump at use sealer on both sides of the the strap to prevent water seapage It may be Bolt the assembly onto the cylinder head necessary to remove the water pump pulley for Install the top adjusting bracket as shown installation Loosely secure the inner end of the reinforcing strap to the Replace the pulley Use a straight edge across the pulleys water pump bolt as indicated to determine whether they are in line If not use the other Tighten the alternator pivot bolt spacer and or washers in any combination to achieve alignment Install an original adjusting strap C6AZ 10145B or the E R A replacement between the alternator Che
183. s showing on the outer master cylinder rod on the inner rod with the jam nuts against the rod end To change the brake pedal height turn both threaded rods equally in or out Check the tightness of the brake lines and switch fittings SECTION F SUSPENSION ASSEMBLY You can temporarily Install the brake cover box DEAD PEDAL INSTALLATION The brake or clutch pedal face angle can be changed with Hold the bracket at the desired height against the side of the top stop screw See page 103 the footbox and mark for the holes Drill through the i footbox and steel tube with a bit Secure the bracket CLUTCH PEDAL HEIGHT walle Pe TEE See page 103 for parts assembly The clutch pedal face should be approximately even with the brake If your clutch pressure plate requires more travel than normal you may need to keep the pedal face higher or alternately use a larger clutch master cylinder 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 137 ADJUSTMENT The throw out arm angle can be changed to raise or lower the pedal e _ Loosen the retaining bolt and slide the arm off the spline It may be necessary to disconnect the clevis from the arm e Have someone hold the clu
184. s were trial fit before paint If the screw holes have paint in them they should be chased with a drill bit If the stud goes in with some difficulty use a similar sheet metal screw to chase the threads in the fiberglass Use a fiber or plastic washer under each snap Do not over torque The studs are plated brass and break easily ebod sidemir 128 SECTION BODY INTERIOR EMBLEMS TRUNK Follow the same procedure as the nose emblem NOSE installation 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 Follow the dimensions in the diagram below for the location of the original type Cobra emblems Drill holes for the emblem studs Access holes are already in the inner panel g emblem2 Secure the emblem with the press on speed nuts provided g emblem1 129 SECTION BODY INTERIOR Project directly up 1 54 from the 4th louver and measure forward for the rear hole g emblem3 For the under car system see page 132 The E R A 427SC was originally designed using an original set of Cobra 427 side pipes When we lengthened the drivers side footbox we had to change the primary pipes to fit Exhaust systems are available from E R A or the suppliers listed on page 27 The outside pipes are available in bare steel or stainless alloy A
185. s will only fit one way If the E R A switch is too close to the steering wheel rim which occurs with some of the flatter wheels the switch arm may be bent slightly for extra clearance SECTION BODY INTERIOR cob nan wiring swbend With the road wheels straight install the hub on the column with the washer and nut Torque the nut to 25 16 ft only after the suspension is aligned and the steering wheel position is determined to be correct 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 If you are tall you may want to add shims and maybe longer bolts between the dash angle bracket and the mounting block Move the steering column in or out relative to the housing until there is 1 5 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 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 the center cap and remove the nut and washer While keeping rearward pressure on the steering wheel hub strike the end of the steering column forward with a brass or lead hammer Be careful not to damage the threads If that does not disengage the taper use a steering wheel puller CENTER CAP
186. spension pieces to tie to wrap soft tie straps around the front crossmember and the upper mounting bolts for the rear subframe TIE DOWNS You or your shipping agent will require ratchet tie downs come alongs and or strong straps We recommend either 4 diagonal connections or 2 longitudinal and 4 lateral ones for a total of 6 Don t forget that the trailer must have anchor points to tie to To avoid scratching the paint on the chassis use 2 wide loops or double 1 wide loops or ratchet straps 5000 Ib minimum rating Make sure that your trailer has places to tie to If you use chains or a come along bring padding or nylon straps for intermediate connections to the chassis INCLEMENT WEATHER A plastic cover will quickly shred at highway speeds A high quality cloth car cover can be used to cover up the plastic but it must be held down with rope all over Looseness will allow any cover to quickly beat itself and your paint job to death 7 SECTION A PARTS NEEDED SPECIAL NOTES The ERA 427SC chassis and body follow the dimensions of the original Cobra very closely Therefore 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 Be careful when selecting and building your components The information on the following pages shows the recommended parts for many possible drive train combinations
187. spots File these spots being careful to hold the file flat Recheck fit and repeat the process if necessary Install the dead pedal over the carpet Attach the tunnel carpet 17 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 To make cleaning easier the two piece floor carpets are held in place with snaps and Velcro Fit the carpets in place and mark the floor where the snaps are to go Drill 1 4 holes and screw the snap bases into place Remove carpets to fit seats FRESH AIR CABLES Lubricate the rubber grommet located midway up 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 63 Attach the cable to the side of the footbox with a cable clamp Also see the illustration on page Error Bookmark not defined 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 Hold the attaching plate against the cover and tunnel Drill four holes int
188. subframe 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 E R A subframe requires XKE style coil over dampers While not necessary special height and damping adjustable units are available from E R A Springs can be changed to ones of higher rate See page 53 16 STEERING GEAR Starting with chassis 759 the car requires a Flaming River gear FR1502 3x3 with modified tie rod adapters This is similar to a Mustang II unit but shortened by 3 Modifications are shown on page and complete units are available from ERA FRONT ROTORS AND CALIPERS WITH BOLT ON WHEELS Most mid sized GM cars from 1970 1978 used the correct pieces with 2 piston calipers Station wagons may use different parts Chevrolet lists the same rotor and calipers for all sedans SECTION A PARTS NEEDED Before purchasing the rotors 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 outer end The wagons used a 750 diameter spindle WITH PIN DRIVE WHEELS The E R A pin drive wheel conversion includes the hub and rotor both compatible with the caliper and bearings listed above OPTIONAL COMPETITION BRAKES E R A offers a conversion to 12 by 1 wide rotors and fixed 4 piston calipers for heavy duty street
189. t pipes must be custom made Alternately you may also build an economical variation to the 427 428 FE using a 390 block Externally this engine is identical to the 427 428 and it accepts most of the same performance parts FLYWHEEL The FE flywheel should use a ring gear with 184 teeth not 153 INTAKE MANIFOLD Low and medium riser intake manifolds including the Edlebrock Performer can be used on the E R A 427SC without modification The manifold may have to be tapped for the temperature gage fitting See notes on page 32 10 CARBURETORS A single 4 barrel Holley carburetor will connect directly to the linkage supplied with the kit Since the carburetors are turned 180 in the dual 4 barrel carburetor installation you must either use the factory Ford linkage which crosses the intake manifold between the carbs or fabricate new linkage All 4 bbl carburetors can be run without chokes with only slight driveability limitations If the choke plate is removed the choke housing should also be removed for extra clearance to the air cleaner Street hoods without scoop require this extra clearance with some intake manifolds Inglese Induction now part of Total Performance Wallingford Connecticut has developed a 4 carburetor Weber 48IDA configuration for the FE block While this really looks impressive it takes a lot of tuning and a perfectly set up linkage for a minimal gain of power not to mention being expensive
190. t 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 the same process with the left front caliper 138 FINAL OPERATIONS e Repeat the sequence with the rear calipers doing the right one first then the left e 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 BOLT ON WHEEL NOTES The standard thread of the front GM lug nuts is ho 20 The rear Jaguar studs are 20 thread size If you have a space saver spare be sure to have lug nuts sized for both PIN DRIVE WHEEL NOTES Some pin drive wheel castings have been porous especially with the real magnesium wheels We recommend that the rim be sealed with epoxy paint from bead to bead inside the tire area Some tire dealers have a special wheel sealant Wing n
191. tach the 24 battery cable to the positive terminal on the battery Place the battery onto the tray with the posts oriented toward the rear of the car this will put the positive terminal under the cowl Attach the other end of the cable to the right side of the starter solenoid Attach the 16 ground cable to the negative terminal of the battery Attach the other end to the right rear intake manifold bolt together with the engine to chassis ground wire See the wiring list Attach the other end of the small wire to the firewall as shown in the wiring instructions After putting grease on the bolt tighten the hold down clamp Attach the 24 cable with eyelets on both ends between the left side of the starter solenoid and the terminal on the starter 111 SECTION BODY INTERIOR REAR MOUNTED BATTERY Mounting details are available at www erareplicas com 427man index htm The battery may be mounted in the trunk for more rear weight bias ERA offers panels that close off the front of the trunk for this purpose Inquire Most states require that the battery be in a closed container to prevent spills and collect corrosive gases Run at least a 2 gage cable from the battery to the starter solenoid Secure it with insulated clamps spaced less than 12 apart The battery can be grounded directly to the frame or at the bumper bracket STEERING COLUMN AND WHEEL Prepare the triumph steering column as described on page 50
192. take will bring the weight a stock 428 to 585 165 The best engine depends on your driving style and your budget If you are not experienced in the FE series engine be wary of building your own exotic engine The FE series is a bit quirky and you may make some very expensive mistakes Before you buy anything get a good Ford engine building book available from Autobooks etc Ford production of major 427 and 428 parts ceased in the 1980s Fortunately most FE engine parts are being reproduced You can still find original 428 cores that were used in many full sized Fords Using a vintage engine may have an advantage when registering your car When you buy parts keep the receipts See Inspection page 152 In general the 428 is much cheaper and easier to find than the 427 The later vintage 428 Cobra Jet CJ or 428 Super Cobra Jet SCJ engine is fine for all around street use offering from 325HP to 425HP with very good low RPM response and tractability Most 428 cores can have their performance updated by the addition of new heads from Edelbrock and Shelby at reasonable cost With an appropriate intake manifold and carburetor a 428 will put out over 400 streetable bhp SECTION A PARTS NEEDED The 427 Side Oiler is the legendary Cobra engine Its cross bolted main bearings improved oiling system and shorter stroke are modifications made for racing It is more reliable above 5500 RPMs with somewhat better high RPM po
193. tch pedal at the 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 bleeding and adjustment are described on page 137 104 SECTION BODY INTERIOR 105 SECTION BODY INTERIOR WINDSHIELD WASHER WINDWINGS AND SUNVISORS The optional windshield washer uses a manual pump like Pre installed The windwings and sunvisors can be the original Cobra If ordered with the kit the fluid attached to the windshield frame before or after the container and the pump unit are installed at the factory If windshield is mounted on the car you are retrofitting your car the reservoir is mounted on the right front splash panel as shown below 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 out the holes before starting Install using the diagram below WINDWINGS Remove the bottom and third screws holding the windshield frame to the windshield Washer Mount the washer jets into the predrilled holes on the cowl jet noses aimed toward the right If you are retrofitting drill the holes for the jets 2 inside and forward of the center of each of the wiper holes It may be necessary to grind the underside of the body for thread clearance e windwing Compare the length of the two new screws provide
194. ter insertion into the hole Weld or braze the pin in the new hole from the back Clean and deburr the crankshaft Install the plastic gear onto the crankshaft engaging the tangs of the gear into the crankshaft notches The orientation of the plastic cam is dependant on which footbox your wiper motor is mounted Wiper mounted on the passenger s footbox The pin is adjacent to the parking cam b wipgear 52 Wiper motor mounted on driver s footbox The pin is opposite the parking cam 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 motor installation are on page 77 SECTION PARTS PREPARATION DAMPERS AND SPRINGS If the car seems too high when first lowered to the floor don t panic The car will settle a bit after driving The spring specifications below have worked for us consistantly The E R A Jaguar subframe requires XKE Series I or dampers Height
195. the threads where the fittings attach to the cooler and adapter ebod oilclr6 The adapter housing mounts onto the engine filter housing using the substitute fitting included The oil filter mounts on the adapter as shown Fit the rubber grommets onto the lines first Then with the shroud removed pass the lines through the shrouding tweeking the grommets into the holes with a screwdriver etc SECTION BODY PREPARATION COOLER WITH REMOTE FILTER FUEL TANK Mount the remote filter on the water pump with the E R A adapter bracket Some modifications to the pump might be The 19 gallon aluminum fuel tank is baffled with one way necessary doors separating the volume into four sections capturing the fuel toward the front center of the tank during cornering and acceleration A drain plug is at the right front of the tank bottom The fuel sender is in the center front section of the tank and installed at E R A If you find it necessary to remove the sender use a fuel resistant sealant like Versachem Gasket Sealant 3 Aviation A jumper wire is taped to the top of the tank that mates with the connection to the rear harness INSTALLATION Place the tank under the car and connect the sending unit wire s Use a grinder to remove 3 8 from the boss Assemble the other components as shown The water f f Raise the tank between the frame rails guiding the filler pump may require modifications to the bottom moun
196. ticking the 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 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 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 of the crank plate exactly opposite the center of the crankpin Use Blair spotweld cutter 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 SECTION PARTS PREPARATION b wiper2 Drill a hole in the opposite side of the crankplate at the position indicated in the illustration Countersink from the crankpin side just enough that the crankpin will be flat on the plate af
197. ting neck through the body hole Hold in place with one boss instructions included with cooler kit USS bolt per side Install the rest of the bolts and washers ebod oilclr5 WITH IN LINE THERMOSTAT Ebod Fueltank x Connect the fuel outlet on the center rear of the tank to the steel line on the chassis both 7 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 Slide the seal plate over the fuel tank neck and secure with the screws See the filler cap illustration oilclr7 SECTION E BODY PREPARATION FUEL FILLER CAP The cap and outside flange are indexed with punch marks or acommon number on the outside edge of the upper mounting flange This corresponds to where the latch of the filler cap falls when the cap is fully screwed onto the flange Note the odd hole falling just outside the upper flange on the body and lower flange A water drain for the filler well is integrated into the bottom flange of the filler cap The tube in the lower mounting flange channels water out of the well through a hole in the trunk FLANGE Put a generous amount of RTV silicone gasket sealer on the top surface of the flange Line up the drain hole on the flange and the body Hold the lower mounting flange in place on the underside of the fender INSTALLATION Tank vent hose Fuel tank extension ebod fuel
198. tom E R A bearings brake parts etc see page 148 SICP E R A Jag Dealer Various ratios of Dana 44 gears Michigan Driveline Modified Flaming River FR1502 3X3 See page for modifications E R A Flaming River 23 SECTION A PARTS NEEDED Radiator hoses FE engine See trimming instructions on page 39 layout on page 144 Upper w o connecting tube Gates 20819 Local auto part supplier Upper w connecting tube Gates 21236 or equivalent and 1 ID x 4 L straight Lower cast iron water pump Gates 21047 or equivalent Lower aluminum pump Goodyear 62107 NAPA NBH8683 CarQuest 21993 or equivalent Connecting tube to radiator Gates 20620 or equivalent Radiator hoses small Block See trimming instructions on page 39 Lower hoses Gates 20620 or equivalent Connecting tube to radiator Gates 20390 or equivalent Pump to connecting tube Upper Depends expansion tank d Upper Gates 20869 trimmed Chevrolet 427 Lower Gates 20620 trimmed 2 offend O Radiator expansion tank See page 9 for hints LF Starter FE engine Delco 323 217 OEM type Powermaster 9406 gear All FE engined Fords drive style 1964 69 The Shelby aluminum block requires a Powermaster 9406 5049 503 49M starter Starter solenoid Ford B6A2 11450 A or C9AZ 11450 A or C7AF Dealer or auto parts store 11450 A used on Ford products 1956 1980 Steering column upper E R A
199. tor tab and install the upper tab from the shroud to the radiator stud Secure with large flat washer and cotter pin Install washers and cotter pins onto the bottom pins too Install the fan and bracket assembly as shown above If you have the optional E R A oil cooler see page 90 the support straps from the oil cooler mount are to the outside of the support straps SECTION BODY PREPARATION OPTIONAL FANS 15 REAR MOUNTED ebod optfan3 TWIN 10 FRONT MOUNTED e ffans2 RETROFIT INSTALLATION Install the blades on the motor shafts with the concave side of the blade facing away from the motor toward the radiator Line up the setscrew with the flat in the shaft Tighten the setscrew with the shaft end flush with the fan hub Install the end plates as shown The end plates are handed The top is angled in slightly and there is a drain hole in the bottom corner Don t tighten the nuts until after the brackets are fastened to the inner panels Remove the grill splitter if you have one Cut a 1 x 4 piece of wood about 13 long Lay several pieces of cardboard 16 x 14 stacked at least 3 thick on the front face of the radiator Rest the fan assembly on the cardboard supporting the fan cross tube by placing the wood between the front of the bottom shroud and the tube Center the fan blades on the radiator and shift the cross tube so that it is horizontal Move each end bracket out flush with the fiber
200. ts Insert the he USS x bolts flat washers on both sides secure with stover nuts Use Grade 5 torque specs on page 151 for all fasteners Loosely fasten the bottom of the subframe to the differential using USS 1 bolts flat and lock washers Shims may be necessary between the channel and the casting so don t tighten the bolts yet Tighten in sequence the top differential bolts the bolts between the top and bottom subframe pieces If the clearance between the differential and the bottom section of the subframe is greater than 040 insert shims to fill the gap Use a medium grade threadlocker on the bolts Install the bushings and side brackets on the front mount tube Tighten one castle nut to 5 lb ft and back off so that the slot aligns with the nearest hole in the shaft Tighten the second nut to 15 lb ft and back off to the nearest hole B rsasblyf SECTION PARTS PREPARATION CONTROL ARMS Install a male right hand thread rod end and jam nut onto each front lower radius arm so that the bushing center to rod end center distance is 16 Leave the jam nuts loose Assemble the rear radius arm as shown fiat man d rradarm Install the front radius arms onto the lower differential bracket as shown fiat mnan d rsasblyt Insert the bushings into the radius arms and lightly lubricate the inside with heavy grease silicone or moly base is best Install the hub carrier onto the front radius
201. uts on the left passenger s side of the car are right hand thread Clockwise rotation tightens the wing nut counter clockwise loosens On the right side passenger s side the wing nuts are left hand thread and clockwise rotation loosens the wing nut counter clockwise tightens Remember Left side right hand thread right side left hand thread Tighten wing nuts in the direction opposite to forward wheel rotation Use anti seize on the knock off threads drive pins wheel mounting surface and the area contacting the wing nut 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 plastic dead blow or lead hammer 3 Ibs to tighten each wing nut Don t over tighten Strike only until the nut stops rotating 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 FINAL OPERATIONS INSTALL WIPER ARMS SUSPENSION ADJUSTMENTS Without the arms installed cycle the motor through high CHASSIS HEIGHT and low speed When you turn off the switch check to see _ _ that the drive posts return to the far right passenger s side After setting the springs as described on page 53 the car position should be driven to settle everything in Don t change the spring heights before driving the car at least
202. wer than the 428 and a little less torque at low RPMs Many of our customers have built 427CID engines of more than 5SOBHP We have found that the extra money spent on 427CID engine will usually be returned in a higher resale value for the finished car The 427CID Center Oiler is now found mostly in boats It lacks the exotic oiling system of the Side Oiler while retaining its bore and stroke Since it was never found in the original Cobra it lacks some internal authenticity but it does look correct There are a few problems associated with converting boat engines to car use Many boat engines rotated in the reverse direction with counter camshafts incorrect crankshaft sealing and oddball distributors among other things Use caution A hybrid 454 CID engine may be created by the use of a 428 crankshaft in a 427 block using Chevrolet pistons and other special efforts This is not an engine for the inexperienced to build but it s great fun to drive with good horsepower and flexibility Aluminum blocks are available from Carroll Shelby Enterprises Genesis Pond and Dove Engineering Shelby Edlebrock and Dove make aluminum cylinder heads For the more adventurous E R A has modified footboxes and steering column to fit the Ford 427 SOHC With its huge ports this engine produces a lot of horsepower but has poor low speed flexibility Because of the width of the heads there is a significant loss of foot room Primary exhaus

427 ROADSTER - Era Replica Automobiles

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