ASSEMBLY and SERVICE MANUAL - erareplicas.com

1 ASSEMBLY and SERVICE MANUAL FOR THE ERA GT ERA REPLICA AUTOMOBILES 608-612 E. MAIN ST. NEW BRITAIN, CT 06051 TEL: 860-224-0253 FAX: 860-827-1055 E-MAIL: WEB SITE: 2005 - ERA REPLICA AUTOMOBILES Revision 4A 1/05 CONTENTS _____ a PARTS NEEDED/ ASSEMBLY SEQUENCE _____ 1 PARTS PREPARATION_____ 20 SUSPENSION AND BRAKES_____ 36 SHIFT LINKAGE AND REAR AXLES _____ 55 ENGINE AND TRANSAXLE _____ 61 FUEL AND COOLING SYSTEMS _____ 65 BODY _____ 75 INTERIOR/VENTILATION _____ 97 UPKEEP - REFERENCE - REGISTRATION _____ 109 INDEX _____ 117 PARTS NEEDED/ ASSEMBLY SEQUENCE 1 PARTS NEEDED/ ASSEMBLY SEQUENCE Parts Needed/ ASSEMBLY Sequence 2 WELCOME! Congratulations on your purchase of the ERA GT kit!

2 O ur goal, when we started on the design and construction of this kit, was to cre-ate an accurate and buildable Ford GT 40 replica with minimum compromises. You are free to make your own "improvements", but be aware that the ERA GT is a complex and integrated design. Changes that you make in one place will proba-bly effect several other systems. If you wish to retain the essence of a true rep-lica, it s best to be conservative. Also, it is usually the case that the more com-plex things get, the less reliable is the result. While this is certainly not a small project, it can be one that is straightforward and very rewarding. Read the MANUAL well. We have tried to include all the informa-tion necessary for you to complete this project.

3 The MANUAL is arranged according to subject, not the direct order that the kit should be put together. This was done to enable the MANUAL to be a reference MANUAL , and to give you some flexibility in your work sequence things should have a definite order. The recommended plan of attack is on the next page. Please use! Good luck, and above all, have fun! Parts Needed/ ASSEMBLY Sequence 3 ASSEMBLY SEQUENCE OVERVIEW: If there is an addendum with this MANUAL , please make notes or changes to the MANUAL as soon as possible. Preparation of many parts can be done before the kit arrives by following the instructions beginning on page 5. If you wish to paint your chassis, you must remove the body and some components from the chassis for paint preparation and undercoating.

4 This is detailed on page 21. On the basic kit, all the bodywork is located in its proper position, secured by temporary fasteners (unless we have been asked to take some optional actions). When you remove the body from the chassis, make note of the positions of hinge, latches and shims by marking and tagging. If any bodywork must be done, it may be best to complete the rough work before dis- ASSEMBLY . The parts that are not included in the kit but are necessary for the car's completion are listed in the latter part of this section. Also provided is a list of sources where quality components can be found. If you cannot out-source an item listed: Sometimes the part numbers listed here have been superseded or de-leted.

5 Call us before you panic. We usually have new information or we can find out for you. also stocks many parts for our turnkey projects. We may be able to supply you what you want. When your kit arrives, check it for completeness of parts. You will find packing lists for each box. Check each box carefully for accuracy. If you think there is a mistake, please call us immediately. FOLLOW THE SEQUENCE OF ASSEMBLY ON THE NEXT PAGE! IT WILL SAVE YOU TIME AND PREVENT HEADACHES. Parts Needed/ ASSEMBLY Sequence 4 GENERAL SEQUENCE OF ASSEMBLY FOR COMPLETE INFORMATION ON INDIVIDUAL SYSTEMS, CHECK THE INDEX ON PAGE 117. The sequence below is not cast in stone. There are, however, some things on the list where order is critical.

6 They are marked with an asterisk.(*). If at all possible, use the priorities below. It will reduce your effort, save time and result in a better finished product. *Disassemble the kit as necessary, using the in-structions on page 21. *Clean and paint the chassis and suspension components, Section 76. *If your chassis is not stainless steel, rust proof the inside the rockers and through the access holes provided. See page 76. Install the front inner and bottom splash pan-els,and the rear subframe splach panel. Page 87. *Install the brake lines, page 14. *Install the internal aluminum water lines with rear hoses, page 70. Install the brake pedal ASSEMBLY , page 49. Install the throttle cable and front linkage, page 98.

7 Install the speedometer cable, page 99. Install the emergency brake cable and handle, page 53. Install the radiator, AC condenser, with fans, page 70. Install the air conditioning lines, Section H. *Install the roof. Check the fit of the front and rear body, and doors, Section G. Paint all sections of the body. See stripe info. *Install the wiper motor and linkage. See the separate wiring instructions *Install the fuel tanks, fillers and lines, page 66. Install the dash access panel (passenger com-partment) electrical accessories. See separate wiring instructions. Install the voltage regulator and starter solenoin. See the separate wiring instructions Install battery cables.

8 See the separate wiring in-structions *Install wiring harnesses D, E and L if applica-ble. See the separate wiring instructions *Install the suspension, front and rear Pages Error! Bookmark not defined. and 43. Install the air conditioning main box and/or heater, and the cowl hoses for the fresh air vents, page 104. Install the air conditioning hoses from main box to rear bulkhead, page 103. *Install the shift linkage on the tunnel with "Z" Bar, page 56. Fit the air conditioning compressor and alterna-tor onto the engine, page 24. Wire the engine. See the separate wiring in-structions. Install the engine/transaxle, page 63. Install the rear axles, page 60. *Install the rear shift linkage, page 56.

9 Install the front body, Section page 87. Install the front body sealing hardware and gas-kets, page 81. Install the rear body, page . Install sound deadening panels if required, page 98. Install the dashboard, page 101. Install the steering column/housing, page 100 . Install interior, page 97. -PARTS PREPARATION- 5 PARTS REQUIRED AN OVERVIEW, WITH SPECIAL NOTES The ERA GT chassis and body follow the dimensions of the original GT40 very closely. Therefore, your mechanical components must conform to similar space limitations as the original car. Some configura-tions will fit together better than others, and some are simply not possible. Be careful when selecting and building your compo-nents.

10 The information on the following pages shows the recommended parts for many possible drivetrain combinations. ENGINE: Because of space considerations and transaxle com-patibility, the following engine parts are especially critical. All are covered in detail in thelatter part of this section. Block: Don t use a pre-1965 model. The bolt pattern won t match the bell housing. Front Cover (only one is acceptable, see parts list) Front crankshaft and damper: See page 6 for dimensional limitations Water Pump: A Ford Motorsport shorty pump or Snow-White pump is highly recommended. Alternately, you can use an externally mounted electric pump made by Davies-Craig of Australia. Inquire.