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Era Replica Automobiles ERA GT Assembly And Service Manual

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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: era@aol.com
WEB SITE: www.erareplicas.com
COPYRIGHT 2001 - ERA REPLICA AUTOMOBILES

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  • Page 1 ASSEMBLY 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: era@aol.com WEB SITE: www.erareplicas.com COPYRIGHT 2001 - ERA REPLICA AUTOMOBILES...

  • Page 2: Table Of Contents

    CONTENTS _______________________ a PARTS NEEDED/ASSEMBLY SEQUENCE_____________________________________________________ 1 PARTS PREPARATION ____________________________________________________________________ 20 SUSPENSION AND BRAKES _______________________________________________________________ 36 SHIFT LINKAGE AND REAR AXLES ________________________________________________________ 53 ENGINE AND TRANSAXLE ________________________________________________________________ 59 FUEL AND COOLING SYSTEMS ____________________________________________________________ 63 BODY ___________________________________________________________________________________ 73 INTERIOR/VENTILATION _________________________________________________________________ 95 UPKEEP - REFERENCE - REGISTRATION __________________________________________________ 107 INDEX _________________________________________________________________________________ 115 THE FOLLOWING SUPPLEMENTS ARE ALSO AVAILABLE OR IN PROGRESS:...

  • Page 3: Parts Needed/Assembly Sequence

    PARTS NEEDED/ASSEMBLY SEQUENCE PARTS NEEDED/ASSEMBLY SEQUENCE...
  • Page 4 O ur goal, when we started on the design and construction of this kit, was to create 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...
  • Page 5 Parts Needed/Assembly Sequence 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 If you wish to paint your chassis, you must remove the body and some components from the chassis for paint preparation and undercoating.
  • Page 6 Parts Needed/Assembly Sequence GENERAL SEQUENCE OF ASSEMBLY FOR COMPLETE INFORMATION ON INDIVIDUAL SYSTEMS, CHECK THE INDEX ON PAGE 115. The sequence below is not cast in stone. There are, however, some things on the list where order is critical. 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.

  • Page 7: Parts Required

    -PARTS PREPARATION- PARTS REQUIRED AN OVERVIEW, WITH SPECIAL NOTES The ERA GT chassis and body follow the dimensions Flywheel (must match the bell housing, clutch of the original GT40 very closely. Therefore, your and crankshaft) mechanical components must conform to similar Clutch (must fit the transaxle, flywheel and bell space limitations as the original car.
  • Page 8 -PARTS PREPARATION- ENGINE AND ACCESSORIES E.R.A. has developed our ERA GT around parts pump extends into the rear bulkhead (and has a and accessories from the 1965-on small Ford fiberglass cover.) All engines must use a short block. The earlier 1961-1964 221, 260 CID...
  • Page 9 -PARTS PREPARATION- Alternator: Ford, 1965-78, w/single V-groove Oil pan and pump: To prevent the sump from pulley and external regulator. Fits most Mustangs hanging below the chassis, the maximum oil pan w/o AC. depth is 7 ". There must also be clearance for A heavy duty unit (100 Amp) is recommended the starter when using the ERA bell housing.
  • Page 10 -PARTS PREPARATION- Water pump: A "shorty" water pump is When examining your potential or existing engine, measure the flywheel ring gear diameter to the recommended for all cars and mandatory with air conditioning. The Snow White unit is " shorter outside of the gear teeth.

  • Page 11: Speedometer Gear

    -PARTS PREPARATION- The Pantera bell housing for the 25/1 can be TRANSAXLE - BELL HOUSING redrilled to enable transaxle inversion. OVERVIEW Unfortunately, the bell housing depth must also be reduced " and the bottom edge must be removed The original GT40 used the German ZF 5DS-25 for ground clearance.
  • Page 12 -PARTS PREPARATION- TRANSAXLE-CLUTCH-FLYWHEEL SELECTION TABLE and this TRANSAXLE with this ENGINE ⇓ Early (5 DS-25/1) Late (5DS-25/2) 1965-1966 289 CID Note A Note B w/157/160T ring gear 1968-1981? 289, 302 CID Note C Note D w/164T ring gear 1982 on 302 CID w/ Note E Note F 157/160T ring gear...
  • Page 13 -PARTS PREPARATION- Dimensions given below are subject to final COIL-OVER DAMPERS (SHOCK adjustment for your preferred ride height. We ABSORBERS) recommend 5 inches front, 5.25" back for street ground clearance (tub to ground). The original The following dampers fit the chassis well and have GT40's had 4.8"...

  • Page 14: Steering Gear

    -PARTS PREPARATION- COMPETITION: STEERING GEAR Properly set up with good street tires at normal 1965-1975 MGB: The early unit (pre 1969) has pressures, the street suspension should generate gearing that results in 2.5 turns, lock to lock, and is more than 1G, and is very well balanced. Handling recognized by a bulge in the pinion end cap.
  • Page 15 -PARTS PREPARATION- REAR: 1988-94 Corvettes (with 12" rotors) have their emergency brake built into the caliper. The 12” rear rotors are very tight with 15" pin drive wheels: Normal wheel weights that stick to the inside of the wheel will not clear the caliper. Balancing weights must be very thin, or clip onto the rim edge.
  • Page 16 -PARTS PREPARATION- Because of tight clearance between the caliper and the SUSPENSION AND BRAKE PARTS, wheel, very thin wheel weights must be used. BOLT-ON WHEELS: Complete caliper assemblies are available from ERA or Baer Racing. Hub bearings and caliper bridges are REQUIRED PARTS illustrated on page 38.

  • Page 17: Brake Caliper

    -PARTS PREPARATION- Washer, cal. mt. E.R.A. REAR - PIN DRIVE Bolt, caliper plate supplied Uses 1989-92 Corvette pieces with the emergency Spring, levr arm ret. 10112651 brake built into the caliper. Plate, caliper mounting 10112652 Except for the pin drive hub, parts are the same as Guide pin the Bolt-on.

  • Page 18: Wheels And Tires

    -PARTS PREPARATION- Retainer 562248 (moving the wheel toward the centerline of the car). Cotter pin Remember; Suspension harshness increases with very Rotor, 12" from GM 10097655 large tires, and since the car is very light, smaller sizes Pin Drive Hub are more than adequate for spirited driving.
  • Page 19 -PARTS PREPARATION- Wiper arm:(15" pivot to end) Wiper blade:(18"). Assemblies are available from E.R.A.
  • Page 20 -PARTS PREPARATION- SOURCES (800 Tel. Nos.do not apply in State being called) Aviad Metal Products 7570 Woodman Place, Van Nuys, CA, 91405. Tel. 818-786- Oil pan 4025 5-B Hamilton Bus. Pk., Dover, NJ 07801, Tel. 973-9260 AVO Dampers CFI Motorsports Clark Bros.

  • Page 21: Tools Required

    -PARTS PREPARATION- TOOLS REQUIRED Standard combination wrenches from " to ". You may need two of each. Socket sets in ", " and " with extensions and universal joints. Torque wrench. Screwdrivers in various sizes. Small jack Jack stands (4) Patience (YOU MAY NOT HAVE) 8 mm.

  • Page 22: Parts Preparation

    -PARTS PREPARATION- PARTS PREPARATION...

  • Page 23: Engine Preparation

    -PARTS PREPARATION- DOOR REMOVAL: KIT DISASSEMBLY Record the number and placement of shims Unless E.R.A. has already painted and/or during the removal of the door so that the undercoated your chassis, it for you, it is alignment can be restored upon installation. See page 80 for door details.
  • Page 24 -PARTS PREPARATION- • You must remove the ball joint that some Maximum pan depth without hanging carburetors come with, replacing it with a HM-3 below chassis: 7.3" (Heim) rod end and #10 screw. • Maximum width at widest point ahead of Weber conversion manifolds generally have starter: 14"...
  • Page 25 -PARTS PREPARATION- Standard wire sets for the small block are usually AC AND ALTERNATOR MOUNTING too short. It may be necessary to use the longer AIR CONDITIONING COMPRESSOR wires from two sets, or cut your wires from bulk MOUNTING rolls. Universal sets that "Fit everything" may have the necessary lengths also, but check that the SPECIAL NOTES ends are appropriate or can be changed to ones...

  • Page 26: Alternator Mounting

    -PARTS PREPARATION- acmount altmt Install the brace from the water pump right-most 289/302 Engine: Use the " x 5" bolt with the bolt to the compressor bracket. The " rod end of shorter spacer through the outer hole in the the compressor tensioner goes on top of the brace, bracket.

  • Page 27: Oil Filter

    -PARTS PREPARATION- The adjusting bracket is mounted on the lower As with the later transaxle, the ring gear must be flipped to the other side of the pinion gear so that left bolt on the front cover, and the slotted end is offset toward the front of the car.

  • Page 28: General Hints

    -PARTS PREPARATION- A 10.5" Long type clutch from various 260, 289, The ring gear bearings may be damaged during 302, and 351W Ford engines must be used, so it is disassembly, and it is good practice to replace sometimes necessary to redrill the flywheel for the them anyway.

  • Page 29: Input Shaft

    -PARTS PREPARATION- Remove the differential side bearings from the CASE MODIFICATIONS differential. This requires a special tool, or a lot of Check the internal clearance for running the cursing. The ring gear assembly will not come out ring gear on the opposite side of the case. Later of the case with the bearings on it.
  • Page 30 -PARTS PREPARATION- Drill and tap an oil level hole in the right side of the case in the position shown. The hole should be drilled to 1 " and tapped " NPT, and a pipe plug installed. When filling the transmission from the top, the oil level should reach the bottom of the hole.
  • Page 31 -PARTS PREPARATION- The proper backlash is etched on the outside edge of the ring gear, with some other numbers. Look for "0,20" or "0,25" or a similar number. This is the backlash in millimeters. Multiply by .0394 for the inch equivalent. Adjust the ring gear backlash by changing the shims behind the cups of the differential bearings in each side plate.
  • Page 32 -PARTS PREPARATION- See page 8 for clutch/flywheel bolt pattern. FLYWHEEL AND CLUTCH Clutch: You must use a 10.5" clutch as listed on PANTERA BELL HOUSING: page 8 for a guaranteed fit. For other clutches, we While the clutch and flywheel components can have also included an illustration (page 30) remain stock Pantera (164 tooth flywheel), the bell showing the approximate clearance available...
  • Page 33 -PARTS PREPARATION- With the clutch installed, use a straight edge across the pressure plate to measure the height of the fingers relative to the engine plate. See page 31. Temporarily install the throwout bearing onto the adapter sleeve, and engage the unit onto the transmission throwout guide sleeve.
  • Page 34 -PARTS PREPARATION- Center the rack by equalizing the distance each STEERING GEAR end extends from the housing (+/- "). There are two original MGB steering gears With the steering gear assembly oriented with the available (Type 1 and 2 shown below) that require mounting faces down, mark the pinion shaft on its some tie-rod modifications, and one new ERA uppermost surface.

  • Page 35: Wiper Motor

    -PARTS PREPARATION- With the flat in the pinion shaft straight up, adjust The chrome bezel must be modified by machining, the outer clevises so that they are 26.5" +/- " so that it is no longer beveled on one side. The (see page 32) from the clevis hole center-line to bezel is also available from ERA on an exchange hole center-line, and equally spaced from the rack...
  • Page 36 -PARTS PREPARATION- Put 1 or 2 drops of oil in the lower bearing of the armature housing. Excess oil will contaminate the brushes later on. Install the armature housing, aligning the marks on the housing and the frame. Reinstall the long retaining screws.
  • Page 37 -PARTS PREPARATION- wiperlay Partially fill the gear housing with grease, and place the cable into the guide. Some guides have cast-in liners while others have separate plastic pieces. Install the connecting rod with its thrust washers, and the connecting rod circlip. If possible, test the clearance between the connecting rod and the lower part of the housing by rotating the crankshaft.

  • Page 38: Suspension And Brakes

    -SUSPENSION AND BRAKES- SUSPENSION AND BRAKES...
  • Page 39 -SUSPENSION AND BRAKES- FRONT UPRIGHT ASSEMBLY THE FOLLOWING PIECES ARE INCLUDED IN THE KIT: (2) Hub carrier center casting 1 each left and right steering arms, with top boss installed (2) Bottom boss " x 1" Socket cap screw, stainless steel "...
  • Page 40 -SUSPENSION AND BRAKES- Install bearing races in hub: REAR HUB CARRIER ASSEMBLY: Inner: LM12710 Set the hub carrier outside face up, and place the Outer: L68110 appropriate caliper mounting plate (Left: GM At this point we recommend that the hub/rotor 10052211, Right: GM 10052212) on top, lining up combination be sent out to an automotive machine the holes so that the caliper will be mounted...

  • Page 41: Installation

    -SUSPENSION AND BRAKES- Using the four " x 2 " hex cap screws BOLT-ON WHEEL HUB CARRIERS provided, bolt the steering gear to the chassis FRONT HUBS: brackets with a shim under each mount. The shims allow exact bump steer adjustment for those Install the hub bearing (GM 14084142) to the who demand competition tolerances.
  • Page 42 -SUSPENSION AND BRAKES- LOWER CONTROL ARM: REAR TRAILING ARM INSTALLATION The anti-sway bar tabs are located on the upper The upper and lower trailing arms and rear upper rear part of the arm as installed in the car. Install control arms are threaded left on one end and right the control arm into the brackets as illustrated on the other.
  • Page 43 -SUSPENSION AND BRAKES- Lower trailing arm installation gt\man\c\ftrarmmt Slide the boots over each trailing arm, together with the emergency brake cables. gt\man\c\rltaboot...
  • Page 44 -SUSPENSION AND BRAKES- Gt\man\c\rsusp Install the rear lower control arm onto the hub carrier. Slide the lower fulcrum pin through the REAR UPPER AND LOWER CONTROL front bearing, .282" spacer, and the hub carrier. ARM INSTALLATION There are shims provided to fit between the hub carrier and the rod end.
  • Page 45 -SUSPENSION AND BRAKES- Secure each end with a flat washer and locknut. COIL-OVER INSTALLATION Install the upper and lower trailing arms onto the For specifications see page 11. hub carrier pins with " x 1 " bolts, flat washers and locknuts. Do not tighten the lower FRONT bolts.

  • Page 46: Damper Adjustment

    The bump/rebound ratio is one end of the vehicle than the other. If this designed for the ERA GT and only detail changes occurs, keep increasing the bump adjustment on need be made for optimum handling.

  • Page 47: Wheel Alignment

    -SUSPENSION AND BRAKES- Camber is the vertical tilt of the tire WHEEL ALIGNMENT toward the outside. Camber controls the contact patch of the tire. Negative All alignment operations should be done with the camber tends to give higher cornering ride height set to your preference. See the section on force limits, but wears the inside of the springs (page 10) for further information.

  • Page 48: Tire Pressures

    -SUSPENSION AND BRAKES- Camber is adjusted by threading the nuts Set the camber by adjusting the upper radius securing the upper ball joint to the upper control rod. arm in or out. Hold the ball joint so that it is in Set the toe-in by lengthening or shortening the line with the king pin axis while adjusting and upper and lower trailing arms equally.

  • Page 49: Technical Overview

    -SUSPENSION AND BRAKES- BRAKES TECHNICAL OVERVIEW The clutch master cylinder is identical to the front brake master cylinder. Hydraulic pressure is created by two Girling- Lockheed Master Cylinders actuated by an From chassis 2055, 2 psi residual pressure valves were added to the system to alleviate some soft adjustable balance bar.

  • Page 50: Pedal Assembly

    The 12" rotors (88-94) have the emergency brake integral with the caliper. BRAKE LINES As delivered, the ERA GT kit has all the steel lines, fittings, adapters, flex hoses, etc. fitted to the chassis. Do not assume that any connection is tight.
  • Page 51 -SUSPENSION AND BRAKES- Generally, for those over 5'11" tall, the assembly will be most comfortable in the forward-most position, in the rearward-most position for those under 5'6", somewhere in between for the rest of you. Within limits, you may adjust the links between the pedals and the master cylinders.

  • Page 52: Front Caliper

    -SUSPENSION AND BRAKES- To decrease the braking at one end of the car, use more spacers on the side of the balance bar going to that end's master cylinder. Transfer a spacer from the opposite side of the bar. Total spacer length must remain the same.
  • Page 53 -SUSPENSION AND BRAKES- EMERGENCY BRAKE HANDLE AND CABLE c\ebillust Trim the LHD emergency brake handle (part The emergency brake system is a single number is on page as shown on page 16). The continuous cable, pulled by a balance wheel on RHD handle comes with the kit.
  • Page 54 -SUSPENSION AND BRAKES- CALIPER-TYPE EMERGENCY BRAKE Install the special cable clamp bracket onto each caliper with a single bolt. See below. ADJUSTMENT Adjust the nuts on the cable housing at the front chassis bracket. The lever arms must be free to fully return.

  • Page 55: Shift Linkage And Rear Axles

    SHIFT LINKAGE AND REAR AXLES...

  • Page 56: Installation

    -SHIFT LINKAGE/REAR AXLES- SHIFT LINKAGE AND SHIFTER BOX LEFT HAND DRIVE THE SHIFT LINKAGE CONSISTS OF: SHIFT BOX ADJUSTMENT: Shift box with handle, extension and reverse Temporarily secure the assembled shift box to the lockout mechanism. tunnel with four -20 screws. "Z"...
  • Page 57 -SHIFT LINKAGE/REAR AXLES- Feed the "Z" rod through the slot above the With the shift lever vertical, rotate the "Z" bar so tunnel, snaking the end through the support bearing that it is centered in the slot in back of the seats, housing on the rear firewall.
  • Page 58 -SHIFT LINKAGE/REAR AXLES- At this point you should be able to select 1 st plane. Readjust if necessary. Raise the reverse through 5 th gears and the lever should return lockout lever to check selection of reverse. naturally to the neutral position in the second/third Grease the rubbing areas of the shift box generously.
  • Page 59 -SHIFT LINKAGE/REAR AXLES- RIGHT HAND DRIVE SHIFT LINKAGE The RHD shift linkage consists of a rear rod with With the shift lever oriented vertically, twist the offset, double coupling sleeve, front rod with a flat rear rod so that the offset gives maximum plate, shift lever pivot box, and shift lever.

  • Page 60: Rear Axles

    -SHIFT LINKAGE/REAR AXLES- Check that there is clearance in the appropriate REAR AXLES areas to allow 23 degrees rotation of the flange from perpendicular, especially at the outside end OVERVIEW of the shaft where it mates with the hub carrier. We’re working on an adapter that will fit the BMW Inadequate clearance will result in binding of the M1 transaxle.

  • Page 61: Engine And Transaxle

    -ENGINE AND TRANSAXLE- ENGINE AND TRANSAXLE...
  • Page 62 -ENGINE AND TRANSAXLE- Rotate the external throwout arm forward until the JOINING THE ENGINE AND throwout bearing hits the fingers of the clutch. (If TRANSAXLE your transaxle has the clutch shaft return springs, this takes a fair amount of pressure). Before you attempt to install the engine and If there is not room between the arm and the transmission, check the preparation outlined on...
  • Page 63 -ENGINE AND TRANSAXLE- Install the water manifold on the intake manifold. REMOVING THE TRANSAXLE, See page 68. LEAVING ENGINE IN PLACE INSTALLATION INTO CHASSIS Possible, but difficult. The engine and transmission must be installed as a Remove rear body, anti-sway bar, slave cylinder unit, sliding in from the rear of the car.

  • Page 64: Oil Cooler

    -ENGINE AND TRANSAXLE- SPECIFICATIONS, ZF (TYPICAL) LUBRICATION GEAR RATIOS Capacity: Initial fill, 2.7 qts, 2.5 qts. after Differential: 4.22:1 drain/ing in the car. Fill to the overflow level of Speedo: 2.0:1 the hole that was made in the right side of the case.

  • Page 65: Fuel And Cooling Systems

    -FUEL AND COOLING SYSTEMS- FUEL AND COOLING SYSTEMS...

  • Page 66: General Description

    -FUEL AND COOLING SYSTEMS- FUEL SYSTEM GENERAL DESCRIPTION: LEFT/RIGHT FUEL BALANCE Two independent tanks of approximately 8 gallons The level of the left and right tanks is dependent capacity each are in the chassis pontoons. Each on their use: There is no automatic balance. For impact resisting plastic tank is carried in an ideal suspension balance the driver can maintain aluminum cradle and filled with anti-slosh/anti-...
  • Page 67 -FUEL AND COOLING SYSTEMS- SINGLE PUMP DESIGN The fittings on the top of the tank cover must be installed or removed through the door sill access The pump draws fuel from a crossover valve hole (at either side of the dash) after the tank is in actuated by the power line from the uninstalled place.
  • Page 68 -FUEL AND COOLING SYSTEMS- Install the upper hose (F) onto the filler cap flange, Both the filter and the pump must be run as low as with the lower clamp installed on the hose but not possible. Use a 1 "...

  • Page 69: Fuel Filter

    -FUEL AND COOLING SYSTEMS- *Carburetor(s) with fuel overflow plumbing must utilize an electrically operated fuel control valve that diverts the fuel to the same side as the fuel is being drawn from. See the fuel flow schematic for the proper hook-ups. FUEL FILTER: Recommendedfilter: Wix 33033 or equivalent (3.5"...

  • Page 70: Parts Needed

    -FUEL AND COOLING SYSTEMS- ENGINE COOLING AND HEATER PARTS INCLUDED IN KIT: (2) Pipesfrom front to back, installed in chassis. "S" tube from water pump to firewall. "L" tube from firewall to header tank. "T" tube, between intake manifold, header tank and "L" tube. Radiator with fans and fan thermo-switch Optional: Front intermediate pipes, from the radiator to the longitudinal pipes.

  • Page 71: Setting Up The System

    -FUEL AND COOLING SYSTEMS- MODIFYING THE SNOW-WHITE WATER PUMP Plug the heater outlet. This can be done by tapping the casting and installing a "NTP pipe plug, or using a short length of hose and a plug. Use teflon or thread sealing compound on the threass.

  • Page 72: Filling The System

    -FUEL AND COOLING SYSTEMS- "S" TUBE: This piece is shaped to go outside of the shifting rod (Snow White pump only- the Ford pump is on the other side). If the air conditioning compressor is installed on the engine, the tube will come very close to it, with the tube outlet pointing forward and to the inside about 45 degrees.
  • Page 73 -FUEL AND COOLING SYSTEMS- Allow the system to rise to operating temperature. As the temperature continues to rise, pressure will rise also, so it is now a good time to shut down the engine and check the hose connections. Tighten as necessary.
  • Page 74 -FUEL AND COOLING SYSTEMS-...

  • Page 75: Body

    BODY BODY...
  • Page 76 BODY Follow the same preparation procedures for all the CHASSIS PAINTING: chassis attachments that are to be painted the same color as the chassis; rollbar, door hinges, door If you have an early non-stainless steel chassis, latch striker mounting plates, rear body latch painting and rust proofing are the most important mounts, battery/storage bin covers, rear sub-frame, operations you will do to ensure the long term...
  • Page 77 BODY ROLL BAR: Fit the painted bar to the chassis in it exactly the same position as it was when shipped, replacing any shims to their former location. Use the flat bar washers under the nuts and lock washers (see figure below). Assemble the upper rear body latches and release levers to their mounting brackets and attach these units to the bar.
  • Page 78 BODY ROOF / BULKHEAD ASSEMBLY The roof assembly is bolted, riveted, and bonded to the chassis. This multiple attachment achieves a unitized type construction that adds some stiffness to the chassis tub. The roof/door relationship should have been verified before initial disassembly and any adjustments and notes of shims, etc.
  • Page 79 BODY ENGINE BULKHEAD PANELS: FRONT COMPARTMENT / WHEELHOUSE PANELS Rivet and bond all the bulkhead panels in place (except for the center access panel.) Use silicone See illustration on page 78. The aluminum panels or urethane sealant/caulking material between the enclosing the front compartment and wheel housings panel and the rollbar.

  • Page 80: Front Compartment

    BODY G\frntbay1 FRONT COMPARTMENT WEATHERSTRIPPING Install the aluminum weather-strip rails onto the cowl. These units were fitted at the factory and held in place by 2 or 3 screws for shipping. Replace them to their original locations and screw them in place with # 6 screws. Use a sealant caulk under the rails.
  • Page 81 BODY Temporarily fasten part #2 to #3 with two screws or Cleco fasteners. Remove the weather seal from #2 and fit onto rail #1 with its end flush with the end of the rail. G\TOPCOWL G\FSEALS COWL TO NACA DUCT: The upper end of #1 is attached to #2 as shown.

  • Page 82: Installation

    BODY To enable the two weather seals to fit together effectively the end of rail #5 must also have a portion removed. See the illustration. With the seal refitted to the rail, move the rail to the outside until the seal lightly contacts the body. Drill holes and use sheet metal screws to hold rail #5 in place.

  • Page 83: Height Adjustment

    BODY Raise the door into place and screw the upper ball pivot up into the top receptacle on the hinge plate. Unscrew each upper and lower ball pivot equally, bottoming them out in their receptacles. Unscrew each ball pivot another half turn to preload the sockets and ighten the jam nuts against the pivots.

  • Page 84: Door Latch

    BODY LOCKS DOOR LATCH The latch assembly is cable actuated, either directly or through a lever mounted on the top of the door. The latch body is fastened to an intermediate aluminum latch plate that is attached to the end face of the door. The door locks, if ordered with the kit, were fitted at the factory and it is a simple matter to re-install them as shown below.
  • Page 85 BODY Fit the body of the latch through the opening in 2. Window sill mounted release handle - road car the end of the door, making sure the plate on the option I. actuator goes around the adjustable actuator rod on the outside door handle.

  • Page 86: Top Buttons

    BODY WEATHER-STRIPPING: The door weather seals were initially fitted at the factory and should have been checked for proper fit earlier upon disassembly (page 21). With final installation special concern should be given to the joint areas where the upper and lower seals meet. Use sealing caulk or putty to prevent water seepage between the sill flange and the door opening flanges where they do not butt together.
  • Page 87 BODY Install the subframe with (2) " x 5" bolts at the REAR SUBFRAME: top and " x 5" bolts at the bottom, noting the The subframe serves as the rear body mounting orientation of insertion shown below. frame and supports the lower rear suspension arm pick-ups.
  • Page 88 BODY ALIGNMENT To adjust the body side-to-side alignment, thread the pivot bushings in or out. With body positioned in If the mounting plates have not been moved since proper alignment carefully tighten bolts. delivery, changing the alignment should not be necessary.
  • Page 89 BODY BODY LATCHING AND FASTENING: The side latches were fit at the factory and should have been left in place when doing the bodywork. When refitting be sure to replace any original shims. Adjust the latch by lengthening or shortening the adjustable pivot link.
  • Page 90 BODY Before closing the rear body, make sure the latch REAR BODY LATCHING (TOP) releases are working properly. If the rear body is The rear body is held down with lever latches on closed and the windows are installed, the engine either side of the engine compartment and pin compartment is the only way to access the latches.
  • Page 91 BODY Release FRONT BODY ATTACHMENTS: RADIATOR STONE GUARD; Paint the screen and frame semi-gloss black. Fit the screen to the frame by tightly wrapping the edges around the frame and secure with black plastic tie-wraps through the holes provided. Attach to the backside of the body radiator opening with 4 screws as shown.
  • Page 92 BODY We paint a ” strip of flat black on the perifery of the acrylic (underside) to hide the edge where it overlaps the body. Tape the window in place and apply masking tape around the perifery to mark on. Use a ”...
  • Page 93 BODY LIGHTS GLAZING INSTALLATION: You may wish to have a glass specialist install the windshield and rear window. You can do it at All the lights are pre-fit. Fit them to the body home, but it is delicate operation. The following using your notes from section A.
  • Page 94 BODY Once the windshield is laid in place, trace the When the gasket has been almost completely inside body edge onto the glass with a grease installed, trim the end leaving about " more than pencil. you think necessary. Refit the gasket, again forcing it back on itself, trying to get the ends to Remove the glass and spacers, and lay flat, butt one another.

  • Page 95: Side Windows

    BODY SIDE WINDOWS See the Body Finishing supplement for hints in the working of Plexiglas. Each door window is made from a special hard Refer to the illustrations when assembling the surfaced acrylic material and is held in place by hinges and adjusting bracket.
  • Page 96 BODY When attaching the covers do not over tighten the WIPER DRIVE POST screws. Also see page 33 and 34 for wiper drive details. IF YOU USE RUBBER GASKETS: The added Assembly the drive through the cowl after thickness of the gasket will effect the trimming modifying the bezel as indicated on page 33.

  • Page 97: Interior/Ventilation

    - Interior/Ventilation - INTERIOR/VENTILATION...
  • Page 98 - Interior/Ventilation - WIRING THE DASH AND FRONT THROTTLE LINKAGE AND CABLE: FIREWALL OVERVIEW See the wiring supplement for details. LEFT HAND DRIVE The throttle pedal acts on a bellcrank mounted on SOUND DEADENING AND HEAT the forward end of the tunnel which, in turn, pulls INSULATION: the cable that attaches on to the carburetor(s).

  • Page 99: Speedometer Cable

    - Interior/Ventilation - There are 3 threaded rods provided in the kit. SPEEDOMETER CABLE: Which one you use will depend on the forward Note: Because of the variations in speedometer and aft location of the brake box. Determine and transmission drive gearing, there is a gear where you want the brake box first, and then find reduction unit in the cable about two feet from the the most appropriate rod length.
  • Page 100 - Interior/Ventilation - CARPETS Follow the diagram below for the proper placement of each piece. #15 is glued to the removable passenger floorboard mounted on the three chassis brackets. The rocker sill carpets are fastened with snaps at the top for access to the fuel senders.
  • Page 101 - Interior/Ventilation - DASHBOARD Competition Layout Road Car with stalk Competition Car – RHD the defroster vents. Open up both doors and slide REMOVAL, PREPARATION AND the dashboard rearward and out. INSTALLATION The dashboard may be covered in cloth or vinyl, If necessary, remove the steering wheel and hub or painted flat black.

  • Page 102: Rear Access Panel

    - Interior/Ventilation - REAR ACCESS PANEL TUNNEL COVER Thecenter access panel behind the seats may be The tunnel cover is secured on either side at the removed to allow engine servicing by sliding the front and rear. If you have seat tracks, sliding the seats forward and unscrewing the trim screws seat forward makes it easier to remove the rear around the periphery.
  • Page 103 - Interior/Ventilation - AIR CONDITIONING/HEATER GENERAL CONFIGURATION The ERA Air Conditioning System is an integrated heater/air-conditioning system utilizing a combination core, with blower, valves and thermostat mounted in a single box over the footwell. This housing is very similar to the one originally found in the street version of the GT40 which contained only the heater.

  • Page 104: Function And Controls

    - Interior/Ventilation - COMPONENT INSTALLATION FUNCTION AND CONTROLS: EVAPORATOR/HEATER/BLOWER BOX The AC control panel consists of a three speed See the diagram below. fan switch, AC temperature control rheostat, three sliding controls controlling the source of the air, direction of forced air, and the temperature of the heated air.
  • Page 105 - Interior/Ventilation - CONTROL BOX AND CABLES 1. Compressor discharge to condenser(top) Length (LHD): 132" Length (RHD): 164" Install through the right hole (see page 64) in the engine firewall, leaving 17" of hose exposed, along the passenger side of the tunnel.
  • Page 106 - Interior/Ventilation - AIR DUCT HOSES Because it's tight in the cowl section, the SEE PAGE 24 FOR INSTALLATION OF THE configuration must be followed carefully. Install a COMPRESSOR AND BRACKET ONTO " ID hose onto the left side of the cowl ENGINE BLOCK.
  • Page 107 - Interior/Ventilation - WIRING, A.C. Also see the instructions in the wiring supplement for specific connections. There is also an AC electrical schematic that will accompany the main wiring diagram. Mount the control box on the access panel in front of the dash panel.
  • Page 108 -INDEX- Wire #L21 connects to the pressure switch mounted between the condenser and the drier. ROOF VENT The other pressure switch wire(L28) should be grounded to the chassis tube. Air is exhausted through the inside louvers in the Ground #L2 to the dash access panel screw. Wire cab ceiling and out the louver on the roof.

  • Page 109: Upkeep - Reference - Registration

    -INDEX- UPKEEP - REFERENCE - REGISTRATION...

  • Page 110: Recommended Service

    -INDEX- RECOMMENDED SERVICE EVERY GASOLINE FILLUP: Check engine oil and water EVERY 3000 MILES Change engine oil and filter Check engine drive belts for wear and tension Grease rear axle sliding splines EVERY 6000 MILES Inspect front and rear brake linings Spray Lubriplate or equiv.

  • Page 111: Maintenance Parts

    -INDEX- MAINTENANCE PARTS All pieces listed below are included in the kit but are listed here for reference and long term service. Part numbers listed are typical, but equivalent brands may be substituted unless otherwise stated. BRAKES, MASTER CYLINDERS, LINES, FITTINGS: Master cylinder, front* Girling 3/4"...

  • Page 112: Steering Column

    -INDEX- Trailing arm ends, upper, lower forward end Heim HMRL-8 rearward end Heim HMR-8 Bushing, isolator, upper and lower Energy Suspension 2191G Upper radius arm ends, inner Heim HMRL-8 outer Heim HMR-8 Sway bar link ends Heim HMR-6 bushings Nissan 54617-21002 Drive axles - see Section D STEERING COLUMN: Bushing, upper column housing...
  • Page 113 -INDEX- FASTENERS INCLUDED IN KIT OR WITH OPTIONS T=top F=front R=rear U=upper L=lower HC=Hex cap screw SCS=Socket cap screw TR=Threaded rod Quant Size Type Application(s) " x " Shift box to tunnel, col.mt. " x 1 " Fuel tanks " x "...

  • Page 114: Torque Specifications For Fasteners

    -INDEX- M14 x 40 SCS, DIN 912-12 F caliper (anchor plate), two piston w/11.5" rotor M14 x 50 F caliper (anchor plate), two piston w/12" rotor M12 x 40 F caliper (anchor plate), single piston M14 x 70 SCS, DIN 912-12 R hub carrier bearing(housing) M10 x 40 Stud, DIN 935...
  • Page 115 -INDEX- INSPECTION AND REGISTRATION Without researching and writing 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.
  • Page 116 -INDEX- INSURANCE Many insurance companies will allow you to add the E.R.A. GT to your present policy. If not, there are a number of insurance agencies specializing in composite cars. Look in issues of Kit Car Illustrated, Specialty Cars and related magazines, and Cobracountry.com for the latest offerings. Below is a short, but not necessarily current, list.

  • Page 117: Index

    -INDEX- INDEX Valve cover..............7 Bulkhead panels, engine..........77 —:— Bulkhead, Rear..............100 —C— —A— Cable Aero-fairings, door............84 Battery ................15 Air conditioning............101 Speedometer ...............15 Charging with Freon..........104 Speedometer ...............97 Compressor mounting ..........22 Throttle ..............21, 96 Condensor..............103 Caliper, Brake ..............47 Wiring ..............
  • Page 118 -INDEX- Backlash ..............28 —G— Disassembly, kit ............. 20 Distributor ..............21 Gage Door Oil pressure fitting on block ........21 Aero-fairings .............. 84 Water temperature ............21 Handle ................ 81 Gear Ratios..............62 Limit strap ..............83 Lock ................82 —H— Striker................. 77 Weatherstripping ............
  • Page 119 -INDEX- License plate bracket ............90 Rollbar Lights Installation ..............75 Installation..............91 Roof installation ..............76 Limit strap, door ............. 83 Rotor, brake..............12 Linkage Rotor, Brake ..............47 Throttle............... 21 Rugs, installation.............98 Linkage, ................57 Rust proofing..............74 Lock, Door..............82 —S— —M— Seat Belts...............100 Maintenance parts............
  • Page 120 -INDEX- Front................13 —U— Sway bar ................. 12 Undercoating..............74 —T— —V— Tank Cooling system expansion.......... 15 Vent panels, Rear ............90 Expansion..............70 Vent, Roof..............106 Tank, Fuel............... 64 Vent, Transaxle ...............27 Thermostat, water ............70 Voltage regulator ............75 Throttle linkage ............21, 47 Voltage Regulator ............16 Throttle pedal adjustment ..........

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