Page 1 ASSEMBLY SERVICE MANUAL FOR THE Era Replica Automobiles 427 ROADSTER Chassis 758 on Revision 10m 06/2012 Copyright 2012, Era Replica Automobiles...
Page 2 DesignCad 2D and 3D. Images were translated to GIF and JPEG format, and linked to this file. The Legal Stuff Information in this manual is correct to the fullest extent of our abilities. Era Replica Automobiles assumes no liability for any direct, indirect, incidental or consequential damage resulting from the information within..
Page 3: Table Of Contents
Contents SECTION C: CHASSIS ....111 PEEDOMETER ABLE ....114 PREPARATION ......55 ATTERY AND ABLES ..115 TEERING OLUMN AND HEEL This manual is arranged by ......... 115 HIFT EVER ......57 EMOVAL assembly sequence, not topic.......... 116 UNNEL ........
Page 4 SECTION A - PARTS NEEDED...
Page 5: Read Me First
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.
Page 6: Section A Parts Needed
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 154.. Read this section thoroughly before purchasing any parts.
Page 7: Picking Up Your Kit
SECTION A - PARTS NEEDED PICKING UP YOUR KIT The kit can be transported from our factory in an enclosed trailer, standard automobile trailer or rampback hauler. Shipping space for the parts in cartons will also be required, although most will fit inside the kit. We have used several shipping commercial companies with excellent results.
Page 8: Special Notes
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.
Page 9: Engine
SECTION A -PARTS NEEDED- ENGINE FORD FE SERIES Remember! All piston engines have a limited torque spread. If you decide to build a fire-breathing monster, expect to Bore Stroke Torque suffer at the lower RPMs. Because the E.R.A. 427SC is light, net lb-ft every hiccup is felt.
Page 10 SECTION A -PARTS NEEDED- In general, the 428 is much cheaper and easier to find than CARBURETORS the 427. The later vintage 428 Cobra Jet (CJ) or 428 Super A single 4-barrel Holley carburetor will connect directly to Cobra Jet (SCJ) engine is fine for all-around street use, the linkage supplied with the kit.
Page 11: Clutch
SECTION A -PARTS NEEDED- FORD 289/302/351 CLUTCH Pre-serpentine belt engines are easily adapted to the 427SC, No matter what engine, E.R.A. recommends using a clutch although primary exhaust pipes must be specially fabricated. with stock pressure for street use. Because the car is very The chassis mounts are the same as for the FE block.
Page 12: Transmission
SECTION A -PARTS NEEDED- When combined with an MSD ignition system, a special Tremec 500 and 600: This is a new, stouter TKO, with a resistor is required. Call Unilite for details. gear spread similar to the Richmond Gear 5-speed. Overdrive 5 gear.
Page 13 SECTION A -PARTS NEEDED-...
Page 14 SECTION A -PARTS NEEDED- FORD C-6 AUTOMATIC FOUR SPEED TOP LOADER Use the C-6 appropriate to your engine. Because there isn't Rebuilt transmissions are available. See the list of resources a transmission oil cooler built into the radiator, you must fit or ask E.R.A.
Page 15: Speedometer Drive Gears
SECTION A -PARTS NEEDED- Before you install the speedometer driven gear, check that drive gears. See page 15 for calculations and page 15 for part numbers. its spiral meshes properly with the drive gear. Transmissions have come through with both the LH and RH SPEEDOMETER DRIVE GEARS Ford transmissions used a variety of drive gears.
Page 16: Shift Linkage
SECTION A -PARTS NEEDED- LEVER SHIFT LINKAGE If you don't want to modify the Mustang lever yourself (see All shift linkage (modified Hurst) is available from E.R.A. page 48), E.R.A. manufactures a duplicate the original shift lever to fit the Top-Loader (with stock or Hurst linkages) or TOP LOADER Richmond gear transmissions with the Long shifter.
Page 17: Rear Drive/Suspension Assembly
SECTION A -PARTS NEEDED- REAR DRIVE/SUSPENSION ASSEMBLY Jaguar-based Suspension Custom ERA Rear Suspension  Gear ratio - There should be a tag on one of the rear The E.R.A. 427SC is designed to use either the Jaguar rear cover bolts (for example, 43/13 on the tag = 3.31 suspension (in an E.R.A.
Page 18: Front Rotors And Calipers
SECTION A -PARTS NEEDED- TRIUMPH COLUMN FRONT ROTORS AND CALIPERS The preferred parts are from a Spitfire or GT-6, vintage WITH BOLT-ON WHEELS 1972 to mid 1977. Get the upper column and housing, upper and lower clamps and both switches. Most mid-sized GM cars from 1970-1978 used the correct See page 51 for bushing remove and replacement, pieces, with 2...
Page 19: Wiper Motor And Components
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.
Page 20: Wheels, Bolt-On
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 "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.
Page 21: Tires
SECTION A -PARTS NEEDED- TIRES RADIATOR HOSES (rim size appropriate for tires) The 427SC requires several standard molded hoses, depending on your equipment. FE and small block hoses Diameter Front Rear are listed on page 25. In some configurations, the hoses Max.
Page 22: Part Numbers And Sources
SECTION A -PARTS NEEDED- PART NUMBERS AND SOURCES Source addresses, etc. are found on page 28. PART PART NUMBER SOURCE Alternator Ford Small Block, FE and 429 Delco 321-147 (rebuilt) or any '70's Ford with Most Fords, 1971-1980 separate regulator. A 100A unit is not necessary but will fit: Delco 334-2000 (’83 Ford Crown Vic Commercial/Police Ford SOHC...
Page 23 SECTION A -PARTS NEEDED- Bell-housing FE (390/427/428): Lakewood 15210 for. Various, E.R.A. Ford small block: Lakewood 15200: Top-loader, Richmond Gear, TKO with short input shaft Lakewood 15202: Tremec (May need spacer. See page 14) Lakewood 15203: T-5 See mod's necessary on page 35. Dealer, E.R.A.
Page 24 SECTION A -PARTS NEEDED- Complete rebuilt Ford units are available from several Ask us ENGINES AND ENGINE suppliers PARTS C9LY-6038-A, C9LY-6038-B (‘69 Mercury) Ford Dealer Mounts 31-3058 (L), 31-3059 (R) Republic 429/460 Ford 427, 428 63-64 Ford w/390-428 cid, Ford C3AZ-6038A,B E.R.A.
Page 25 SECTION A -PARTS NEEDED- Radiator hoses, FE engine See trimming instructions on page 39, layout on page 150. 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...
Page 26 SECTION A -PARTS NEEDED- Speedometer Cable AC 11589234 (1967 Mustang) E.R.A., dealer, auto parts store Ford Top Loader Richmond Gear Champ 400020 See page 14 for other parts. Cable drive gears, etc. E.R.A., Dan Williams Ent Top Loader, T-5, Tremec Speedo drive gear C4DZ-17285A (LH, 7 tooth, black) Ford dealer...
Page 27 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 16) Inquire about a plate that may be necessary. Richmond Gear 5 speed Long shifter.
Page 28: Source Master List
SECTION A -PARTS NEEDED- SOURCE MASTER LIST Because of rapid changes in area codes, these phone numbers may be out of date. BUSlNESS NAME SPECIALTY ADDRESS Arthur Allen Mfg. Speedo reducers, angle 235 E. O’Connor Drive, Elkhorn, WI 53121 arthurallen.com drives (800)683-500 Oil pans and pickups...
Page 29: Tools Needed
SECTION A -PARTS NEEDED- TOOLS NEEDED Tool List Most of the tools required for assembly of the E.R.A. Body Installation 427SC are found in the average car person's home  Pop rivet gun with adapters for " and " rivets workshop.
Page 30 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 cartridges min. chassis *Adhesive for bonding rear body Polyester resins thickened...
Page 31: Section B: Parts Preparation
SECTION B: 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.
Page 32: Engine/Components
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 ...
Page 33: Alternator Mounting
SECTION B -PARTS PREPARATION- ALTERNATOR MOUNTING, FE BLOCK: ALTERNATOR MOUNTING: 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.
Page 34 SECTION B -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 fork (see page 26 for part number) should be modified as shown. Drill (remember that the part is hardened) the indentation to ”...
Page 35 SECTION B -PARTS PREPARATION- TKO 3550, 500 AND 600 (STANDARD-LENGTH- Elongate the holes as shown above. The mount is installed onto the transmission with washers as shown below. Note INPUT) NOTES that the hole elongation is toward the front. Note that the transmission mounting boss is metric-threaded (10 x .1.5) on the inner holes, ½-13 on the outer holes.
Page 36 SECTION B -PARTS PREPARATION- FE ENGINE The optional E.R.A./Lakewood blow-shield is already The adapter bracket and slave cylinder are installed with a trimmed on the bottom edge. single bolt on the front side of the left rear engine block Note that every bell-housing should be checked for bell-housing flange.
Page 37 SECTION B -PARTS PREPARATION- SHELBY 427 BLOCK CLUTCH THROWOUT ROD The bracket for the Ford FE block must be modified to fit. E.R.A. supplies two threaded rods between the clutch Remove the locating tab and drill two new holes. Note the slave cylinder and the throw-out fork in the bell-housing.
Page 38 SECTION B -PARTS PREPARATION- ADJUSTMENTS STARTER "Permantly" install all the clutch components onto the Any standard or aftermarket starter may be used. Note flywheel, using an alignment tool for the driven disc. that some gear-drive starters may have to be rotated on their mounting flange.
Page 39 SECTION B -PARTS PREPARATION- RADIATOR HOSES: HOSE TRIMMING INSTRUCTIONS The two lower radiator hoses must be modified to fit. The installation layout is also shown on page 150. After checking fit, cut and trim the hoses as shown. FE (390/427/428 ENGINE) STANDARD UPPER HOSE 21047: Standard cast-iron water pump, others with 2”...
Page 40: Rear Suspension, Jaguar
SECTION B -PARTS PREPARATION- SMALL BLOCK FORD REAR SUSPENSION, JAGUAR: Use the center portion from the radiator to the lower connecting tube. (You must tell us that you’re using a DISASSEMBLY small block when you order.) See the exploded view of the lower control arm on page Upper hose 41.
Page 41 SECTION B -PARTS PREPARATION- (Jaguar OEM part numbers) JAGUAR LOWER CONTROL ARM LAYOUT AND PARTS Slide the fulcrum shafts through the subframe and ASSEMBLY brackets. Add shims between the brackets and the differential to take up any side clearance. Tighten the The description below is a supplement to a good Jaguar bolts holding the brackets to the case.
Page 42 SECTION B -PARTS PREPARATION- EB_JAG b\jagcage Remove the clevis pins securing the brake levers (a) to the compensator links (B + D). TRAILING END ROD ENDS: Remove the bolts securing the compensator bracket (c) Install the trailing arm rod ends onto the lower control onto the rear end cage and remove.
Page 43 SECTION B -PARTS PREPARATION-  If you have stock XKE springs on stock (or their XJ6 OR XJ12 REAR SUSPENSION CORE equivalent) XKE dampers, replace one stock spring If you have a block on either brake actuating lever, it must on each side with a 10"...
Page 44: Rear Suspension, E.r.a. Design
SECTION B -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.
Page 45 SECTION B -PARTS PREPARATION- ASSEMBLY AXLE ASSEMBLY The stock Jaguar XJ inner axle must be shortened to XKE Series I/II length. Alternately, you may build the axle from scratch. Specifications are available from us. Complete assemblies and parts are available from E.R.A. Clean and deburr the axle splines.
Page 46 SECTION B -PARTS PREPARATION- 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 0.110" CAC3818/12 0.112" CAC3818/14 0.114" CAC3818/16 0.116"...
Page 47 SECTION B -PARTS PREPARATION- Turn the assembly upside-down. Install the bottom Install the front radius arms onto the lower differential section of the subframe by inserting the rear ears just in bracket as shown. 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...
Page 48: Shift Lever (Ford)
SECTION B -PARTS PREPARATION- Install the anti-sway bar onto the rear of the subframe with SHIFT LEVER (FORD) "-USS nuts, flat and lock washers as illustrated above. Install the brake calipers, using M12 x 30mm Allen cap E.R.A. has complete reproduction shift levers and linkage screws and wave washers.
Page 49 SECTION B -PARTS PREPARATION- Save the dog, spring, and washer. Push the cable back up If brazing, use as small a flame as possible, holding the into the lever about 4 inches, but don't remove it end of the brazing rod against the cable and dog. Direct completely.
Page 50: Drive Shaft
SECTION B -PARTS PREPARATION- TREMEC TKO SERIES STEERING GEAR All Tremec transmissions keep the lever in the stock (full See page 25 for part numbers. back) location to use the bent-forward shift lever available from ERA. The E.R.A. supplied steering gear does not require the preparation below.
Page 51: Wipers
SECTION B -PARTS PREPARATION-  Using a dowel just small enough to fit inside the BUSHING REPLACEMENT (LATE) housing, drive the upper bushing out through the The one-piece nylon bushing is staked into the housing. If upper end of the column from the bottom. ...
Page 52 SECTION B -PARTS PREPARATION- Unfortunately, the best wheel boxes (listed on page 27) are MOTOR PREPARATION rarely available. If your wheelboxes do not match the specifications on page 19, the crankshaft in the wiper motor may be modified to compensate. See Stroke Changes below.
Page 53 SECTION B -PARTS PREPARATION- 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.
Page 54: Dampers And Springs
SECTION B -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 II dampers. Height adjustable dampers are available from E.R.A. DAMPERS SPECIFICATIONS Position...
Page 55: Section C: Chassis Preparation
SECTION C: CHASSIS PREPARATION Assembling the chassis and preparation for paint...
Page 57: Body Removal
SECTION C -CHASSIS PREPARATION- 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.
Page 58 SECTION C -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.
Page 59: Chassis Paint
SECTION C -CHASSIS PREPARATION-  DASHBOARD AND GLOVE BOX: Also remove rear wheelhouse closing panels from inside both rear wheel wells. These panels are the Remove steering column if fit, page 115. ones that close off the wheel area from the Remove the 5 chrome screws and trim washers securing passenger compartment.
Page 60: Section D
SECTION C -CHASSIS PREPARATION- SECTION D: BODY/CHASSIS ASSEMBLY Assembly of the body and basic mechanical components.
Page 61: Fastener Notes
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 158.
Page 62: Brake And Fuel Lines
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 chassis, apply the supplied insulation as shown. The edge the lines in place with the plastic clips and Tek screws. strips are not absolutely needed but make the installation Seal the thread holes with silicone to prevent rusting.
Page 63 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 Position the short bonding strips at least " back from the holes. Lift each footbox up and slip in from the center of front cowl transverse tube (leaving room for the firewall the car towards the outside.
Page 64 SECTION D - BODY/CHASSIS ASSEMBLY FRESH AIR CONTROL VALVES THROTTLE LINKAGE Mount the pedal assembly onto the footbox. See page 87 for details. ID PLATE Install the ID plate on the driver’s footbox with "diam. x "L aluminum blind rivets as shown. d\idplate d\lftair Screw on top of the foot box after putting a bead of caulk...
Page 65 SECTION D - BODY/CHASSIS ASSEMBLY VOLTAGE REGULATOR More chassis and body ID numbers The regulator (part number on page 27) installs with #10 The chassis is stamped with the ID number in three places: sheet metal screws bolts on top of the left foot box into captive speed-nuts.
Page 66 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.
Page 67: Body Mounting
SECTION D - BODY/CHASSIS ASSEMBLY BODY MOUNTING Use a caulking gun to apply body sealant (also used on the Preparation Is Everything! Before starting, have all tools floors and foot boxes) to the chassis and corresponding and materials ready and read the text below. body parts except: ...
Page 68 SECTION D - BODY/CHASSIS ASSEMBLY  HOOD The firewall where it mounts onto the steel crossmember. (Pre-installed) Bolt the hinges loosely into the body from  inside the grille opening. The hood hinges are marked L The overlapping joint between the upper and lower and R.
Page 69 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.
Page 70: Section E Body Preparation
SECTION E BODY PREPARATION...
Page 71: Fitting The Roll Bar
SECTION E -BODY PREPARATION- BODY PREPARATION AND PAINT FITTING THE ROLL BAR 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.
Page 72 SECTION E -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 rear section of the front flare a bit to fit a 245-width tire. The driver’s side is tighter than the passenger’s side.
Page 73 SECTION E -BODY PREPARATION-...
Page 74: Body Preparation And Hood
SECTION E -BODY PREPARATION- RIVET-ON SCOOP HOOD Locate the hood scoop, inlet hole, and rivet spacing and number as shown below. Note that he hole is offset to the INNER PANEL MODIFICATIONS passenger’s side to match the engine. The "Turkey pan" or single round air cleaner does not require inner panel modifications.
Page 75 SECTION E -BODY PREPARATION- COWL EDGES PAINTING You may round the edges of the front and back cowl to The E.R.A. body requires only the standard techniques for fiberglass preparation, nothing special. Because of our give the original aluminum-wrapped-around-tubes look. methodical production rates, bodies are “seasoned”...
Page 76 SECTION E -BODY PREPARATION- ebod\stripe...
Page 77: Detail Undercoating
SECTION E -BODY PREPARATION- DETAIL UNDERCOATING WINDSHIELD WIPERS Prepare the wiper motor and other components as It’s not necessay to protect the outside body from stones described on page 52. thrown by the tires. That protection is built into an extra layer of material added when the fiberglass is laid up.
Page 78: Trunk Lid
SECTION E -BODY PREPARATION- 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.
Page 79: Hood Gasket
SECTION E -BODY PREPARATION- HOOD GASKET Permanently install the gaskets to the underside of the hood as described on page 68. Door gasket installation is described on page 86. FRESH AIR HOSES After putting edge protector on the aluminum, carefully feed the fresh air duct hoses through the hole in the back panel of the front inner wheelhouse panels.
Page 80: Wiring And Electrical
SECTION E -BODY PREPARATION- WIRING AND ELECTRICAL Use the layout diagrams below and the wiring instructions to find reference points in the harnesses. This section presents general outlook on the layout of the FRONT WIRING HARNESS various harness components. All individual connections are detailed in a separate list that comes with the harness.
Page 81 SECTION E -BODY PREPARATION- FRONT ENGINE COMPARTMENT PARKING LIGHTS 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. e\fparkwir X-MEMBER 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.
Page 82: Rear Harness
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.
Page 83: Interior Panels
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 needed. Pass the harness through the gap in the aluminum filler and up through the hole in the side of the footbox.
Page 84: Drive Shaft
SECTION E -BODY PREPARATION-  C-6 Automatic - Special chassis mount, no adapter It's easiest to install the engine and transmission necessary 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.
Page 85: Doors
SECTION E -BODY PREPARATION- DOORS DRILL HOLES FOR SNAP FASTENERS (IF NOT DONE ALREADY) Use the aluminum banana strips (note that the left and right are different) as a template to drill ¼” holes into the fiberglass door inner panel. INSTALLING POCKETS Lay the doors on a soft surface, outside surface down.
Page 86 SECTION E -BODY PREPARATION- DOOR WEATHERSEALS DOOR PULL STRAP (OPTIONAL) Lay the doors, outer surfaces down, on a soft surface. Drill a hole (#30 bit) just to the rear of the side curtain Clean the door edge and rubber with a mild solvent. Glue ferrule.
Page 87: Accelerator Pedal And Exhaust Heat Shields
SECTION E -BODY PREPARATION- 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.
Page 88: Linkage 87
SECTION E -BODY PREPARATION- EXHAUST HEAT SHIELDS E.R.A. offers a set of heat shields that help to contain heat of the primary exhaust pipes where they are close to the d\htshld2 foot-boxes. They can be fit before the engine is in place Hold the vertical shield against the bottom of the tube at and are easily removed for primary pipe installation.
Page 89: Roll Bar
SECTION E -BODY PREPARATION- ROLL BAR RADIATOR AND FANS 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 Install the upper shroud on the bottom side of the cowl Armor-All...
Page 90 SECTION E -BODY PREPARATION- OPTIONAL FANS Cut a 1" x 4" piece of wood, about 13 " long. Lay several pieces of cardboard 16" x 14" (stacked at least 15" REAR MOUNTED " 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.
Page 91: Grille Air Foil
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.
Page 92 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 91 for 6” Cooler shroud layout. bottom of the upper control arm inner pivot, then through Hose connections are the described below.
Page 93: Fuel Tank
SECTION E -BODY PREPARATION- FUEL TANK The 19-gallon aluminum fuel tank is baffled, with one-way 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.
Page 94: Fuel Filler Cap
SECTION E -BODY PREPARATION- Remove excess RTV and clear the drain hole with a wire, FUEL FILLER CAP etc. Install the vent and drain hoses to the lower flange as shown. Run the drain hose through the hole in the bottom The cap and outside flange are indexed with punch marks corner of the well at the side of the trunk.
Page 95: Section F: Suspension Assembly
SECTION F: SUSPENSION ASSEMBLY...
Page 96 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.
Page 97: Front Suspension
SECTION F -SUSPENSION ASSEMBLY- COIL-OVER DAMPER FRONT SUSPENSION See page 54 for installing the spring onto the damper. Final LOWER CONTROL ARM height adjustment is described on page 145. Lubricate the chassis receptacles and the sides of the Spacers for the lower mounts are provided with the control arm bushings with silicone or petroleum jelly.
Page 98 SECTION F -SUSPENSION ASSEMBLY- STEERING GEAR 12” BRAKES: HUB AND ROTOR MOUNTING F\fjfq1 b\steeringgearmt Prepare the rack and pinion assembly for as described on page 50. 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.
Page 99 SECTION F -SUSPENSION ASSEMBLY- ROTOR/HUB GENERAL INSTALLATION Parts are listed on page 22. Pin drive: If the rotor is not already installed on the pin drive hub, torque the drive pins to 35 lb-ft (with high- strength thread locking compound, i.e. Locktite red) and the nuts to 35 lb-ft.
Page 100: R Ear Suspension , J Aguar - Based
SECTION F -SUSPENSION ASSEMBLY- REAR SUSPENSION, JAGUAR-BASED XJ COMPONENTS IN E.R.A. SUBFRAME Thread the trailing arms onto the rod ends (with jam nuts) already installed on the lower control arms. Thread on until one or two threads show. Leave the jam nuts loose. ANTI-SWAY BAR Studs are already on the chassis.
Page 101 SECTION F -SUSPENSION ASSEMBLY- Lubricate the insides of the upper chassis brackets with lithium grease so that the sides of the rubber bushing will slide into them. Guide the suspension assembly into the chassis brackets. Using a little light oil on the threads, install the "...
Page 102 SECTION F -SUSPENSION ASSEMBLY- The cable passes through the right block and connects to the left lever. See page 42. Adjustment Fully release the handbrake lever. Adjust the cable length by screwing the threaded end out of the block to a point just short of where the handbrake operating levers on the calipers begin to move.
Page 103: Rear Suspension, E.r.a. Design
SECTION F -SUSPENSION ASSEMBLY- Support the chassis with jack-stands so that there is at least REAR SUSPENSION, E.R.A. DESIGN 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.
Page 104: Brake And Clutch Pedal
SECTION F -SUSPENSION ASSEMBLY- EMERGENCY BRAKE BRAKE AND CLUTCH PEDAL Attach the emergency brake cables and balance bracket as shown. The front cable is attached to the handle as shown on page 101. d\brpedal f\eraeblay INSTALLATION SAFETY STRAP: If necessary, clean and grease the needle bearings in the chassis and in the brake pedal.
Page 105 SECTION F -SUSPENSION ASSEMBLY- If even more adjustment is required, a " bore Tilton You can temporarily Install the brake cover box. cylinder can be substituted for the BMW clutch master The brake or clutch pedal face angle can be changed with cylinder.
Page 106 SECTION F -SUSPENSION ASSEMBLY- DEAD PEDAL INSTALLATION Hold the bracket at the desired height against the side of the footbox and mark for the holes. Drill through the footbox and steel tube with a " bit. Secure the bracket with a #12 Tek screw. D\deadped...
Page 107: Section G
SECTION G: BODY/INTERIOR...
Page 108: Windshield Washer
SECTION G - 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.
Page 109: Windshield
SECTION G - BODY/INTERIOR SUNVISORS WINDSHIELD (Pre-installed) With a small stiff wire, clean out the holes Slip the aluminum trim plates onto the windshield posts tapped in the upper windshield frame. with the convex side up and the screw holes to the outside. Push the wire to the bottom of the hole and mark where it Fill the underside of the trim plates with sealer or ribbon- is flush with the windshield frame surface.
Page 110: Heater/Defroster
SECTION G - BODY/INTERIOR Bolt the heater in place as shown, using nylon locking HEATER/DEFROSTER 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 Install the water shut-off valve in the water outlet of the required.
Page 111: S Peedometer C Able
SECTION G - BODY/INTERIOR Smiths gage notes: The oil pressure line requires a "- " pipe reducer at the filter housing or block adapter. There is a fiber sealing washer attached to the gage to seal the gage end fitting. At the gauge side of the oil pressure line, use Teflon®...
Page 112 SECTION G - BODY/INTERIOR 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.
Page 113 SECTION G - BODY/INTERIOR RICHMOND GEAR 5 SPEED The transmission requires a right-angle-drive adapter installed as shown. The parts required are listed on page Cable routing for TKO600 TREMEC TKO/500/600 The drive cable is also secured to the top of the transmission case.
Page 114: B Attery And C Ables
SECTION G - BODY/INTERIOR REAR MOUNTED BATTERY BATTERY AND CABLES Mounting details are available at FRONT MOUNTED BATTERY www.erareplicas.com/427man/index.htm. The battery may be mounted in the trunk for more rear See page 23 for battery and battery cable sizes and weight bias.
Page 115: Ever
SECTION G - BODY/INTERIOR STEERING COLUMN AND WHEEL Prepare the triumph steering column as described on page Before the Triumph steering column is installed, check that the signal canceling cam on the steering column shaft is oriented correctly. See page 51. ASSEMBLY cob\man\wiring\swbend With the road wheels straight, install the hub on the...
Page 116: Tunnel
SECTION G - BODY/INTERIOR The shift lever may be mounted in several different ASH TRAY locations, depending on your transmission. If your Top- Note that some transmissions are taller than others, so loader mounting matches the diagram on page 16 or you confirm that you have enough clearance under the tunnel have a Richmond Gear 5 speed, E.R.A.
Page 117 SECTION G - BODY/INTERIOR eint\tunnel...
Page 118: C Arpets
SECTION G - BODY/INTERIOR CARPETS In general, the carpet pieces should be installed in their numerical order. Trim any unfinished carpet edge as needed. Left footbox, front Right footbox, front Tunnel side, front left Left footbox, left side Tunnel side, front right Right footbox, right side Bulkhead behind seat, right lower filler...
Page 119 SECTION G - BODY/INTERIOR INTERIOR REAR PANEL After masking the body, spray or brush contact cement Install the side carpets, starting by lining up the on the panel areas and the back sides of the vinyl and corner(s) as shown. carpet.
Page 120 SECTION G - BODY/INTERIOR FOOTBOXES Corner Detail Spray contact cement on the front and sides. Note where the dead-pedal mounting holes are. Glue in the front panel first. When gluing in #2, use the corner below the door hinge area and the front vertical edge for reference.
Page 121 SECTION G - BODY/INTERIOR UNDER DOOR Trim around the top socket and locate the holes for the door striker mounting bracket. TUNNEL Before you glue in the rug, take note of the location of the seat belt hole at the rear bottom corner. Locate the holes for the dash tube in the aluminum and Remove the door strikers, mounting brackets and any trim the carpet back.
Page 122 SECTION G - BODY/INTERIOR STEP MOLDING FRONT TOP PANEL 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.
Page 123 SECTION G - BODY/INTERIOR 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.
Page 124 SECTION G - 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.
Page 125: Hand Brake Lever Cover
SECTION G - BODY/INTERIOR 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.
Page 126: Shoulder Harness
SECTION G - BODY/INTERIOR SEAT BELT/SHOULDER HARNESS E.R.A. offers reproductions of the original competition belts. Inquire. 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 holes in the cover and attach with the trim screws.
Page 127: Eat Mounting
SECTION G - BODY/INTERIOR SHOULDER HARNESSES SEAT MOUNTING Locate the mounting holes in the chassis with an awl, and Lay the floor carpets in place, and locate the seat mounting cut holes in the carpet. See page 83. The optional four- holes through the carpet.
Page 128: D Oor I Nstallation
SECTION G - 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 154.
Page 129: Nstallation
SECTION G - BODY/INTERIOR SEAT BELT/SHOULDER HARNESS BUMPERS, JACK-PADS The bumpers or jackpads are factory fit and installed. The E.R.A. offers reproductions of the original competition belts. aluminum spacer sleeves can be easily polished with very Inquire. fine steel wool and/or car polish. EINT\SEATBELT Slip the ends of the belts in the clip to the eyelets of the anchors already in place.
Page 130: Ir Inlet Ducts
SECTION G - BODY/INTERIOR With the front uprights installed as shown above, hold the FRESH AIR INLET DUCTS nudge bar between them, aligned with the body opening and with about " clearance between it and the body. The left and right ducts will only fit one way. Use the diagram below as a guide.
Page 131: Lights
SECTION G - BODY/INTERIOR Two styles of front signal/parking lights are used on the LIGHTS E.R.A. 427SC. Both are valid duplicates of the original Cobra: HEADLIGHTS  SC style (used on original race cars) Uses a twist- off lens. Used with the rectangular taillight, Extra-bright Lights duplicating early (65-66) original 427 Cobras.
Page 132: Eflector ( Bottom )
SECTION G - BODY/INTERIOR REAR REFLECTOR (BOTTOM) (Used only with round taillights) Mount with the notch to the bottom. Some reflectors will have mounting studs, the others require a sheet-metal screw. ebod\Reflectr LICENSE PLATE LIGHT e\tailites To make the tail light connections: ...
Page 133: Light (Optional )
SECTION G - BODY/INTERIOR BACK-UP LIGHT (OPTIONAL) MIRRORS DASH Assemble the mirror as shown. The upper and lower clamps hold the rim against the reflector. Note that the stainless steel reflector is only polished on one side. ebod\bulite Back-up lights may be required in some states. The type and location of the light is the customer's choice, but we recommend mounting the light on a bumper bracket or the nudge bar.
Page 134: Naps
SECTION G - BODY/INTERIOR SIDE Position mirror pedestal on the fender over the hole markings and within the gasket outline. INSTALLATION Holding the pedestal in position, drill two " holes where Follow the instructions included with the mirrors for marked, making sure to hold the drill at the proper angle. disassembly.
Page 135: E Mblems
SECTION G - BODY/INTERIOR TRUNK EMBLEMS 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.
Page 136: Ipes
SECTION G - BODY/INTERIOR Note! Ford numbers the cylinders on the FE engine 1-4 on SIDE PIPES the right (passenger’s side) bank, 5-8 on the left side). The E.R.A. supplied primary pipes may differ from standard For the under-car system see page 138. Ford practice and be numbered (from the front) 1-4 on the The E.R.A.
Page 137 SECTION G - BODY/INTERIOR ebod\spipesup Bolt together the sets of connecting brackets as shown. ebod\spipebk1 Position the brackets in place, one end of each set on a primary pipe, the other end on a side pipe. Position each set of brackets on pipes diagonally opposite each other so that they are easily reached.
Page 138 SECTION G - BODY/INTERIOR FINAL INSTALLATION HINTS EXHAUST SYSTEM, UNDER-CAR Use gaskets coated with high temperature silicone (such as For side pipe installation, see page 136. Permatex Ultra Copper 81878) on both sides. Special exhaust-tolerant silicone is available at most automotive INSTALLATION supply stores.
Page 139: Onvertible Top
SECTION G - 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.
Page 140 SECTION G - BODY/INTERIOR 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.
Page 141: S Ide Curtains
SECTION G - BODY/INTERIOR SIDE CURTAINS FITTING THE TONNEAU COVER If your top has not already been fit, the windshield angle Stretch the cover over the snaps. Starting in the middle may be matched to fit the front edge of the side curtain. snap in the front, mark and install the snaps as described Once the windshield angle has been determined, the top above for the top.
Page 142: Section H Final Operations
SECTION H FINAL OPERATIONS...
Page 143: Lutch Hydraulics
SECTION H -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. Loosen the nipple about turn with a " or 7 mm wrench. PRESSURE HOSE INSTALLATION Work the arm on the clutch pedal shaft (instead of pushing on the clutch pedal itself) until only clear fluid comes out of...
Page 144: Brake Hydraulics
SECTION H -FINAL OPERATIONS -  Do the same process with the left front caliper. WITH SPRING  Repeat the sequence with the rear calipers, doing the Remove the spring. Adjust as above, but leave just " right one first, then the left. clearance.
Page 145: Nstall Wiper Arms
SECTION H -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 54, the car position.
Page 146 SECTION H -FINAL OPERATIONS - ALIGNMENT FRONT Note! Some automated alignment machines require a Specifications below are for street driving. Competition specific car to tell the operator how to move shims. The settings will differ. closest production car is the ’73-’76 Chevrolet Monte Carlo. See pages 97 for suspension assembly.
Page 147 SECTION H -FINAL OPERATIONS - REAR (ERA) DAMPER ADJUSTMENT Camber: - deg. deg. SPAX Toe-in: 0- " (0- deg.) Spax dampers do not have separate bump and rebound controls, but a reasonable performance compromise can be made using common sense and a screwdriver. The bump/rebound ratio is designed for the ERA 427SC and only detail changes need be made for optimum handling.
Page 148: Rake Balance Adjustment
SECTION H -FINAL OPERATIONS - Final adjustments can be made to effect the "turn-in" of BRAKE BALANCE ADJUSTMENT the car. That is, whether the car has initial understeer or oversteer. By increasing the rebound control at one end it Do not change the brake bias until after the brakes have will decrease the initial adhesion at that end.
Page 149: Luids
SECTION H -FINAL OPERATIONS - f\brkbal 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.
Page 150: Cooling System
SECTION H -FINAL OPERATIONS - SETUP COOLING SYSTEM 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 Install the radiator hoses (and optional top tube connector) not recommend using a restrictor plate in place of a and lower hose connector.
Page 151: Eadlight Adjustment
SECTION H -FINAL OPERATIONS -  AT LOW SPEEDS Check for exhaust leaks.  Our standard fan is adequate for practically any small block Re-torque the exhaust manifold bolts. engine under normal conditions – and OK for mild FE  Check the hand brake.
Page 152: Driving/Controls
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...
Page 153: Recommended Periodic Service
SERVICE + MAINTENANCE PARTS RECOMMENDED PERIODIC SERVICE Fluids and capacities are listed on page 149. EVERY GASOLINE FILL-UP: EVERY 12,000 MILES   Check engine oil and water Check transmission oil  FIRST 1000 MILES Grease rear axle and driveshaft universal joints ...
Page 154: Aintenance /Parts
SECTION H -REFERENCE - 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 149.
Page 155 SECTION H -REFERENCE - SUSPENSION, JAGUAR REAR: SUSPENSION, REAR, OUTBOARD BRAKES Inner pivot bearing, Tor. B146 Outer fulcrum bearing, Timken 03062/03162 lower wishbone lower wishbone Outer fulcrum bearing, Timken 03062/03162 Upper trailing arm, Frnt HMR-8 lower wishbone Rear HML-8 Seal, inner fulcrum Jaguar C17168 Upper radius rod, inner HMR-8...
Page 156 SECTION H -REFERENCE - STEERING COLUMN CAPACITIES/LUBRICANTS Bushing, column Lucas 209423 Engine Oil housing Ask your engine builder for viscosity recommendations. RELAYS, SWITCHES FE engine with Canton pan: 7.5 qts. Relay (Horn and Bosch/Tyco V23234- w/ oil cooler 8 qts. radiator fan) A001-X032 or Add for remote filter: .5 qt.
Page 157 SECTION H -REFERENCE - Cooling system capacity. JACKING Ford FE engine - 4 gallons FRONT Ford small block - 3.5 gallons The car can also be jacked up on the lower control arms at FREEZING POINTS FOR the ball joint (be careful not to damage the grease fitting), SOLUTIONS OF ETHYLENE GLYCOL or the front crossmember as shown.
Page 158: Inspection And Registration
SECTION H -REFERENCE - BOLT TORQUE SPECIFICATIONS Use figures below only if unspecified in the relevant instructions. Torques are listed 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...
Page 159 SECTION H -REFERENCE - 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.
Page 160: I Nsurance
SECTION H -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.
Page 161 INDEX Pedal height ............104 Accent tubes ............. 116 Rear................ 17 Air cleaner..............74 Rotor installation............ 98 Air hoses ..............79 Bulkhead, Rear ............83 Alignment, suspension ..........146 Bumpers..............129 Alternator ..............22 Removal ..............57 Mounting FE ............... 33 Cable Mounting, Small block Ford ........
Page 162 INDEX Installation ..............97 Gaskets and sealant ..........138 Rear.................23 Heat shield installation ........... 88 Road settings............146 Leaks ..............138 Specifications, front and rear........54 Primary pipes............136 Dash tubes ..............124 Side pipes ............. 136 Dashboard..............110 Undercar............... 138 Controls ..............152 Expansion tank ..........21, 25, 38 Removal..............59 Switch knob ............111 Fan, Radiator ..............
Page 163 INDEX Prop (stay) .............. 69 Master cylinder, Brake Scoop Parts ..............154 Ford FE, small block .......... 74 Master cylinder, Clutch Striker..............69 Parts ..............154 Horns................62 Mirror Hoses, radiator............21 Dash mount............133 Installation............150 Fender ..............134 Layout and parts .............
Page 164 INDEX Automatic function ...........151 Side curtains ..........86, 109, 141 Optional ..............90 Side pipes ..............136 Standard ..............89 Signal lights........... See Lights Mounts ..............89 Slave cylinder Shrouding ...............57 Clutch ............... 36, 37 Upper connecting tube..........25 Snaps, top/tonneau ........... 134 Radiator hoses Soft top ..............
Page 165 INDEX Hub Carrier Weatherseal............78 ERA..............45 Weatherseals ............69 Jaguar parts............41 Turkey pan ..............74 Rebuilding ............40 Selection ............. 17 Undercoating.............. 77 Urethane bushings..........41 Understeer..............148 Tuning ..............146 Unilite ................ 11 Sway bar................: Universal joints............40 Switch, Thermostatic..........

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427sc

Era Replica Automobiles 427 ROADSTER Assembly And Service Manual

Section a Parts Needed

Section B: Parts Preparation

Section C: Chassis Preparation

Section D

Body/Chassis Assembly

Section E Body Preparation

Section F: Suspension Assembly

Section G

Body/Interior

Section H Final Operations

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