Hey car enthusiasts! Ever dreamed of bringing a vintage beauty back to life? Today, we're diving deep into the world of the 1986 Ford EXP Sport Coupe. This isn't just a car; it's a piece of history, a testament to 80s automotive design, and a fantastic project for any gearhead. In this guide, we'll cover everything you need to know about restoring and repairing your classic EXP, from understanding its unique features to tackling common issues. Get ready to roll up your sleeves and get your hands dirty because we're about to embark on an exciting journey! First off, the Ford EXP, a two-door coupe that graced the roads from 1982 to 1988, was Ford's answer to the sporty compact market. Based on the Ford Escort platform, the EXP offered a distinctive blend of style and fuel efficiency. The 1986 model, in particular, holds a special place in the hearts of collectors and DIY mechanics alike. Now, before we jump into the nitty-gritty of repairs, let's talk about why you might want to consider taking on this project. First and foremost, restoring a classic car is incredibly rewarding. There's a unique sense of accomplishment that comes with bringing a vintage vehicle back to its former glory. Secondly, the Ford EXP is relatively affordable compared to other classic cars, making it an accessible project for those on a budget. And finally, the EXP has a dedicated following, meaning you'll find plenty of resources, parts, and community support along the way. Whether you're a seasoned mechanic or a novice enthusiast, this guide will provide you with the knowledge and confidence to restore your 1986 Ford EXP and keep it running smoothly for years to come. Let's get started, shall we?

Understanding Your 1986 Ford EXP Sport Coupe

Before you start wrenching, it's crucial to understand your machine. The 1986 Ford EXP Sport Coupe, while sharing its platform with the Escort, boasted unique styling and features that set it apart. This section will walk you through the key components and specifications you should know. The heart of the EXP is its engine. The 1986 model came equipped with either a 1.9-liter inline-four engine. Understanding the engine type, its horsepower, and torque ratings will help you diagnose and repair engine-related issues. The engine's performance, though not groundbreaking by today's standards, was adequate for its time, providing a balance between fuel efficiency and driving fun. Next up, the transmission. The EXP was offered with a manual or an automatic transmission. Knowing the type and condition of your transmission is vital for smooth shifting and overall driving experience. The suspension system, another critical component, is responsible for the car's ride quality and handling. The EXP featured a MacPherson strut front suspension and a torsion-beam rear suspension. Regular inspection and maintenance of these components are essential for safety and comfort. Now, let's talk about the body and interior. The EXP's sleek, aerodynamic design was ahead of its time. The car's unique styling, including its pop-up headlights and sloping roofline, made it stand out from the crowd. The interior, though simple by modern standards, offered a comfortable and functional driving environment. Familiarizing yourself with the EXP's features, such as the instrument panel, seats, and other interior components, will assist you in maintaining and restoring the car. The electrical system, often overlooked, plays a critical role in the car's operation. The 1986 EXP used a 12-volt electrical system to power various components, including lights, the radio, and the engine's control unit. Understanding the basics of the electrical system will help you diagnose and repair electrical issues, which are common in older cars. Finally, let's not forget about the brakes. The EXP had disc brakes in the front and drum brakes in the rear. Ensuring that the brakes are in good working condition is paramount for safety. By taking the time to understand these key components and specifications, you'll be well-prepared to tackle any repair or restoration project.

Common Problems and How to Fix Them

Alright, let's get into the nitty-gritty of repairing your 1986 Ford EXP. Every classic car has its quirks, and the EXP is no exception. In this section, we'll cover some of the most common issues you might encounter and provide you with practical solutions. First up, engine problems. Like any car of its age, the EXP's engine may suffer from wear and tear. Common issues include oil leaks, reduced compression, and overheating. If your engine is losing oil, check for leaks around the oil pan, valve cover, and rear main seal. Replacing worn gaskets and seals is often the solution. Reduced compression can lead to poor performance and hard starting. A compression test will help you identify this issue, and it might indicate the need for valve work or a complete engine overhaul. Overheating can be caused by a faulty thermostat, a clogged radiator, or a failing water pump. Addressing these issues promptly is crucial to prevent engine damage. Next, we have transmission troubles. The EXP's transmission, whether manual or automatic, can develop problems over time. Common issues include hard shifting, slipping gears, and leaks. If you have a manual transmission, check the clutch for wear and tear. A worn clutch can cause difficulty in shifting gears and can eventually lead to complete failure. Automatic transmissions can suffer from slipping gears, which can be caused by low fluid levels or internal component failure. Regular fluid changes and inspections can prevent some of these issues. Suspension woes are another area to watch out for. The EXP's suspension can wear out over time, leading to a rough ride and poor handling. Common issues include worn shocks and struts, ball joints, and bushings. Replacing these components can dramatically improve your car's ride quality and handling. Look out for the signs of worn suspension components. The handling will become sloppy, and you might hear noises when going over bumps. Don't forget about the electrical gremlins! Electrical problems are a common headache in older cars. Issues like dim headlights, non-functioning gauges, and starting problems can be frustrating. Start by checking the fuses and relays. A faulty fuse can easily cause electrical problems. If the fuses are okay, check the wiring for corrosion or damage. Cleaning or replacing corroded wires can often solve the problem. Finally, there's rust. Rust is the enemy of all classic cars, and the EXP is no exception. Rust can develop on the body, frame, and undercarriage. Regular inspections and preventative measures, such as rust-proofing, are essential to protect your car. Addressing these common problems with the right tools and a little bit of patience will go a long way in keeping your EXP in top condition.

Step-by-Step Repair Guides and Maintenance Tips

Now, let's get into some practical repair guides and maintenance tips to keep your 1986 Ford EXP running smoothly. We will break down common repairs into easy-to-follow steps to make the restoration process easier. Let's start with an engine oil change. This is one of the most basic but important maintenance tasks. First, gather your supplies: new oil, a new oil filter, a wrench for the oil filter, and a drain pan. Warm up the engine, then position the drain pan under the oil drain plug. Remove the drain plug and let the old oil drain completely. While the oil is draining, locate the oil filter and remove it using the appropriate wrench. Install the new oil filter, making sure to lubricate the rubber seal with fresh oil. Once the oil has drained, reinstall the drain plug and tighten it to the manufacturer's specifications. Now, you can refill the engine with the correct amount and type of oil specified in your owner's manual. Another common repair is replacing the spark plugs. This is a relatively easy task that can significantly improve your engine's performance. First, gather your supplies: new spark plugs, a spark plug socket, and a ratchet. Locate the spark plugs in your engine. Disconnect the spark plug wires and carefully remove the old spark plugs using the spark plug socket. Install the new spark plugs, tightening them to the manufacturer's specifications. Reconnect the spark plug wires, ensuring they are connected to the correct spark plugs. Replacing brake pads is another essential maintenance task for safety. Gather your supplies: new brake pads, a wrench, and a jack. Jack up the car and remove the wheel to access the brakes. Remove the brake caliper and the old brake pads. Install the new brake pads and reassemble the caliper. Repeat these steps for each wheel. Besides these repair guides, regular maintenance is key to keeping your EXP in good shape. Check your oil and coolant levels regularly. Replace the air filter as needed. Inspect your tires for wear and tear, and rotate them as necessary. These simple steps will help you extend the life of your car and keep it running smoothly. Remember, the key to successful repairs is to take your time, follow the instructions carefully, and don't be afraid to ask for help when needed.

Sourcing Parts and Finding a Community

One of the most crucial aspects of restoring your 1986 Ford EXP is finding the right parts and building a community. In this section, we'll guide you on where to source parts and connect with other EXP enthusiasts. Finding parts for a classic car can be a challenge, but with the right resources, you can keep your EXP in top shape. Start by checking online auto parts retailers. Websites like RockAuto and Amazon often have a wide selection of parts for older vehicles, including the EXP. Also, consider local auto parts stores. They may not always have parts in stock, but they can often order them for you. Don't forget about junkyards and salvage yards. These are excellent places to find used parts at a fraction of the cost of new ones. Also, you can find original and used parts through specialized online forums and marketplaces. There are also several online forums and clubs dedicated to the Ford EXP. These communities are an invaluable resource for information, advice, and parts. Members often share tips, tricks, and resources, making your restoration journey much easier. Participate in these forums, ask questions, and share your experiences. These communities are a great way to learn from others and get support when you need it. Consider joining a local car club or attending car shows. Car clubs often have access to unique parts and resources, and they can provide a social outlet for your passion. Attending car shows is a great way to meet other enthusiasts and show off your restored EXP. Make sure to document your restoration process. Take pictures, videos, and notes as you work. This documentation will be invaluable for future reference and will allow you to track your progress. Also, consider creating a blog or a social media page to share your project with others. Sharing your experience can inspire others to restore their classic cars and contribute to the community. By utilizing these resources and connecting with other enthusiasts, you'll be well-equipped to tackle any repair and restoration project on your 1986 Ford EXP. Remember, the journey is just as important as the destination. Enjoy the process of bringing your classic car back to life!

Safety Precautions and Tools You'll Need

Before you start any repair, safety should be your number one priority. Working on cars can be dangerous, so it's essential to take the necessary precautions to protect yourself and your vehicle. First, always wear appropriate safety gear. This includes safety glasses to protect your eyes, gloves to protect your hands, and work boots to protect your feet. Proper ventilation is also important. Working in a well-ventilated area can prevent you from inhaling harmful fumes. Never work on a car that is running in an enclosed space. Before you begin any repair, always disconnect the negative terminal of the battery. This will prevent accidental shorts and electrical shocks. Use jack stands to support the car whenever you're working underneath it. Never rely on a jack alone. Make sure that the jack stands are placed on a stable surface and in the correct locations. Gather the right tools before you start any repair. The tools you'll need will vary depending on the repair, but some essential tools include a socket set, a wrench set, screwdrivers, pliers, and a multimeter. A repair manual is also essential. It provides detailed instructions and diagrams that will help you complete repairs correctly. Consider investing in quality tools. While they may be more expensive upfront, they will last longer and make your repairs easier and more enjoyable. Use the right tools for the job. Using the wrong tool can damage your car and make the repair more difficult. Take your time and don't rush. Rushing can lead to mistakes and injuries. Work in a well-lit area. Good lighting will make it easier to see what you're doing and prevent accidents. If you're not comfortable with a repair, seek professional help. There's no shame in admitting that you need help. A professional mechanic can provide expert assistance and ensure that the repair is done correctly. By following these safety precautions and using the right tools, you can ensure that your 1986 Ford EXP Sport Coupe repair project is safe, successful, and enjoyable.

Conclusion: Enjoying the Ride

Congratulations, gearheads! You've made it to the end of our comprehensive guide to repairing and restoring the 1986 Ford EXP Sport Coupe. We've covered everything from understanding your car's unique features to tackling common problems and sourcing the necessary parts. Remember, restoring a classic car is more than just a repair project; it's a labor of love. It's about preserving a piece of automotive history and enjoying the satisfaction of bringing a vintage beauty back to life. As you work on your EXP, remember to take your time, be patient, and enjoy the process. Don't be afraid to ask for help or seek advice from other enthusiasts. The classic car community is a welcoming and supportive one. Now that you have the knowledge and resources to restore your EXP, it's time to get started! Start with a thorough inspection of your car to identify any issues. Then, create a plan and prioritize your repairs. Don't be overwhelmed by the scope of the project. Break it down into smaller, manageable tasks. Keep track of your progress and celebrate your successes along the way. Remember to document your restoration process. Take pictures, videos, and notes as you work. This documentation will be a valuable reference for future repairs and a great way to share your project with others. And most importantly, enjoy the ride! There's nothing quite like cruising down the road in a classic car that you've restored yourself. The feeling of pride and accomplishment is unmatched. Whether you're a seasoned mechanic or a novice enthusiast, the 1986 Ford EXP Sport Coupe is a fantastic project that will provide you with years of enjoyment. So, get out there, start wrenching, and bring your classic car back to life. Happy restoring, and safe travels!