differential FORD MUSTANG 2003 Workshop Manual

16. Rotate the differential several times to verify that the differential bearings have seated correctly.
17. Using the special tools, recheck the backlash.
zIf backlash is within the specification, go to Backlash within specification in this
procedure. If backlash is not within the specification, repeat Backlash not within
specification in this procedure.
z The specification shown is the full allowable range. For the preferred range, refer to
Specifications in this section.
Backlash within specification 18. Remove the bolts and bearing caps.
19. Set the differential bearing preload. 1. To establish differential bearing preload, increase both left and right differential bearing shim sizes by the specification shown.
2. Using the special tool, fully seat the differential bearing shims. Make sure the assembly rotates freely. Klj . 11 ba
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20. Install the bearing caps and bolts.
21. Using the special tools, recheck the backlash.
zThe specification shown is the full allowable range. For the preferred range, refer to
Specifications in this section.
22. Install the axle shafts. For additional information, refer to Axle Shaft in this section.
23. Install the differential housing cover and refill the rear axle with specified lubricant. For additional information, refer to Differential Housing Cover in this section. Klj . 12 ba
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REMOVAL AND INSTALLATION
Axle Housing
Removal and Installation
1. CAUTION: The vehicle must be on level ground and at curb height.
Mark the rear shock absorbers relative to their protective sleeve. zDuring installation, raise the suspension to this reference mark before tightening the
suspension fasteners.
2. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
3. Remove the rear wheel and tire assemblies. For additional information, refer to Section 204 - 04 .
4. NOTE: If necessary, use Rust Penetrant and Inhibitor F2AZ-19A501- A meeting Ford
specification ESR-M99C56- A to loosen the sensor for removal.
Remove the rear anti- lock brake sensors from the rear disc brake adapters. For additional
information, refer to Section 206 - 09A .
5. Disconnect the parking brake cables and conduits from the rear disc brake calipers. For additional information, refer to Section 206 - 05 .
SECTION 205-
02B: Rear Drive Axle/Differential — Ford 8.8-Inch Ring
Gear 2003 Mustang Workshop
Manual Klj . 1 ba
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9. Remove the stabilizer bar. For additional information, refer to
Section 204 - 02 .
10. Position a suitable transmission jack under the differential housing (4010) for support and strap it securely in place.
11. Remove and discard the nuts and bolts retaining the upper suspension arm and bushings to the differential housing. Klj . 3 ba
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12. Remove and discard the nuts and bolts retaining the shock absorbers to the axle.
13. Lower the differential housing to unload the rear springs.
14. Remove the rear springs.
15. Remove and discard the nuts and bolts retaining the lower suspension arm and bushings to the
axle.
16. Disconnect the lower suspension arm and bushings from the axle. Klj . 4 ba
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DISASSEMBLY AND ASSEMBLY
Differential Case and Ring Gear —
Conventional
Disassembly 1. Remove the differential assembly from the differential housing. For additional information, refer to Differential Case in this section.
2. Remove the bolts.
3. CAUTION: Do not damage the threads in the bolt holes.
Insert a punch in the bolt holes and drive off the ring gear.
SECTION 205-
02B: Rear Drive Axle/Differential — Ford 8.8-Inch Ring
Gear 2003 Mustang Workshop
Manual Special Tool(s)
2-
Jaw Puller
205- D072 (D97L-4221- A) or
equivalent Installer, Differential Side
Bearing
205-
010 (T57L-4221- A2) Step Plate
205-
D061 (D83T-4205- C2) or
equivalent Klj . 1 ba
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4. Using the special tools, remove the differential bearings (4221), if necessary.
5. Remove the bolt.
6. Remove the differential pinion shaft (4211).
7. Rotate and remove the differential pinion gears (4215) and differential pinion thrust washers
(4230). Klj . 2 ba
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8. Remove the differential side gears (4236) and the differential side gear thrust washers (4228).
Assembly 1. Lubricate the differential side gear thrust washers and the differential side gear journals, and assemble the washers to the gears.
zUse SAE 75W- 140 High Performance Rear Axle Lubricant F1TZ-19580- B or equivalent
meeting Ford specification WSL- M2C192-A.
2. Lubricate the differential pinion thrust washers and the differential pinion gears, and assemble the washers to the gears.
zUse SAE 75W- 140 High Performance Rear Axle Lubricant F1TZ-19580- B or equivalent
meeting Ford specification WSL- M2C192-A. Klj . 3 ba
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3. Position the differential side gear and thrust washer assemblies in the differential case.
4. Engage the differential pinion gears with the differential side gears and rotate the pinion gears
to align with the differential pinion shaft bore.
5. Insert the differential pinion shaft. zAlign the hole in the differential pinion shaft with the hole in the differential case.
6. Install a new bolt finger- tight. Klj . 4 ba
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7. Using the special tool, install the new differential bearings, if removed.
8. Position the ring gear and the differential case. Align the bolt holes by starting two bolts through
the holes in the differential case and the ring gear. Press the ring gear on the differential case.
9. Install the bolts. zApply Stud and Bearing Mount EOAZ-19554- BA or equivalent meeting Ford specification
WSK- M2G349- A1 to the bolt threads.
10. Install the differential assembly. For additional information, refer to Differential Case in this Klj . 5 ba
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