differential FORD MUSTANG 2003 Workshop Manual

DISASSEMBLY AND ASSEMBLY
Differential Case and Ring Gear —
Traction-Lok®
Disassembly 1. Remove the differential assembly from the differential housing. For additional information, refer to Differential Case in this section.
2. Remove the 10 bolts.
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 Gauge, Differential Clutch
205-
022 (T66L-4204- A) Gauge, Differential Clutch
205-
135 (T80P-4946- A) 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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3.
CAUTION: Do not damage the threads in the bolt holes.
Insert a punch in the bolt holes, and drive off the ring gear.
4. Using the special tools, remove the differential bearings (4221), if necessary.
5. Remove the bolt and the differential pinion shaft (4211).
6. WARNING: Due to the spring tension, use care when removing the differential Klj . 2 ba
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clutch spring (4214). Failure to follow these instructions may result in personal injury.
Remove the differential clutch spring.
7. Remove the differential gears. 1. Remove the two differential pinion gears (4215).
2. Remove the two differential side gears (4236).
3. Remove the two differential pinion thrust washers (4230).
8. CAUTION: Keep the differential clutch packs (4947) in order. Do not mix them.
Always reassemble them in the same sequence.
Separate the differential clutch packs and shims from the differential side gears and tag them
"right" and "left".
zClean and inspect the remaining differential components for wear and damage and install
new parts as necessary. Klj . 3 ba
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9.
CAUTION: Do not use acids or solvents when cleaning the differential clutch pack.
Wipe components only with a clean, lint- free cloth.
Clean and inspect the differential clutch packs for wear and damage and install new parts as
necessary.
Assembly
1. CAUTION: 118 ml (4 oz) of the specified Ford Friction Modifier must be used in the
axle.
Lubricate each steel clutch plate and soak all friction plates for no less than 15 minutes.
zUse Additive Friction Modifier C8AZ- 19B546-A or equivalent meeting Ford specification
EST- M2C118- A
2. CAUTION: Do not mix the differential clutch packs or shims from one side with the
other.
Assemble the differential clutch packs (without the shims) on their respective differential side
gears. Klj . 4 ba
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3. Place the base portion of the special tool in a vise. Install the differential differential side gear
and differential clutch pack (without the shim) on the tool.
4. Position the special tool hand- tight on top of the differential clutch pack.
5. Install the special tool over the disc and differential clutch pack. Klj . 5 ba
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6. Install the nut.
7.
NOTE: Clutch Pack Rebuild Kit F5AZ- 4947-A is available for this application.
Select and insert the thickest feeler gauge blade that will enter between the tool and the
differential clutch pack. The reading will be the thickness of the new clutch shim.
8. Remove the special tools from the differential clutch pack and differential side gear assembly.
9. Install shim(s) on the differential clutch pack and differential side gear assembly.
10. Install the differential side gear assemblies in the differential case. Selective Shims
Part Number Description
EOAZ-
4A324- G 0.025 Inch
EOAZ-
4A324- H 0.030 Inch
EOAZ-
4A324- C 0.035 Inch
EOAZ-
4A324- D 0.040 Inch
EOAZ-
4A324- F 0.045 Inch Klj . 6 ba
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11. Install the differential pinion gear and differential pinion thrust washer assemblies in the
differential case.
12. Using a soft- faced hammer, install the differential clutch spring.
13. Install the differential pinion shaft and install a new bolt finger- tight. Klj . 7 ba
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14. Mount the differential case and the special tool in a vise. Using the special tool, check the
torque necessary to rotate one differential side gear.
zIf reusing the original clutch plates, the initial minimum break- away torque must be no
less than the specification. The minimum rotating torque necessary to keep the
differential side gear turning with new clutch plates may vary.
15. Using the special tool, install the differential bearings, if removed.
16. Position the differential ring gear and the differential case. Align the bolt holes by starting two bolts through the holes in the differential case and the differential ring gear. Press the
differential ring gear on the differential case. Klj . 8 ba
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17. Install the bolts.
zApply Stud and Bearing Mount EOAZ-19554- BA or equivalent meeting Ford specification
WSK- M2G349- A1 to the bolt threads.
18. Install the differential assembly in the differential housing. For additional information, refer to Differential Case in this section. Klj . 9 ba
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SPECIFICATIONS
SECTION 205-
02C: Rear Drive Axle/Differential — Ford 8.8-Inch IRS 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants/Adhesive/Sealants
Premium Long-
Life Grease XG -1-C ESA-
M1C75- B SAE 75W-
140 High Performance Rear Axle Lubricant F1TZ-
19580- B WSL-
M2C192- A Additive Friction Modifier C8AZ-
19B546-A EST-
M2C118- A Clear Silicone Rubber F7AZ-
19554-CA ESB-
M4G92- A Stud and Bearing Mount EOAZ-19554-
BA WSK-
M2G349- A1 Threadlock and Sealer EOAZ-19554-
AA WSK-
M2G351- A5 High Temperature Nickel Anti-
Seize Lubricant F6AZ-9L494-
AA ESE-
M12A4-A Capacity
Additive Friction Modifier 118 ml (4 oz)
Rear axle lubricant 1.23-
1.37 liters (2.6- 2.9 pints) Rear axle lubricant level 6.35 mm (1/4 inch) from the bottom of
the fill hole Clearance, Tolerance and Adjustments
Maximum carrier spread 0.762 mm (0.030 in)
Maximum differential ring gear backface runout 0.076 mm (0.003 in)
Maximum differential case runout 0.076 mm (0.003 in)
Backlash between differential ring gear and pinion teeth 0.203 mm (0.008 in)-
0.330 mm (0.013
in) Preferred backlash 0.254 mm (0.010 in)
Maximum backlash variation between teeth 0.1016 mm (0.004 in)
Maximum radial runout of rear axle pinion flange in
assembly TIR 0.254 mm (0.010 in)
Available drive pinion bearing adjustment shim in steps of:
0.0254 mm (0.001 in) 0.254 mm (0.010 in)-
0.965 mm (0.038
in) Lubricant deflector to differential housing cover 5.08 mm (0.200 in)-
6.35 mm (0.250 in)
Torque Specifications Description Nm lb-
ft lb-
in Rear axle wheel hub retainer 340 251 —
Driveshaft to pinion flange bolt 112 83 —
Rear axle differential front lower insulator nut and bolt 70 52 —
Rear axle differential rear insulator bolt 103 76 —Klj . 1 ba
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