differential FORD MUSTANG 2003 Workshop Manual

new pinion bearings in the Specifications portion of this section.
z For used pinion bearings, if the preload recorded prior to disassembly is lower than the
specification for used bearings, then tighten the nut to specification. Refer to torque
specifications for used pinion bearings in the Specifications portion of this section.
z For used pinion bearings, if the preload recorded prior to disassembly is higher than the
specification for used bearings, then tighten the nut to the original reading as recorded.
18. CAUTION: 118 ml (4 oz) of Additive Friction Modifier C8AZ- 19B546-A or equivalent
meeting Ford specification EST- M2C118-A 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.
19. CAUTION: Do not mix the clutch plates, clutch discs or shim from one side with the
other.
Assemble the differential clutch packs (without the shims) on their respective differential side gear. Klj . 20 ba
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20. Place the base portion of the special tool in a vise.
21. Install the differential clutch pack and differential side gear (without the shim) on the special tool.
22. Position the special tool hand-
tight on top of the differential clutch pack. Klj . 21 ba
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23. Install the special tool over the disc and differential clutch pack.
24. Install the nut.
25. 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. 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 . 22 ba
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26. Remove the special tool from the differential clutch pack and differential side gear assembly.
27. Install the shim(s) on the differential clutch pack and differential side gear assembly.
28. Install the differential side gear assemblies in the differential case.
29. Install the differential pinion gear and differential pinion thrust washer assemblies in the
differential case.
30. Using a soft- faced hammer, install the differential clutch spring. Klj . 23 ba
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31.
NOTE: If a new bolt is unavailable, coat the original bolt threads with Threadlock and Sealer
EOAZ- 19554- AA or equivalent meeting Ford specification WSK-M2G351- A5 prior to final
installation.
Install the differential pinion shaft and install a new bolt finger- tight.
32. 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.
33. CAUTION: The Master bearings are marked LH and RH. Install them as shown.
Install the special tools on the differential case. Klj . 24 ba
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34.
CAUTION: Do not damage the aluminum differential housing while carrying out
these procedures.
Place the differential case with the special tools in the differential housing.
35. Position the special tool on the outside mounting hole.
36. NOTE: Repeat this step until obtaining a consistent reading.
Measure the total end play. 1. Attach the special tool and position the indicator tip on the machined surface of the differential case flange.
2. Move the differential case to the left and the right (as far as possible).
3. Record the reading on the differential bearing shim selection procedure line A. Differential Bearing Shim Selection Chart
8.8-
inch Aluminum Axle Example Actual
Line-
A End play without ring gear 0.498
Line-
B End play with ring gear (ring gear side) -
0.245 Minus (-
) Line-
C Subtract Line-B from Line- A, also record on Line C, below 0.253 Klj . 25 ba
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a
Round off initial thickness to the nearest shim thickness as in example for final shim
thickness.
37. Remove the Dial Indicator and the differential case from the differential housing. 38. Draw - file the differential ring gear mounting surface to remove any nicks or burrs. 8.8-
inch Aluminum
Axle Left Differential Bearing
Height Right Differential Bearing
Height Example Actual Example Actual
Master bearing height 0.8695 0.8695 0.8695 0.8695
Line-
D Actual bearing
height -0.8478 Minus (-
) -0.8491 Minus (-)
Line-
E Difference 0.0217 0.0204
8.8-
inch Aluminum
Axle Left Side
8.8-
inch Aluminum
Axle Right Side
Example Actual Example Actual
Line-
B End play
Line- E Bearing height 0.2450
+0.0217 + Line-
C End play
Line- E Bearing height 0.2530
+0.0204 +
TOTAL Lines B and E
Backlash (subtract) 0.2667
-0.0060 -0.006 TOTAL Lines C and E
Backlash/preload (add) 0.2734
+0.020 +0.020
Initial thickness
a 0.2607 Initial thickness 0.2934
Final shim thickness
—
left 0.261 Final shim thickness —
right 0.293 Klj . 26 ba
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39. Install the differential ring gear.
1. Place the differential ring gear on the differential case.
2. Hand start three bolts to align the holes in the differential ring gear and the differential case.
3. Place the differential case and differential ring gear onto the press bed blocks with the differential ring gear teeth facing downward.
4. Press the differential ring gear into place.
40. Install the remaining bolts.
41. Place the differential case with the special tools into the differential housing. Klj . 27 ba
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42.
NOTE: The bolts retaining the differential ring gear to the differential case may interfere while
carrying out this procedure. If so, remove three to five bolts to provide clearance.
Measure the end play. 1. Attach the special tool and position the indicator tip on the machined surface of the differential case flange.
2. Rock the differential ring gear to allow full mesh with the drive pinion gear.
3. With the gears in full mesh, set the special tool to zero.
4. Move the differential case as far as possible to the left and note the reading.
5. Record the reading on the differential bearing shim selection procedure line B.
„Remove the special tool.
43. Remove the differential case from the differential housing.
44. Remove the bolts. Apply Stud and Bearing Mount EOAZ-19554- BA or equivalent meeting Ford
specification WSK-M2G349- A1 to the bolt threads, and reinstall the bolts.
45. NOTE: Measure the stand height of both differential bearings prior to installation.
NOTE: Mark the differential bearings left and right before measuring them.
Install the special tool. Klj . 28 ba
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1. Place the special tool base in a soft-
jawed vise with the bearing mounting surface above
the vise jaws.
2. Position the differential bearing on the special tool base.
3. Attach the bolt, spring, washers and spacer.
4. Tighten the bolt.
46. Measure the differential bearing stand height. 1. Invert the special tool and clamp the bolt head in a vise.
2. Position a depth micrometer flat on the differential bearing.
47. Measure both differential bearings stand height. Record the measurement on the differential bearing shim selection procedure line D.
48. Press the left and right differential bearing on the differential case.
49. Install the special tools. Klj . 29 ba
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