differential FORD MUSTANG 2003 Workshop Manual

REMOVAL AND INSTALLATION
Exhaust Gas Recirculation (EGR) Valve —
Cobra
Removal and Installation 1. Disconnect the accelerator cable and the speed control cable.
2. Remove the accelerator cable bracket bolts.
3. Release the clip and position the accelerator cable bracket and the cables aside.
4. Disconnect the electrical connectors from the fuel pulse damper, EGR vacuum regulator solenoid, supercharger bypass vacuum solenoid, and the differential pressure feedback EGR
system.
SECTION 303-
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5. Disconnect the vacuum hoses from the differential pressure feedback EGR system.
6. Disconnect the vacuum hoses from the supercharger bypass vacuum solenoid, and the
actuator.
7. Disconnect the vacuum hoses from the fuel pulse damper and the EGR vacuum regulator solenoid.
8. Disconnect the vacuum hose from the EGR valve. Klj . 2 ba
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REMOVAL AND INSTALLATION
Exhaust Manifold to Exhaust Gas Recirculation (EGR)
Valve Tube
Removal and Installation
NOTE:
3.8L shown, 4.6L (2V) similar.
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100 - 02 .
2. Disconnect the exhaust gas recirculation (EGR) valve tube from the exhaust manifold.
3. Remove the differential feedback exhaust gas recirculation (EGR) system vacuum hoses and the bracket bolts. Position the bracket assembly aside.
4. Disconnect the EGR tube from the EGR valve.
SECTION 303-
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REMOVAL AND INSTALLATION
Differential Pressure Feedback Exhaust Gas Recirculation
(EGR) System
Removal and Installation
1. NOTE: The 4.6L (2V) is shown. The 4.6L (4V) and 3.8L are similar.
NOTE: Bolts may be used in place of nuts on some applications.
Remove the differential pressure feedback EGR. 1. Disconnect the connector.
2. Remove the hoses.
3. Remove the nuts and the differential pressure feedback EGR.
2. To install, reverse the removal procedure.
SECTION 303-
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12. Remove the throttle body and spacer assembly.
13. Release the clip and position the accelerator cable bracket and the cables aside.
14. Disconnect the electrical connectors from the fuel pulse damper, EGR vacuum regulator
solenoid, supercharger bypass vacuum solenoid, and the differential pressure feedback EGR
system.
15. Disconnect the vacuum hoses from the differential pressure feedback EGR system. Klj . 3 ba
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REMOVAL AND INSTALLATION
Supercharger Bypass Vacuum Solenoid —
Actuator
Removal 1. Disconnect the electrical connectors from the EGR vacuum regulator solenoid, the supercharger bypass vacuum solenoid, and the differential pressure feedback EGR system.
2. Disconnect the vacuum hoses from the differential pressure feedback EGR system.
3. Disconnect the vacuum hoses from the supercharger bypass vacuum solenoid, and the actuator.
4. Disconnect the vacuum hoses from the EGR vacuum regulator solenoid.
SECTION 303-
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9. Connect the vacuum hoses to the differential pressure feedback EGR system.
10. Connect the electrical connectors to the EGR vacuum regulator solenoid, the supercharger bypass vacuum solenoid, and the differential pressure feedback EGR system. Klj . 5 ba
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Clearance 41.7322-42.5958 1.643-1.677
Selective steel plate 1.702-
1.803 0.067-0.071
1.956-
2.057 0.077-0.081
2.210-
2.311 0.087-0.091
2.464-
2.565 0.097-0.101
Torque Specifications Description Nm lb-
ft lb-
in Rear transmission support crossmember bolts 55 40 —
Rear insulator bolts 80 59 —
Extension housing bolts 28 21 —
Transmission fluid pan bolts 14 10 —
Front pump bolts 27 20 —
Front pump support bolts 23 17 —
Harness electrical connector bolt 5 — 44
Inspection cover bolts 35 26 —
Main control valve body bolts 10 — 89
Main control valve body cover plate bolts 10 — 89
Main control valve body separator plate bolts 10 — 89
Manual lever shaft nut 33 24 —
Manual lever shaft outer nut 33 24 —
Fluid cooler line case fittings 21 15 —
Pressure tap plugs 12 9 —
Rear driveshaft bolts 112 83 —
Starter bolts 25 18 —
TCC solenoid bolt 10 — 89
Torque converter drain plug 12 9 —
Torque converter nuts 37 27 —
Digital transmission range (TR) sensor bolts 9 — 80
Transmission bell housing bolts 47 35 —
Vehicle speed sensor (VSS) plug bolt 9 — 80
Output shaft speed (OSS) sensor bolt 12 9 —
Starter B+ cable 11 8 —
Exhaust manifold bolts 40 30 —
Exhaust pipe bolts 40 30 —
Transmission vent tube 12 9 —
Manual control valve detent lever spring bolt 10 — 89
Cooler tube nut to case fitting 18 13 —
Rear differential retaining nuts (front) 90 66 —
Rear differential retaining bolts and nuts (rear) 70 52 — Klj . 5 ba
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15. Install the cover.
16. Reconnect the connector.
17. Reconnect the connector.
18. Install the dual converter Y pipe.
19.
NOTE: The output shaft and the drive shaft are a balanced assembly.
Install the driveshaft. zAlign the yellow dots and position the driveshaft on the transmission.
z Position the driveshaft to the rear differential. Klj . 5 ba
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REMOVAL AND INSTALLATION
Muffler —
3.8L
Removal and Installation 1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. Support the rear axle with a suitable jack.
3. Remove the upper arm- to-differential bolt.
4. Remove the nut and bolt and disconnect the rear shock absorbers (18124) from the axle housing.
zDiscard the nut.
5. Lower the rear axle.
6. Remove the dual converter assembly flange nuts.
SECTION 309-
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