lock FORD MUSTANG 2003 Owner's Manual

REMOVAL AND INSTALLATION
Driveshaft
Removal and Installation
1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. Carry out the following: 1. Place an index mark on the rear axle pinion flange and the driveshaft centering socket yoke.
2. Remove the four bolts.
3. CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion
flange pilot. Never hammer on the driveshaft or any of its components to disconnect the
yoke from the flange. Pry only in the area shown, with a suitable tool, to disconnect the
yoke from the flange.
Using a suitable tool as shown, disconnect the driveshaft centering socket yoke from the rear
axle pinion flange.
4. CAUTION: Do not allow the slip yoke to bottom on the transmission output shaft. SECTION 205-
01: Driveshaft 2003 Mustang Workshop Manual Material
Item Specification
Threadlock® and
Sealer
E0AZ-
19554- AA WSK-
M2G351- A5 (type
II) Klj . 1 ba
22003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

Lower the rear end of the driveshaft to clear the rear axle housing. Pull the driveshaft rearward
until the driveshaft slip yoke clears the transmission extension housing.
zPlace a paint index mark on the driveshaft slip yoke and the transmission output shaft.
z Place a commercially available plug in the extension housing to prevent fluid leakage.
5. CAUTION: Install the driveshaft with new bolts. If new bolts are not available, apply
threadlock and sealer to the threads of the original bolts.
CAUTION: Do not allow the slip yoke to bottom on the transmission output shaft.
CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion
flange pilot. To make sure that the yoke seats squarely on the flange, tighten the bolts
evenly in a cross pattern as shown.
NOTE: Clean all foreign material from the yoke areas of the driveshaft.
To install, reverse the removal procedure. Klj . 2 ba
22003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

REMOVAL AND INSTALLATION
Driveshaft —
Cobra
Removal and Installation 1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. NOTE: To aid disassembly and assembly, lubricate the exhaust hangers with silicone lubricant.
Remove the two exhaust hangers from the rubber mounts.
3. Remove the nuts on the left side exhaust.
4. Lower the muffler pipe enough to clear the flange. Move the muffler assembly forward to disconnect the third exhaust hanger.
5. Carry out the following: 1. Place an index mark on the rear axle pinion flange and the driveshaft centering socket yoke. SECTION 205-
01: Driveshaft 2003 Mustang Workshop Manual Material
Item Specification
Threadlock® and Sealer
E0AZ-
19554- AA WSK-
M2G351- A5 (type
II) Silicone Lubricant
(Aerosol)
F5AZ-
19553- AA ESR-
M13P4-A Klj . 1 ba
32003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

2. Remove the four bolts.
6. CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion
flange pilot. Never hammer on the driveshaft or any of its components to disconnect the
yoke from the flange. Pry only in the area shown, with a suitable tool, to disconnect the
yoke from the flange.
Using a suitable tool as shown, disconnect the driveshaft centering socket yoke from the rear
axle pinion flange.
7. CAUTION: Do not allow the slip yoke to bottom on the transmission output shaft.
Lower the rear end of the driveshaft to clear the rear axle housing. Pull the driveshaft rearward
until the driveshaft slip yoke clears the transmission extension housing. zPlace a paint index mark on the driveshaft slip yoke and the transmission output shaft.
z Place a commercially available plug in the extension housing to prevent fluid leakage.
8. CAUTION: Install the driveshaft with new bolts. If new bolts are not available, apply
threadlock and sealer to the threads of the original bolts.
CAUTION: Do not allow the slip yoke to bottom on the transmission output shaft.
CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion
flange pilot. To make sure that the yoke seats squarely on the flange, tighten the bolts
evenly in a cross pattern as shown.
NOTE: Clean all foreign material from the yoke areas of the driveshaft.
To install, reverse the removal procedure. Klj . 2 ba
32003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

SPECIFICATIONS
a
In- vehicle repair refill capacities are determined by filling the rear axle with the specified lubricant to
6.4- 14.3- mm (1/4- 9/16-in) below the bottom of the fill hole.
SECTION 205-
02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring
Gear 2003 Mustang Workshop
Manual General Specifications
Item Specification
Lubes and Sealers
SAE 80W-
90 Premium Rear Axle Lubricant XY-
80W90- QL WSP-
M2C197- A Premium Long-
Life Grease XG -1-C ESA-
M1C75- B Rust Penetrant and Inhibitor F2AZ-19A501-
A ESR-
M99C56- A High Temperature Nickel Anti-
Sieze Lubricant
F6AZ- 9L494- AA ESE-
M124A- A Clear Silicone Rubber F7AZ-
19554-CA ESB-
M4G92- A Threadlock and Sealer EOAZ-19554-
AA WSK-
M2G351- A5 Lubricant Fill Level Checks
Approximate axle fill capacity
a 1.54-1.66-
liters (3.25-3.50- pints)
6.4-14.3- mm (1/4-9/16- in) below the bottom of
the fill hole Clearance, Tolerance and Adjustments
Maximum ring gear back face runout 0.102 mm (0.004 in)
Maximum differential case runout 0.076 mm (0.003 in)
Differential side gear thrust washer thickness 0.762 mm -
0.813 mm (0.030 in - 0.032 in) Differential pinion gear thrust washer thickness 0.762 mm -
0.813 mm (0.030 in - 0.032 in) Maximum axle shaft end play 0.762 mm (0.030 in)
Ring gear backlash 0.203 mm-
0.381 mm
(0.008 in- 0.015 in)
[(0.305 mm- 0.381 mm
(0.012 in- 0.015 in) preferred] Variation between teeth maximum backlash 0.102 mm (0.004 in)
Pinion flange runout 0.25 mm (0.010 in) T.I.R.
Torque Specifications Description Nm lb-
ft lb-
in Bolt retaining the differential pinion shaft to the differential case 30 22 —
Bolt retaining the driveshaft yoke to the pinion flange 112 83 —
Bolt retaining the differential housing cover to the differential housing 44 32 —
Oil filler plug 30 22 —
Pinion bearing preload (used pinion bearings) 0.9-
1.5 — 8-
14 Pinion bearing preload (new pinion bearings) 1.8-
3.3 — 16-
29 Adapter for 205-
S127 2.2 — 20 Klj . 1 ba
22003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

4 4222 Differential bearing cup
5 4067 Differential bearing shim
6 4216 Rear axle differential gear case bolt
7 4204 Differential case
8 — Ring gear (part of 4209)
9 — Bearing cap (part of 4010)
10 4010 Rear axle housing
11 373098-
S Filler plug
12 4662 Collapsible spacer
13 4670 Rear axle drive pinion shaft oil slinger
14 4676 Rear axle drive pinion seal
15 4851 Pinion flange
16 389546-S100 Pinion nut
17 4621 Differential pinion bearing
18 2C026 Rear brake disc
19 — Axle shaft flange (part of 4234)
20 2C189 Rear brake anti-
lock sensor indicator 21 2552 Rear disc brake caliper
22 N601951-S2 Bolt
23 N804361-S100 Clip
24 — Bolt
25 2C190 Rear brake anti-
lock sensor 26 2C101 Left hand rear disc brake adapter
27 2C100 Right hand rear disc brake adapter
28 N8015163-S190 Caliper anchor bolt
29 2C028 Rear wheel brake disc shield
30 N602726-S2 Bolt (3 req'd)
31 4616 Differential drive pinion bearing cup
32 4628 Rear axle pinion bearing cup
33 4630 Differential pinion bearing
34 — Drive pinion gear
(part of 4209)
35 4663 Drive pinion bearing adjustment shim
36 — Bolt (part of 4010)
37 4241 Differential pinion shaft lock bolt
38 4211 Differential pinion shaft
39 4N237 U-
washer 40 383548 Bolt
41 — Rear axle identification tag
42 4033 Differential housing cover
43 4230 Differential pinion thrust washer
44 4215 Differential pinion gear Klj . 2 ba
32003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

z
The axle housing assembly consists of a cast center section with two steel tube assemblies and
a stamped differential housing cover (4033). The differential housing cover uses silicone sealant
as a gasket.
z The hypoid- design gearset consists of 7.5- inch ring gear (4209) and a drive pinion gear (4209).
Two opposed tapered roller bearings support the drive pinion in the axle housing (4010).
z A collapsible spacer (4662), located on the differential pinion shaft, maintains pinion bearing
preload. The pinion nut adjusts the preload.
z Differential bearing shims (4067), located between the differential bearing cups (4222) and the
rear axle housing, adjust the differential bearing preload and the ring gear backlash.
z The differential case (4204) is a one- piece design with two openings to allow for assembly of
the internal components and lubricant flow. Two opposed tapered roller bearings (differential
bearings) (4221) support the differential case in the axle housing. Removable bearing caps
(4010) retain the differential assembly in the axle housing.
z Inside the differential case, the differential pinion shaft (4211) supports two differential pinion
gears (4215). The pinion gears engage the differential side gears (4236), to which the axle
shafts (4234) are splined. The differential pinion shaft lock bolt (4241) retains the differential
pinion shaft in the differential case.
z An embossed metal tag, bolted to the differential housing cover, contains rear axle
identification. Klj . 3 ba
32003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

IN-
VEHICLE REPAIR
Axle Shaft
Removal 1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. Remove the wheel and tire assembly. For additional information, refer to Section 204 - 04 .
3. Remove the rear brake disc (2C026). For additional information, refer to Section 206 - 04 .
4. Remove the differential housing cover (4033) and drain the lubricant. For additional information, refer to Differential Housing Cover in this section.
5. Remove the differential pinion shaft (4211). 1. Remove the differential pinion shaft lock bolt (4241).
2. Remove the differential pinion shaft.
6. CAUTION: Do not damage the rubber O- ring in the axle shaft groove.
Remove the U- washer (4N237).
1. Push the axle shafts (4234) inboard.
2. Remove the U- washer.
7. CAUTION: Damage to the rear brake anti- lock sensor (2C190) may occur if it is not
removed before the axle shaft.
Carefully remove the rear brake anti- lock sensor. For additional information, refer to Section SECTION 205-
02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring
Gear 2003 Mustang Workshop
Manual Klj . 1 ba
42003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

1. Position the two U-
washers on the button end of the axle shaft.
2. Pull the axle shaft outward.
4. NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with Threadlock and
Sealer EOAZ- 19554-AA or equivalent meeting Ford specification WSK-M2G351- A5 prior to
installation.
Install the differential pinion shaft. 1. Align the hole in the differential pinion shaft with the case lock bolt hole.
2. Install a new differential pinion shaft lock bolt.
5. Install the differential housing cover and fill the rear axle with the specified lubrication. For additional information, refer to Differential Housing Cover in this section.
6. Install the rear brake anti- lock sensor. For additional information, refer to Section 206 - 09A .
7. Install the rear brakes. For additional information, refer to Section 206 - 04 .
8. Install the tire and wheel assembly. For additional information, refer to Section 204 - 04 .
9. Lower the vehicle. Klj . 3 ba
42003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

5.
CAUTION: Do not under any circumstance loosen the nut to reduce preload. If it is
necessary to reduce preload, install a new collapsible spacer (4662) and nut.
CAUTION: Remove the special tool while taking preload readings with the Nm
(inch/pound) torque wrench.
Tighten the nut to set the preload.
zRotate the drive pinion occasionally to make sure the differential pinion bearings (4630)
(4621) seat correctly. Take frequent differential pinion bearing torque preload readings by
rotating the drive pinion with a Nm (inch/pound) torque wrench.
z If the preload recorded prior to disassembly is lower than the specification for used
bearings, then tighten the nut to specification. 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.
z Refer to the torque specification for used differential pinion bearings in the Specifications
portion of this section.
6. CAUTION: Align the index marks.
CAUTION: Install the driveshaft with new bolts. If new bolts are not available, apply
Threadlock and Sealer EOAZ-19554- AA or equivalent meeting Ford specification WSK-
M2G351- A5 to the threads of the original bolts.
CAUTION: The driveshaft centering socket yoke fits tightly on the pinion flange
pilot. To make sure that the yoke seats squarely on the flange, tighten the bolts evenly in
a cross pattern as shown.
Connect the driveshaft. For additional information, refer to Section 205 - 01 . Klj . 4 ba
52003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...