FORD MUSTANG 2003 Workshop Manual

DESCRIPTION AND OPERATION
Universal Joints
The universal joints are:
zlubed- for-life design and require no lubrication.
z equipped with nylon thrust washers, located at each base of the bearing cup, which control end
play, position the needle bearing and improve grease movement.
SECTION 205-
01: Driveshaft 2003 Mustang Workshop Manual Item Part Number Description
1 4635 Universal joint (U-
joint) 2 — Grease seal (part of 4635)
3 — 32 needle bearings (part of 4635)
4 — Thrust washer (part of 4635)
5 — Bearing cup (part of 4635)
6 — Spider (part of 4635) Klj . 1 ba
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Klj . 2 ba
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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
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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
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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
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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
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Klj . 3 ba
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DISASSEMBLY AND ASSEMBLY
Driveshaft Slip Yoke
Disassembly
1. Remove the driveshaft (4602). For additional information, refer to Driveshaft in this section.
2. CAUTION: Under no circumstances is the driveshaft assembly to be clamped in the
jaws of a vise or similar holding fixture. Denting or localizing fracture can result, causing
driveshaft failure during vehicle operation.
Place the driveshaft (4602) on a suitable workbench. Be careful not to damage the tube.
3. NOTE: If components are not marked and therefore installed incorrectly, driveline imbalance
can occur.
Index- mark the driveshaft components.
4. Clamp the special tool in a vise.
SECTION 205-
01: Driveshaft 2003 Mustang Workshop Manual Special Tool(s)
Installer/Remover, C Frame
and Screw
205-
086 (T74P-4635- C) Klj . 1 ba
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5. Remove all four of the snap rings.
6.
NOTE: If necessary, use a pair of pliers to remove a bearing cup if it cannot be pressed out all
the way.
Remove the driveshaft slip yoke (4841).
1. Position the driveshaft slip yoke in the U- joint tool.
2. Press out a bearing cup.
3. Rotate the driveshaft slip yoke.
4. Press on the spider to remove the remaining bearing cup.
5. Remove the driveshaft slip yoke.
7. Repeat Step 5 to remove the remaining bearing cups and spider from the driveshaft.
8. Clean the yoke area at each end of the driveshaft.
Assembly 1. NOTE: Universal joint service kits are to be installed as complete assemblies only. Do not mix
components from other U- joint kits.
Install the bearing cup. 1. Start a new bearing cup into the driveshaft yoke. Klj . 2 ba
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„
Check the needle bearings for correct positioning.
2. Position the new spider in the driveshaft yoke.
3. Using the special tool, press the bearing cup to just below the snap ring groove.
2. NOTE: Use the yellow snap rings supplied in the kit to assemble the universal joint (U- joint). If
difficulty is encountered with the yellow snap rings, install the black snap rings, as required.
Remove the driveshaft from the special tool, and install the snap ring.
3. Repeat Steps 1 and 2 to install the opposite side of the driveshaft yoke.
4. Inspect the driveshaft slip yoke. Install new if necessary.
5. Repeat Steps 1 and 2 to install the remaining new bearing cups, spider, driveshaft slip yoke, and the snap rings.
6. NOTE: Do not strike the bearings.
Check the U- joints for freedom of movement.
z If binding, strike the yoke with a brass or plastic hammer.
7. Install the driveshaft. For additional information, refer to Driveshaft in this section. Klj . 3 ba
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