FORD MUSTANG 2003 Workshop Manual

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
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206 - 09A .
8. CAUTION: Do not damage the wheel bearing oil seal.
Remove the axle shaft.
Installation 1. Lubricate the lip of the wheel bearing oil seal zUse Premium Long- Life Grease XG-1-C or equivalent meeting Ford specification ESA-
M1C75- B.
2. CAUTION: Do not damage the wheel bearing oil seal.
Install the two axle shafts.
3. CAUTION: Do not damage the rubber O- ring in the axle shaft groove.
Install the U- washer. Klj . 2 ba
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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
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Klj . 4 ba
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IN-
VEHICLE REPAIR
Rear Wheel Bearing and Axle Shaft Oil Seal
Removal 1. Remove the axle shaft (4234). For additional information, refer to Axle Shaft in this section.
2. NOTE: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged.
Using the special tools, remove the rear wheel bearing and wheel bearing oil seal.
SECTION 205-
02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring
Gear 2003 Mustang Workshop
Manual Special Tool(s)
Adapter for 303-
224
205- 153 (T80T-4000- W) Installer, Axle Shaft Bearing
205-
124 (T78P-1225- A) Installer, Rear Axle Oil Seal
205-
390 (T97T-1177- B) Remover, Axle Bearing
205-
219 (T85L-1225- AH) Slide Hammer
100-
001 (T50T-100- A) Klj . 1 ba
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Installation
1. Lubricate the new rear wheel bearing with the specified lubricant.
2. Using the special tools, install the new rear wheel bearing.
3. Lubricate the lip of the new wheel bearing oil seal. zUse Premium Long- Life Grease XG-1-C or equivalent meeting Ford specification ESA-
M1C75- B.
4. Using the special tools, install the new wheel bearing oil seal.
5. Install the axle shaft. For additional information, refer to Axle Shaft in this section. Klj . 2 ba
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Klj . 3 ba
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IN-
VEHICLE REPAIR
Drive Pinion Flange and Drive Pinion Seal
Removal 1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. Remove the rear wheel and tire assemblies. For additional information, refer to Section 204 - 04 .
3. CAUTION: Remove the rear brake calipers to prevent drag during the drive pinion
bearing preload adjustment.
CAUTION: Do not allow the calipers to hang from the brake hoses.
Remove the rear brake caliper and support bracket from the knuckle as an assembly. Wire the
caliper and support bracket assembly out of the way. For additional information, refer to Section 206 - 04 .
4. CAUTION: Index- mark the driveshaft flange and pinion flange (4851) to maintain
initial balance during installation.
CAUTION: The driveshaft centering socket yoke fits tightly on the 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.
Disconnect and position the driveshaft out of the way. For additional information, refer to
SECTION 205-
02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring
Gear 2003 Mustang Workshop
Manual Special Tool(s)
2-
Jaw Puller
205- D072 (D97L-4221- A) or
equivalent Holding Fixture, Drive Pinion
Flange
205-
126 (T78P-4851- A) Installer, Drive Pinion Flange
205-
002 (TOOL- 4858-E) or
equivalent Klj . 1 ba
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Section 205 - 01 .
5. Install an Nm (inch/pound) torque wrench on the nut and record the torque necessary to maintain rotation of the drive pinion gear through several revolutions.
6. CAUTION: After removing the nut, discard it. Use a new nut for installation.
Use the special tool to hold the pinion flange while removing the nut.
7. Index- mark the pinion flange and drive pinion gear stem to maintain initial balance during Klj . 2 ba
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installation.
8. Using the special tool, remove the pinion flange.
Installation 1. Inspect the pinion flange seal journal for rust, nicks, and scratches prior to installing the flange. Polish the seal journal with fine crocus cloth, if necessary.
2. Lubricate the pinion flange splines. zUse SAE 80W- 90 Premium Rear Axle Lubricant XY-80W90- QL or equivalent meeting
Ford specification WSP- M2C197-A.
3. NOTE: Disregard the index marks if installing a new pinion flange.
Position the pinion flange.
4. Using the special tools, install the pinion flange. Klj . 3 ba
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