differential FORD MUSTANG 2003 Owner's Guide

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
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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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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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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
32003 Mustang Workshop Manual
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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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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
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IN-
VEHICLE REPAIR
Differential Housing Cover
Removal 1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. NOTE: Empty the lubricant into a clean container for reuse.
Remove the differential housing cover (4033). 1. Remove the 10 bolts and drain the lubricant from the differential housing (4010).
2. Remove the differential housing cover.
Installation 1. CAUTION: Make sure the machined surfaces on both the differential housing and
the differential housing cover are clean and free of oil before applying the new silicone
sealant. To prevent contamination, cover the inside of the rear axle (4001) prior to
cleaning the machined surface.
Clean the differential housing and the differential housing cover gasket mating surfaces.
2. CAUTION: Install the differential housing cover within 15 minutes of applying the
silicone, or it will be necessary to remove and reapply new sealant.
Apply a continuous bead of sealant of the specified thickness to the differential housing cover.
zUse Clear Silicone Rubber F7AZ- 19554-CA or equivalent meeting Ford specifications
ESB- M4G92- A.
SECTION 205-
02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring
Gear 2003 Mustang Workshop
Manual Klj . 1 ba
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3.
NOTE: If possible, allow one hour before filling the axle with lubricant to make sure the silicone
sealant has cured.
Install the differential housing cover. 1. Install the differential housing cover.
2. Install the 10 bolts.
4. NOTE: 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.
Fill the rear axle to the level shown, approximately 1.54-1.66- liters (3.25-3.50-pints) of lubricant,
and install the filler plug.
zUse SAE 80W- 90 Premium Rear Axle Lubricant XY-80W90- QL or equivalent meeting
Ford specification WSP- M2C197-A.
5. Lower the vehicle. Klj . 2 ba
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IN-
VEHICLE REPAIR
Axle Housing Bushing
Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure can result in major service expense. A new part with
the same part number must be installed if installation becomes necessary. If substitution is
necessary, the part must be of the same finish and property class. Torque values must be used
as specified during reassembly to make sure of correct retention of these parts.
1. Remove the upper arm and bushing (5500). For additional information, refer to Section 204 - 02 .
2. Using the special tools, remove the bushing.
Installation 1. Using the special tools, install the bushing.
SECTION 205-
02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring
Gear 2003 Mustang Workshop
Manual Special Tool(s)
Axle Suspension Bushing Set
204-
S030 (T78P-5638- A) Klj . 1 ba
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IN-
VEHICLE REPAIR
Drive Pinion SECTION 205-
02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring
Gear 2003 Mustang Workshop
Manual Special Tool(s)
Adapter for 205-
S127
205- 105 (T76P-4020- A3) Adapter for 205-
S127
205- 109 (T76P-4020- A9) Adapter for 205-
S127
205- 110 (T76P-4020- A10) Adapter for 205-
S127
205- 111 (T76P-4020- A11) Adapter for 205-
S127
205- 125 (T78P-4020- A15) Adapter for 303-
224
205- 153 (T80T-4000- W) Gauge Tube
205-
D034 (D80T-4020- F49) or
equivalent Handle (Long)
205-
D055 (D81L-4000- A) or Klj . 1 ba
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