height FORD MUSTANG 2003 Owner's Guide

REMOVAL AND INSTALLATION
Axle Housing
Removal
1. CAUTION: The vehicle must be on level ground and at curb height.
Mark the rear shock absorbers relative to their protective sleeve. zDuring installation, raise the suspension to this reference mark before tightening the
suspension component fasteners.
SECTION 205-
02C: Rear Drive Axle/Differential — Ford 8.8-Inch IRS 2003 Mustang Workshop Manual Special Tool(s)
Plug Set, Differential
205-
294 (T89P-4850- B) Protector, Differential Seal
(Pair)
205-
461 Remover, Halfshaft
205-
475 Remover, Steering Arm
211-
003 (T64P-3590- F) Klj . 1 ba
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14.
CAUTION: Install the hardened washer between the lower suspension arm and
bushing and the shock absorber. Failure to do so can result in damage and failure of the
lower suspension arm and bushing.
Position the shock absorber, and install the bolt and the new nut.
15. Install the other halfshaft and knuckle assembly, toe link, and shock absorber as described in the previous steps.
16. Raise the suspension until the shock absorbers compress to the previously established alignment mark (curb height).
17. Tighten the nut. Klj . 11 ba
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a
Round off initial thickness to the nearest shim thickness as in example for final shim
thickness.
37. Remove the Dial Indicator and the differential case from the differential housing. 38. Draw - file the differential ring gear mounting surface to remove any nicks or burrs. 8.8-
inch Aluminum
Axle Left Differential Bearing
Height Right Differential Bearing
Height Example Actual Example Actual
Master bearing height 0.8695 0.8695 0.8695 0.8695
Line-
D Actual bearing
height -0.8478 Minus (-
) -0.8491 Minus (-)
Line-
E Difference 0.0217 0.0204
8.8-
inch Aluminum
Axle Left Side
8.8-
inch Aluminum
Axle Right Side
Example Actual Example Actual
Line-
B End play
Line- E Bearing height 0.2450
+0.0217 + Line-
C End play
Line- E Bearing height 0.2530
+0.0204 +
TOTAL Lines B and E
Backlash (subtract) 0.2667
-0.0060 -0.006 TOTAL Lines C and E
Backlash/preload (add) 0.2734
+0.020 +0.020
Initial thickness
a 0.2607 Initial thickness 0.2934
Final shim thickness
—
left 0.261 Final shim thickness —
right 0.293 Klj . 26 ba
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42.
NOTE: The bolts retaining the differential ring gear to the differential case may interfere while
carrying out this procedure. If so, remove three to five bolts to provide clearance.
Measure the end play. 1. Attach the special tool and position the indicator tip on the machined surface of the differential case flange.
2. Rock the differential ring gear to allow full mesh with the drive pinion gear.
3. With the gears in full mesh, set the special tool to zero.
4. Move the differential case as far as possible to the left and note the reading.
5. Record the reading on the differential bearing shim selection procedure line B.
„Remove the special tool.
43. Remove the differential case from the differential housing.
44. Remove the bolts. Apply Stud and Bearing Mount EOAZ-19554- BA or equivalent meeting Ford
specification WSK-M2G349- A1 to the bolt threads, and reinstall the bolts.
45. NOTE: Measure the stand height of both differential bearings prior to installation.
NOTE: Mark the differential bearings left and right before measuring them.
Install the special tool. Klj . 28 ba
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1. Place the special tool base in a soft-
jawed vise with the bearing mounting surface above
the vise jaws.
2. Position the differential bearing on the special tool base.
3. Attach the bolt, spring, washers and spacer.
4. Tighten the bolt.
46. Measure the differential bearing stand height. 1. Invert the special tool and clamp the bolt head in a vise.
2. Position a depth micrometer flat on the differential bearing.
47. Measure both differential bearings stand height. Record the measurement on the differential bearing shim selection procedure line D.
48. Press the left and right differential bearing on the differential case.
49. Install the special tools. Klj . 29 ba
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REMOVAL AND INSTALLATION
Halfshaft
Removal
NOTE:
This procedure applies to both the LH and RH halfshafts.
1. CAUTION: The vehicle must be on level ground and at curb height.
Mark the rear shock absorber relative to the protective sleeve. zDuring installation, raise the suspension to this reference mark before tightening the
suspension component fasteners.
SECTION 205-
05: Rear Drive Halfshafts 2003 Mustang Workshop Manual Special Tool(s)
Differential Plug
205-
294 (T89P-4850- B) Differential Seal Protector
205-
461 Front Hub Remover
205-
D070 (D93P-1175- B) or
Equivalent Halfshaft Removal Tool
205-
475 Steering Arm Remover
211-
003 (T64P-3590- F) Klj . 1 ba
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7. Connect the suspension upper arm and bushing to the knuckle.
1. Position the suspension upper arm and bushing on the knuckle.
2. Install the new bolt and a new nut. Do not tighten the nut at this time.
8. Connect the tie- rod end to the knuckle.
1. Position the tie- rod link in the knuckle.
2. Install a new nut.
3. Install a new cotter pin.
9. Raise the suspension until the shock absorber is compressed to the previously established alignment mark (curb height). Klj . 7 ba
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The function of the power brake booster check valve is to allow manifold vacuum to enter the power
brake booster and prevent the escape of vacuum in case manifold vacuum is lost during sustained full
throttle operation.
To test the function of the power brake booster check valve :
zStart and run the engine for at least 10 seconds.
z Operate the brake pedal to check for power assist.
z Disconnect the vacuum booster hose from the power brake booster check valve. Do not remove
the power brake booster check valve from the power brake booster.
z There should be enough vacuum retained in the brake booster for at least one more power-
assisted brake operation.
Brake Master Cylinder — Normal Conditions
The following conditions are considered normal and are not indications that the brake master cylinder
is in need of service.
Condition 1: During normal operation of the brake master cylinder, the fluid level in the brake master
cylinder reservoir will rise during brake application and fall during release. The net fluid level (i.e., after
brake application and release) will remain unchanged.
Condition 2: A trace of brake fluid will exist on the booster shell below the master cylinder mounting
flange. This results from the normal lubricating action of the master cylinder bore and seal.
Condition 3: Fluid level will decrease with pad wear.
Brake Master Cylinder — Abnormal Conditions
Changes in brake pedal feel or travel are indicators that something could be wrong in the brake
system. GO to Symptom Chart for abnormal condition diagnosis.
Bypass Condition Test 1. Disconnect the brake lines at the brake master cylinder.
2. Plug the outlet ports of the brake master cylinder.
3. Apply the brakes. If brake pedal height cannot be maintained, the brake master cylinder has an internal leak and must be rebuilt or replaced.
Compensator Port Check
The purpose of the compensator ports in the brake master cylinder is to supply any additional brake
fluid required by the system due to brake pad wear and to allow brake fluid returning from the brake
lines to the brake master cylinder to enter the brake master cylinder reservoir.
The returning brake fluid will cause a slight turbulence in the brake master cylinder reservoir. Klj . 14 ba
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z
excessive connecting rod bearing clearance
Valve Train Analysis— Engine Off—Valve Cover Removed
Check for damaged or severely worn parts and correct assembly. Make sure correct parts are used
with the static engine analysis as follows.
Valve Train Analysis— Engine Off, Rocker Arm
z Check for loose mounting bolts, studs and nuts.
z Check for plugged oil feed in the rocker arms (6564) or cylinder head.
Valve Train Analysis— Engine Off, Camshaft Roller Followers and Hydraulic Lash Adjusters,
Overhead Camshaft
zCheck for loose mounting bolts on camshaft carriers.
z Check for plugged oil feed in the camshaft roller followers, lash adjusters or cylinder heads.
Valve Train Analysis— Engine Off, Camshaft— Engines
z Check for broken or damaged parts.
Valve Train Analysis— Engine Off, Push Rods
z Check for bent push rods (6565) and restricted oil passage.
Valve Train Analysis— Valve Springs
z Check for broken or damaged parts.
Valve Train Analysis— Engine Off, Valve Spring Retainer and Valve Spring Retainer Keys
z Check for correct seating of the valve spring retainer key (6518) on the valve stem and in valve
spring retainer (6514).
z Check for correct seating on the valve stem.
Valve Train Analysis— Engine Off, Valves and Cylinder Head
z Check for plugged oil drain back holes.
z Check for worn or damaged valve tips.
z Check for missing or damaged guide- mounted valve stem seal.
z Check collapsed valve tappet gap.
z Check installed valve spring height.
z Check for missing or worn valve spring seats.
z Check for plugged oil metering orifice in cylinder head oil reservoir (if equipped).
Static checks (engine off) are to be made on the engine prior to the dynamic procedure. Klj . 14 ba
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Valve seat angle 44.75 degrees
Valve spring free length —
Valve spring squareness —
Valve spring compression pressure —
valve
open (without damper) 1000 N (224 lbs) @ 29.2 mm (1.16 in)
Valve spring compression pressure —
valve
closed (without damper) 350 N (79 lbs) @ 40.7 mm (1.62 in)
Valve spring installed height 40.7 mm (1.62 in)
Valve spring installed pressure —
Rocker arm ratio 1.73
Hydraulic Lash Adjuster
Diameter 22.195-
22.212 mm (0.8738- 0.8745 in) Clearance-
to-bore 0.018-
0.068 mm (0.0007- 0.0027 in) Service limit 0.127 mm (0.005 in)
Hydraulic leakdown rate a
Collapsed lash adjuster gap —
Camshaft
Theoretical valve lift @ 0 lash —
intake 11.30 mm (0.45 in)
Theoretical valve lift @ 0 lash —
exhaust 11.47 mm (0.45 in)
Lobe lift —
intake 6.53 mm (0.257 in)
Lobe lift —
exhaust 6.57 mm (0.259 in)
Allowable lobe lift loss 0.127 mm (0.005 in)
Journal diameter 52.082-
52.108 mm (2.0505- 2.0515 in) Camshaft journal bore inside diameter —
No. 1 55.689-
55.664 mm (2.192- 2.191 in) Camshaft journal bore inside diameter —
No. 2
and No. 3 55.308-
55.283 mm (2.177- 2.176 in) Camshaft journal bore inside diameter —
No. 4 55.684-
55.664 mm (2.192- 2.191 in) Camshaft journal-
to-bearing clearance 0.025-
0.076 mm (0.001- 0.003 in) Runout 0.05 mm (0.002 in) runout of No. 2 or No. 3
relative to No. 1 and No. 4 End play 0.025-
0.150 mm (0.001- 0.006 in) Cylinder Block
Cylinder bore diameter 96.813 mm (3.81 in)
Cylinder bore maximum taper 0.050 mm (0.002 in)
Cylinder bore maximum out-of-
round 0.050 mm (0.002 in)
Main bearing bore inside diameter 68.905 mm (2.713 in)
68.885 mm (2.712 in)
Camshaft bearing bore inside diameter —
intake 47.097 mm (1.8542 in) max. 47.072 mm (1.8532
in) min. Camshaft bearing bore inside diameter —
exhaust 39.739 mm (1.5645 in) max. 39.714 mm (1.5635
in) min. Head gasket surface flatness 0.08 mm (0.003 in) in 152.0 mm (6.00 in)
Crankshaft
Main bearing journal diameter 63.983-
64.003 mm (2.5190- 2.5198 in) Klj . 2 ba
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