FORD MUSTANG 2003 Workshop Manual

DESCRIPTION AND OPERATION
Rear Drive Axle and Differential
SECTION 205-
02C: Rear Drive Axle/Differential — Ford 8.8-Inch IRS 2003 Mustang Workshop Manual Item Part
Number Description
1 4067 Differential bearing shim
2 4222 Differential bearing cup
3 4204 Differential case
4 4216 Differential ring gear case bolt
5 4230 Differential pinion thrust washer
6 4211 Differential pinion shaft
7 4241 Differential pinion shaft lock bolt
8 — Differential ring gear (part of 4209)
9 4221 Differential bearing Klj . 1 ba
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z
The differential housing (4010) consists of a cast aluminum housing and a cast aluminum
differential housing cover (4033). The differential housing cover uses silicone sealant as a
gasket.
z The hypoid- design gearset consists of a 8.8- inch differential ring gear and a drive pinion gear.
Two opposed pinion bearings (4621) (4630) support the drive pinion gear in the differential
housing.
z A differential drive pinion collapsible spacer (4662), located on the drive pinion gear 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
differential housing, adjust the differential ring gear backlash and the differential bearing
preload.
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 differential bearings (4221) support
the differential case in the differential housing. Removable differential bearing caps retain the
differential assembly in the differential 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 halfshafts 10 4033 Differential housing cover
11 4B416 Inboard CV joint stub shaft pilot bearing housing
seal
12 4B413 Inboard CV joint stub shaft pilot bearing
13 4010 Differential housing
14 4662 Differential drive pinion collapsible spacer
15 4670 Rear axle drive pinion shaft oil slinger
16 4851 Rear axle pinion flange
17 389546-
S100 Pinion nut
18 4859 Drive pinion oil seal deflector
19 4676 Rear axle drive pinion seal
20 4621 Pinion bearing
21 4616 Differential drive pinion bearing cup
22 56187-
S Bolt
23 — Drive pinion gear (part of 4209)
24 — Differential bearing cap
(part of 4010)
25 4628 Rear axle pinion bearing cup
26 4630 Pinion bearing
27 4663 Drive pinion bearing adjustment shim
28 4A321 Rear axle differential clutch shim
29 — Clutch plate (part of 4947)
30 — Clutch disc (part of 4947)
31 4236 Differential side gear
32 4214 Differential clutch spring
33 4215 Differential pinion gear
34 4947 Differential clutch pack Klj . 2 ba
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are splined. The differential pinion shaft lock bolt retains the differential pinion shaft in the
differential case.
z A circlip, located on the inboard CV joint stub shaft, holds the halfshaft in the differential case.
When installed, the circlip engages a groove in the differential side gear.
z The rear axle uses SAE 75W- 140 High Performance Rear Axle Lubricant F1TZ-19580- B or
equivalent meeting Ford specification WSL-M2C192- A.
z An embossed metal tag, bolted to the differential housing cover, contains rear axle
identification. For additional information, refer to Section 205 - 00 . Klj . 3 ba
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IN-
VEHICLE REPAIR
Stub Shaft Pilot Bearing and Seal
Removal 1. Remove the halfshaft assembly. zThe knuckle and halfshaft are removable as an assembly. For additional information,
refer to Axle Housing in this section. If it is necessary to remove the halfshaft from the
knuckle, refer to Section 205 - 05 .
2. NOTE: If only removing the inboard CV joint stub shaft pilot bearing housing seal (4B416),
SECTION 205-
02C: Rear Drive Axle/Differential — Ford 8.8-Inch IRS 2003 Mustang Workshop Manual Special Tool(s)
Remover, Bearing Cup
308-
047 (T77F-1102- A) Protector, Differential Seal
(Pair)
205-
461 Installer, Differential Oil Seal
205-
293 (T89P-4850- A) Adapter for 303-
224 (Handle)
205- 153 (T80T-4000- W) Slide Hammer
100-
001 (T50T-100- A) Installer, Needle Bearing
205-
288 (T89P-1244- A) Klj . 1 ba
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engage the tangs of the special tool only on the seal.
Using the special tools, remove the inboard CV joint stub shaft pilot bearing housing seal and
the inboard CV joint stub shaft pilot bearing (4B413).
1. Firmly engage the tangs of the special tool on the bearing.
2. Remove the bearing and the seal.
Installation 1. Inspect the seal journal for rust, nicks and scratches. Polish the seal journal with fine crocus cloth, if necessary.
2. Lubricate the new inboard CV joint stub shaft pilot bearing. zUse SAE 75W- 140 High Performance Rear Axle Lubricant F1TZ-19580- B or equivalent
meeting Ford specification WSL- M2C192-A.
3. CAUTION: Installation without the correct tools can result in early bearing failure.
Place the inboard CV joint stub shaft pilot bearing onto the special tools.
4. Install the inboard CV joint stub shaft pilot bearing. Klj . 2 ba
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5. Lubricate the lip of the new inboard CV joint stub shaft pilot bearing housing seal.
zUse Premium Long- Life Grease XG-1-C or equivalent meeting Ford specification ESA-
M1C75- B.
6. CAUTION: Installation without the correct tools can result in early seal failure.
Place the inboard CV joint stub shaft pilot bearing housing seal onto the special tools.
7. CAUTION: If the inboard CV joint stub shaft pilot bearing housing seal becomes
misaligned in the bore during installation, remove it and install a new one.
Carefully align the inboard CV joint stub shaft pilot bearing housing seal in the housing bore and
install the seal.
8. CAUTION: Use special tool 205- 461 to avoid damaging the new inboard CV joint
stub shaft pilot bearing housing seal when installing the halfshaft.
Install the halfshaft.
zIf the knuckle and halfshaft were removed as an assembly, refer to Axle Housing in this
section. If the halfshaft was removed from the knuckle, refer to Section 205 - 05 . Klj . 3 ba
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Klj . 4 ba
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IN-
VEHICLE REPAIR
Drive Pinion Flange
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 rear axle pinion flange (4851) to
maintain initial balance during installation.
CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion
flange pilot. Never hammer on the driveshaft (4602) 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 - 01 .
SECTION 205-
02C: Rear Drive Axle/Differential — Ford 8.8-Inch IRS 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. 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 rear axle pinion flange while removing the nut.
7. Index- mark the rear axle pinion flange and drive pinion gear stem to maintain initial balance
during installation. Klj . 2 ba
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8. Using the special tool, remove the rear axle pinion flange.
Installation 1. Inspect the rear axle 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 rear axle pinion flange splines. zUse SAE 75W- 140 High Performance Rear Axle Lubricant F1TZ-19580- B or equivalent
meeting Ford specification WSL- M2C192-A.
3. NOTE: Disregard the index marks if installing a new rear axle pinion flange.
Position the rear axle pinion flange.
4. Using the special tools, install the rear axle pinion flange. Klj . 3 ba
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