lock FORD MUSTANG 2003 Service Manual

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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z
For new differential pinion bearings, tighten the nut to specification. Refer to torque
specifications for new differential pinion bearings in the Specifications portion of this
section.
z For used differential pinion bearings, if the preload recorded prior to disassembly is lower
than the specification for used bearings, then tighten the nut to specification. Refer to
torque specifications for used differential pinion bearings in the Specifications portion of
this section.
z For used differential pinion bearings, 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.
Final assembly 23. Install the differential assembly in the differential housing. For additional information, refer to Differential Case in this section.
24. 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 .
25. Lower the vehicle. Klj . 12 ba
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Remove the axle shafts. For additional information, refer to
Axle Shaft in this section.
3. Wipe the lubricant from the internal working parts and inspect the parts for wear and damage.
4. Rotate the differential assembly to check for roughness indicating bearing/gear damage.
5. Using a suitable dial indicator and the special tool, measure and note the ring gear backface runout.
6. CAUTION: Mark the position and location of the bearing caps, as the arrows may
not be visible. Always install the bearing caps in their identical locations and positions.
Remove the bearing caps. 1. Remove the bolts.
2. Remove the bearing caps.
7. WARNING: Do not allow the differential assembly to fall. Failure to follow these
instructions may result in personal injury and component damage. CAUTION: Place a wood block between the pry bar and the differential housing Klj . 2 ba
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(4010) to protect the machined surface from damage.
Using a pry bar and a wood block, remove the differential assembly from the differential
housing.
8. Remove the 10 bolts.
9. CAUTION: Do not damage the threads in the bolt holes.
Insert a punch in the bolt holes, and drive off the ring gear.
10. If the ring gear backface runout measurement, taken at the beginning of this procedure, did not exceed the specification, proceed to the appropriate procedure as necessary: Drive Pinion ,
Differential Case and Ring Gear — Conventional or
Differential Case and Ring Gear — Traction -
Lok ® in this section, or to Installation in this procedure. If the ring gear backface runout
measurement, taken at the beginning of this procedure, exceeded the specification, the cause
may be a warped ring gear, differential case/differential bearing damage. Proceed as follows to
verify the cause of the excessive runout.
11. Position the differential assembly, including the differential bearing cups (4222) and differential bearing shims (4067), in the differential housing. Install the bearing caps and bolts. Klj . 3 ba
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REMOVAL AND INSTALLATION
Axle Housing
Removal and Installation
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 fasteners.
2. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
3. Remove the rear wheel and tire assemblies. For additional information, refer to Section 204 - 04 .
4. NOTE: If necessary, use Rust Penetrant and Inhibitor F2AZ-19A501- A meeting Ford
specification ESR-M99C56- A to loosen the sensor for removal.
Remove the rear anti- lock brake sensors from the rear disc brake adapters. For additional
information, refer to Section 206 - 09A .
5. Disconnect the parking brake cables and conduits from the rear disc brake calipers. For additional information, refer to Section 206 - 05 .
SECTION 205-
02B: Rear Drive Axle/Differential — Ford 8.8-Inch Ring
Gear 2003 Mustang Workshop
Manual Klj . 1 ba
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17. Remove the axle from the vehicle.
18.
CAUTION: Align the index marks on the driveshaft centering socket yoke and the
pinion flange.
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.
CAUTION: Raise the suspension to the reference marks on the rear shock
absorbers before tightening the suspension fasteners.
NOTE: Apply High Temperature Nickel Anti- Sieze Lubricant F6AZ-9L494-AA meeting Ford
specification ESE-M124A- A to the rear anti-lock brake sensor body where it will make contact
when installed.
Follow the removal procedure in reverse order.
zRefer to Section 204 - 02 for rear suspension fastener tightening specifications.
z Refer to Section 204 - 04 for wheel nut tightening specification. Klj . 5 ba
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SPECIFICATIONS
SECTION 205-
02C: Rear Drive Axle/Differential — Ford 8.8-Inch IRS 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants/Adhesive/Sealants
Premium Long-
Life Grease XG -1-C ESA-
M1C75- B SAE 75W-
140 High Performance Rear Axle Lubricant F1TZ-
19580- B WSL-
M2C192- A Additive Friction Modifier C8AZ-
19B546-A EST-
M2C118- A Clear Silicone Rubber F7AZ-
19554-CA ESB-
M4G92- A Stud and Bearing Mount EOAZ-19554-
BA WSK-
M2G349- A1 Threadlock and Sealer EOAZ-19554-
AA WSK-
M2G351- A5 High Temperature Nickel Anti-
Seize Lubricant F6AZ-9L494-
AA ESE-
M12A4-A Capacity
Additive Friction Modifier 118 ml (4 oz)
Rear axle lubricant 1.23-
1.37 liters (2.6- 2.9 pints) Rear axle lubricant level 6.35 mm (1/4 inch) from the bottom of
the fill hole Clearance, Tolerance and Adjustments
Maximum carrier spread 0.762 mm (0.030 in)
Maximum differential ring gear backface runout 0.076 mm (0.003 in)
Maximum differential case runout 0.076 mm (0.003 in)
Backlash between differential ring gear and pinion teeth 0.203 mm (0.008 in)-
0.330 mm (0.013
in) Preferred backlash 0.254 mm (0.010 in)
Maximum backlash variation between teeth 0.1016 mm (0.004 in)
Maximum radial runout of rear axle pinion flange in
assembly TIR 0.254 mm (0.010 in)
Available drive pinion bearing adjustment shim in steps of:
0.0254 mm (0.001 in) 0.254 mm (0.010 in)-
0.965 mm (0.038
in) Lubricant deflector to differential housing cover 5.08 mm (0.200 in)-
6.35 mm (0.250 in)
Torque Specifications Description Nm lb-
ft lb-
in Rear axle wheel hub retainer 340 251 —
Driveshaft to pinion flange bolt 112 83 —
Rear axle differential front lower insulator nut and bolt 70 52 —
Rear axle differential rear insulator bolt 103 76 —Klj . 1 ba
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a
Use Stud and Bearing Mount EOAZ-19554- BA or equivalent meeting Ford specification WSK-
M2G349- A1.
b With pinion flange yoke seal. Pinion nose crossmember nut 250 184 —
Toe link nut 47 35 —
Shock absorber to lower suspension arm and bushing 133 98 —
Knuckle to lower suspension arm and bushing 115 85 —
Knuckle to upper suspension arm and bushing 90 66 —
Filler plug 34 25 —
Ring gear bolt
a 105 77 —
Differential pinion shaft lock bolt 30 22 —
Bearing cap bolt 105 77 —
Differential housing cover bolt 32 24 —
Pinion bearing preload
—(drive pinion collapsible spacer) used bearings b 0.9-
1.16 — 8-14
New pinion bearings 1.8-
3.2 — 16-
29 Traction-
Lok® clutch gauge nut 6.7 — 60
Initial minimum breakaway torque 27 20 —Klj . 2 ba
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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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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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