manual transmission FORD MUSTANG 2003 Service Manual

If no improvement is noted, rotate the clamps in opposite directions, equal distances from the best
position determined in Step 8. Separate the clamp heads about 13 mm (1/2 inch) and recheck for
vibration at the road speed.
Repeat the process with increasing separation until the best combination is found or the vibration is
reduced to an acceptable level.
10. Install the wheels and road test (vibration noticeable on the hoist may not be evident during the road test). If the vibration is still not acceptable, install a new axle driveline vibration damper
first, if so equipped. If the vibration is still not acceptable, refer to Section 205 - 02A or
Section 205 - 02B for differential case and ring gear runout checks.
Driveshaft Vibrates 1. Road test the vehicle to determine the critical vibration points. Note the road speed, the engine RPM, and the shift lever positions at which the vibration occurs.
2. Stop the vehicle, place the transmission lever in neutral and run the engine through the critical speed ranges determined in Step 1.
3. If no vibration is felt, balance the driveshaft. Refer to Driveline Vibration in this section.
Traction- Lok® Differential Operation Check
A Traction-Lok® differential can be checked for correct operation without removing it from the rear axle
housing.
WARNING: A vehicle equipped with a Traction- Lok® differential will always have both
wheels driving. If only one wheel is raised off the floor and the rear axle is driven by the engine, the wheel on the floor could drive the vehicle off the stand or jack. Be sure both rear wheels are Klj . 14 ba
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off the floor.
With the engine off, raise only one rear wheel. Install the special tool on the wheel nuts.
Use a torque wrench with a capacity of at least 271 Nm (200 lb-
ft) to rotate the axle shaft. Be sure that
the transmission is in NEUTRAL, and that one rear wheel is on the floor while the other rear wheel is
raised off the floor. The breakaway torque required to start rotation must be at least 27 Nm (20 lb- ft).
The initial breakaway torque may be higher than the continuous turning torque.
The axle shaft must turn with even pressure throughout the check without slipping or binding. If the
torque reading is less than specified, check the differential case. Refer to Section 205 - 02A or
Section 205 - 02B .
Traction- Lok® Differential Check Road Test
1. Place one wheel on a dry surface and the other wheel on ice, mud or snow.
2. Gradually open the throttle to obtain maximum traction prior to break away. The ability to move the vehicle demonstrates correct operation of a Traction- Lok® rear axle assembly.
3. When starting with one wheel on an excessively slippery surface, a slight application of the parking brake may be necessary to help energize the Traction- Lok® feature of the differential.
Release the brake when traction is established. Use light throttle on starting to provide
maximum traction.
4. If, with unequal traction, both wheels slip, the limited slip rear axle has done all it can possibly do.
5. In extreme cases of differences in traction, the wheel with the least traction may spin after the Traction-Lok® has transferred as much torque as possible to the non- slipping wheel. Klj . 15 ba
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DESCRIPTION AND OPERATION
Driveshaft
NOTE:
All driveshaft assemblies are balanced. If undercoating the vehicle, protect the driveshaft to
prevent overspray of any undercoating material.
The driveshaft has the following features:
zA tubular shaft used to transfer engine torque from the transmission output shaft to the
differential in the rear axle housing, which transmits torque through the axle shafts to the drive
SECTION 205-
01: Driveshaft 2003 Mustang Workshop Manual Item Part Number Description
1 N800594-S100 Bolt (4 req'd)
2 4635 Universal joint (U-
joint) 3 4602 Driveshaft
4 — Grease seal (part of 4635)
5 — Needle bearings (part of 4635)
6 — Bearing cup (part of 4635)
7 — Thrust washer (part of 4635)
8 — Spider (part of 4635)
9 4841 Driveshaft slip yoke
10 — Snap ring (4 req'd)
(part of 4635)
11 4782 Driveshaft centering socket yoke
12 4851 Rear axle universal joint flange Klj . 1 ba
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wheels.
z Consists of two single- cardan universal joints, a driveshaft slip yoke, a welded tube assembly
and a driveshaft centering socket yoke.
z The splined driveshaft slip yoke permits the driveshaft to move forward and rearward on the
transmission output shaft during drivetrain movement and during driveshaft removal and
installation. Klj . 2 ba
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REMOVAL AND INSTALLATION
Driveshaft
Removal and Installation
1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. Carry out the following: 1. Place an index mark on the rear axle pinion flange and the driveshaft centering socket yoke.
2. Remove the four bolts.
3. CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle 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.
Using a suitable tool as shown, disconnect the driveshaft centering socket yoke from the rear
axle pinion flange.
4. CAUTION: Do not allow the slip yoke to bottom on the transmission output shaft. SECTION 205-
01: Driveshaft 2003 Mustang Workshop Manual Material
Item Specification
Threadlock® and
Sealer
E0AZ-
19554- AA WSK-
M2G351- A5 (type
II) Klj . 1 ba
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Lower the rear end of the driveshaft to clear the rear axle housing. Pull the driveshaft rearward
until the driveshaft slip yoke clears the transmission extension housing.
zPlace a paint index mark on the driveshaft slip yoke and the transmission output shaft.
z Place a commercially available plug in the extension housing to prevent fluid leakage.
5. CAUTION: Install the driveshaft with new bolts. If new bolts are not available, apply
threadlock and sealer to the threads of the original bolts.
CAUTION: Do not allow the slip yoke to bottom on the transmission output shaft.
CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion
flange pilot. To make sure that the yoke seats squarely on the flange, tighten the bolts
evenly in a cross pattern as shown.
NOTE: Clean all foreign material from the yoke areas of the driveshaft.
To install, reverse the removal procedure. Klj . 2 ba
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2. Remove the four bolts.
6. CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle 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.
Using a suitable tool as shown, disconnect the driveshaft centering socket yoke from the rear
axle pinion flange.
7. CAUTION: Do not allow the slip yoke to bottom on the transmission output shaft.
Lower the rear end of the driveshaft to clear the rear axle housing. Pull the driveshaft rearward
until the driveshaft slip yoke clears the transmission extension housing. zPlace a paint index mark on the driveshaft slip yoke and the transmission output shaft.
z Place a commercially available plug in the extension housing to prevent fluid leakage.
8. CAUTION: Install the driveshaft with new bolts. If new bolts are not available, apply
threadlock and sealer to the threads of the original bolts.
CAUTION: Do not allow the slip yoke to bottom on the transmission output shaft.
CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion
flange pilot. To make sure that the yoke seats squarely on the flange, tighten the bolts
evenly in a cross pattern as shown.
NOTE: Clean all foreign material from the yoke areas of the driveshaft.
To install, reverse the removal procedure. Klj . 2 ba
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9. Remove the stabilizer bar. For additional information, refer to
Section 204 - 02 .
10. Position a suitable transmission jack under the differential housing (4010) for support and strap it securely in place.
11. Remove and discard the nuts and bolts retaining the upper suspension arm and bushings to the differential housing. Klj . 3 ba
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21. Insert the special tool into the housing bore.
22. Remove the other halfshaft and knuckle assembly as described in the previous steps.
23. Support the differential housing (4010) with a transmission jack.
24. Remove the bolts.
25. Remove the nuts and bolts. Klj . 6 ba
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26.
CAUTION: Do not damage the axle vent hose.
Lower the rear axle assembly from the vehicle.
27. If removal of the mounting bushings is necessary, remove them by hand.
Installation 1. Install the bushings, if removed.
2. Using the transmission jack, raise the rear axle assembly into position.
3. Install the bolts and nuts.
4. Install the bolts. Klj . 7 ba
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