oil FORD MUSTANG 2003 Service Manual

14. Install the outer differential pinion bearing.
15. Install the rear axle drive pinion shaft oil slinger.
16. Install the drive pinion assembly (drive pinion, shims, bearing, and the collapsible spacer) into
the differential housing bore.
17. NOTE: Coat the rear axle drive pinion seal lips with Premium Long- Life Grease XG-1-C or
equivalent meeting Ford specification ESA-M1C75- B.
Place the rear axle drive pinion seal on the special tool. Klj . 10 ba
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Oil filler plug 30 22 —
Pinion bearing preload (used pinion bearings) 0.9-
1.5 — 8-
14 Pinion bearing preload (new pinion bearings) 1.8-
3.3 — 16-
29 Adapter for 205-
S127 2.2 — 20
Bolt retaining the bearing cap to the differential case 105 77 —
Bolt retaining the ring gear to the differential case 105 77 — Klj . 2 ba
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4 4222 Differential bearing cup
5 4067 Differential bearing shim
6 4216 Rear axle differential gear case bolt
7 4204 Differential case
8 — Ring gear (part of 4209 gearset)
9 — Bearing cap (part of 4010)
10 4010 Rear axle housing
11 373098-
S Filler plug
12 4662 Collapsible spacer
13 4670 Rear axle drive pinion shaft oil slinger
14 4676 Rear axle drive pinion seal
15 4851 Pinion flange
16 389546-S100 Pinion nut
17 4621 Differential pinion bearing
18 2C026 Rear brake disc
19 — Axle shaft flange (part of 4234)
20 2C189 Rear brake anti-
lock sensor indicator 21 2552 Rear disc brake caliper
22 N601951-S2 Bolt
23 N804361-S100 Clip
24 — Bolt (part of 4010)
25 2C190 Rear brake anti-
lock sensor 26 2C101 Left hand rear disc brake adapter
27 2C100 Right hand rear disc brake adapter
28 N8015163-S190 Caliper anchor bolt
29 2C028 Rear wheel brake disc shield
30 N602726-S2 Bolt (3 req'd)
31 4616 Differential drive pinion bearing cup
32 4628 Rear axle pinion bearing cup
33 4630 Differential pinion bearing
34 — Drive pinion gear (part of 4209 gearset)
35 4663 Drive pinion bearing adjustment shim
36 — Bolt (part of 4010)
37 4241 Differential pinion shaft lock bolt
38 4211 Differential pinion shaft
39 4N237 U-
washer 40 383548 Bolt
41 — Rear axle identification tag (part of 4001)
42 4033 Differential housing cover
43 4230 Differential pinion thrust washer
44 4215 Differential pinion gear Klj . 2 ba
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206 - 09A .
8. CAUTION: Do not damage the wheel bearing oil seal.
Remove the axle shaft.
Installation 1. Lubricate the lip of the wheel bearing oil seal zUse Premium Long- Life Grease XG-1-C or equivalent meeting Ford specification ESA-
M1C75- B.
2. CAUTION: Do not damage the wheel bearing oil seal.
Install the two axle shafts.
3. CAUTION: Do not damage the rubber O- ring in the axle shaft groove.
Install the U- washer. Klj . 2 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-
02B: Rear Drive Axle/Differential — Ford 8.8-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
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Installation
1. Lubricate the new rear wheel bearing with the specified lubricant.
2. Using the special tools, install the new rear wheel bearing.
3. Lubricate the lip of the new wheel bearing oil seal. zUse Premium Long- Life Grease XG-1-C or equivalent meeting Ford specification ESA-
M1C75- B.
4. Using the special tools, install the new wheel bearing oil seal.
5. Install the axle shaft. For additional information, refer to Axle Shaft in this section. Klj . 2 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 D6AZ- 19562-AA or equivalent meeting Ford specifications
ESB- M4G92- A.
SECTION 205-
02B: Rear Drive Axle/Differential — Ford 8.8-Inch Ring
Gear 2003 Mustang Workshop
Manual Klj . 1 ba
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equivalent
Holding Fixture, Drive Pinion
Flange
205-
126 (T78P-4851- A) Installer, Drive Pinion Bearing
Cone
205-
005 (T53T-4621- C) Installer, Drive Pinion Bearing
Cup
205-
024 (T67P-4616- A) Installer, Drive Pinion Bearing
(Outer)
205-
231 (T85T-4616- AH) Installer, Drive Pinion Flange
205-
002 (TOOL- 4858-E) or
equivalent Installer, Drive Pinion Oil Seal
205-
133 (T79P-4676- A) Plate, Bearing/Oil Seal
205-
090 (T75L-1165- B) Protector, Drive Pinion Thread
205-
460 Klj . 2 ba
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Removal
1. Remove the differential assembly from the differential housing. For additional information, refer to Differential Case in this section.
2. CAUTION: Record the torque necessary to maintain rotation of the drive pinion gear
through several revolutions prior to removing the pinion flange (4851).
Remove the pinion flange. For additional information, refer to Drive Pinion Flange and Drive Pinion Seal in this section.
3. Force the rear axle drive pinion seal metal flange up. Install gripping pliers and strike with a hammer to remove the seal.
4. Remove the rear axle drive pinion shaft oil slinger (4670).
5. Using the special tool and a soft-faced hammer, drive the pinion assembly out of the outer differential pinion bearing (4621) and remove the drive pinion through the rear of the differential
housing (4010). Puller, Bearing
205-
D064 (D84L-1123- A) or
equivalent Klj . 3 ba
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Setting pinion depth
7. NOTE: Apply only a light oil film on the differential pinion bearings before assembling the tools.
Assemble and position the following in the differential housing.
8. NOTE: This step duplicates final differential pinion bearing preload. Item Part
Number Description
1 205-109 Adapter for 205-
S127 (T76P-4020- A9) 2 205-105 Adapter for 205-
S127 (T76P-4020- A3) (1.612 inch
O.D.) 3 4630 Rear (inner) pinion bearing
4 205-129 Adapter for 205-
S127 (T79P-4020- A18) (1.1884
inch thick) 5 205-110 Adapter for 205-
S127 (T76P-4020- A10) (1.7 inch
thick) 6 4621 Front (outer) pinion bearing
7 205-111 Adapter for 205-
S127 (T76P-4020- A11) Klj . 7 ba
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