FORD MUSTANG 2003 Workshop Manual

0.304 0.012 0.406 0.016
0.330 0.013 0.457 0.018
0.335 0.014 0.457 0.018
0.381 0.015 0.508 0.020
Differential Shim Size Chart — 4067 —Numbers of Stripes and Color Code Dimension A
mm Inch
2—C-
COAL 7.7978-7.8105 0.3070-0.3075
1—C-
COAL 7.7470-7.7597 0.3050-0.3055
5—
BLU 7.6962-
7.7089 0.3030-0.3035
4—
BLU 7.6454-
7.6581 0.3010-0.3015
3—
BLU 7.5946-
7.6073 0.2990-0.2995
2—
BLU 7.5458-
7.5565 0.2970-0.2975
5—
PINK 7.4422-
7.4549 0.2930-0.2935
4—
PINK 7.3914-
7.4041 0.2910-0.2915
3—
PINK 7.3406-
7.3533 0.2890-0.2895
2—
PINK 7.2898-
7.3025 0.2870-0.2875
1—
PINK 7.2390-
7.2517 0.2850-0.2855
5—
GRN 7.1882-
7.2009 0.2830-0.2835
4—
GRN 7.1374-
7.1501 0.2810-0.2815
3—
GRN 7.0866-
7.0993 0.2790-0.2795
2—
GRN 7.0358-
7.0485 0.2770-0.2775
1—
GRN 6.9850-
7.0485 0.2750-0.2755
5—
WH 6.9342-
6.9469 0.2730-0.2735
4—
WH 6.8834-
6.8961 0.2710-0.2715
3—
WH 6.8326-
6.8453 0.2690-0.2695
2—
WH 6.7818-
6.7945 0.2670-0.2675
1—
WH 6.7310-
6.7437 0.2650-0.2655
5—YEL 6.6802-6.6929 0.2630-0.2635
4—YEL 6.6294-6.6421 0.2610-0.2615
3—YEL 6.5786-6.5913 0.2590-0.2595
2—YEL 6.5278-6.5405 0.2570-0.2575
1—YEL 6.4770-6.4897 0.2550-0.2555
5—
ORNG 6.4262-
6.4389 0.2530-0.2535
4—
ORNG 6.3754-
6.3881 0.2510-0.2515
3—
ORNG 6.3246-
6.3373 0.2490-0.2495
2—
ORNG 6.2738-
6.2865 0.2470-0.2475
1—
ORNG 6.2223-
6.2357 0.2450-0.2455
2—
RED 6.1722-
6.1849 0.2430-0.2435
1—
RED 6.1214-
6.1341 0.2410-0.2415 Klj . 33 ba
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Final assembly
58. CAUTION: The machined surfaces on the differential housing and the differential
housing cover must be clean and free of oil before applying the new silicone sealant.
Cover the inside of the axle before cleaning the machined surface to prevent
contamination.
CAUTION: Install the differential housing cover within 15 minutes of applying the
silicone material.
CAUTION: Allow the sealant to cure for one hour before filling the axle with
lubricant.
Apply a continuous bead of sealant, of the specified thickness, to the differential housing cover
mounting surface.
zUse Clear Silicone Rubber F7AZ- 19554-CA or equivalent meeting Ford specification
ESB- M4G92- A.
59. Install the differential housing cover.
60. CAUTION: First fill the rear axle (4001) with 118 ml (4 oz) of Additive Friction
Modifier C8AZ- 19B546-A or equivalent meeting Ford specification EST- M2C118-A.
Install the rear axle assembly in the vehicle. Fill the axle with the specified lubricant. For
additional information, refer to Axle Housing in this section. Klj . 34 ba
352003 Mustang Workshop Manual
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Klj . 35 ba
352003 Mustang Workshop Manual
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SPECIFICATIONS
SECTION 205-
05: Rear Drive Halfshafts 2003 Mustang Workshop Manual General Specifications
Item Specification
Halfshaft assembled length 817.6 mm (32.19 in)
Torque Specifications Description Nm lb-
ft Tie-
rod end to knuckle 47 35
Shock absorber to suspension lower arm 133 98
Suspension upper arm and bushing to knuckle 90 66
Rear brake anti-
lock sensor bolt 7 5
Rear axle wheel hub retainer 325 240 Klj . 1 ba
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DESCRIPTION AND OPERATION
Rear Drive Halfshafts
The rear wheel drive halfshaft system consists of and operates as follows:
zHalfshafts (4K138) transmit engine torque from the rear axle housing to the rear wheels.
z Halfshafts rotate at approximately one- third the speed of a driveshaft and do not contribute to
rotational vibration disturbances.
z A constant velocity (CV) joint is a mechanism for transmitting uniform torque and rotary motion
while operating through a range of angles.
z CV joints at both inboard (differential) and outboard (wheel) ends provide operating
smoothness.
z The inboard CV joints are plunge- type joints that provide the axial movement necessary to
affect shaft length changes.
z The outboard CV joints have a higher angle capability than the inboard CV joints to
accommodate suspension travel.
z Inboard and outboard CV joints connect to a splined shaft.
z A driveshaft bearing retainer circlip retains the splined inboard CV joint to the differential side
gear. Install a new circlip every time you remove the halfshaft from the vehicle.
z A rear axle wheel hub retainer secures the interconnecting shaft and outboard CV joint to the
rear hub.
z The lubed-for- life CV joints use special CV joint grease. They require no periodic lubrication.
z To separate the halfshaft from the rear hub, press the outboard CV joint from the rear hub.
z To separate the halfshaft from the differential, apply a load to the back face of the inboard CV
joint assembly to overcome the circlip.
z The halfshaft assemblies are not repairable. Install a new assembly if worn/damaged.
SECTION 205-
05: Rear Drive Halfshafts 2003 Mustang Workshop Manual Klj . 1 ba
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Halfshaft Handling
CAUTION: Never pick up or hold the halfshaft by the outboard joint.
Handle all halfshaft components carefully during removal and installation.
zDo not over- angle the CV joints.
z Damage will occur to an assembled inboard CV joint if it is over- plunged outward from the joint
housing.
z Never use a hammer to remove or install the halfshafts.
z Never use the halfshaft assembly as a lever to position other components. Always support the
free end of the halfshaft.
z Do not allow the boots to contact sharp edges or hot exhaust components. Item Part Number Description
1 4B422 Driveshaft bearing retainer circlip
2 2C189 Rear brake anti-
lock sensor indicator 3 — Retaining ring (part of 4B402)
4 4B478 Boot clamp (large inboard)
5 — Rear axle shaft inner boot (part of 4B402)
6 4B478 Boot clamp (small inboard)
7 4B478 Boot clamp (small outboard)
8 — Rear axle shaft outer boot (part of 4B402)
9 4B478 Boot clamp (large outboard)
10 2217 Dust seal assembly
11 4B402 Halfshaft assembly Klj . 2 ba
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z
Do not drop assembled halfshafts. The impact will cut the boots from the inside without
evidence of external damage.
z Inspect all machined surfaces and splines for damage.
Wheel and Tire Balancing, Rear
WARNING: Do not balance the rear wheels and tires while mounted on the vehicle.
Possible tire disintegration, differential or halfshaft failure can result, causing personal injury
or extensive component damage. Use an off- vehicle wheel and tire balancer only.
Hoisting
CAUTION: Use a frame- contact hoist only. Vehicle or component damage can result if
other types of hoists are used.
Never raise the vehicle using the halfshafts as lift points.
Undercoating and Rustproofing
During undercoating and rustproofing procedures, protect the boots from the coating materials.
Foreign materials on the rubber boots will cause extreme advanced wear. Klj . 3 ba
32003 Mustang Workshop Manual
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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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2. Raise and support the vehicle. For additional information, refer to
Section 100 - 02 .
3. Remove the rear wheel and tire assembly. For additional information, refer to Section 204 - 04 .
4. Remove and discard the rear axle wheel hub retainer.
5. Remove the rear brake disc. For additional information, refer to Section 206 - 04 .
6. Remove the rear brake anti- lock sensor and position aside.
7. Support the suspension lower arm and bushing. This will ease removal of the lower shock absorber mount bolt. Klj . 2 ba
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8. Disconnect the shock absorber at the suspension lower arm and bushing. Discard the nut and
the bolt.
9. Remove and discard the cotter pin and the nut.
10. Using the special tool, disconnect the tie- rod link at the knuckle. 11. Disconnect the suspension upper arm and bushing at the knuckle. Discard the nut and the bolt. Klj . 3 ba
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