length FORD MUSTANG 2003 Workshop Manual

Lateral runout means measuring the movement or "wobble" of a wheel or tire at the sidewall. Radial
runout means measuring the out-of-
round at the tread surface.
Rustling
Intermittent sound of varying frequency (100- 2000 Hz), sounds similar to shuffling through leaves.
Shake
A low- frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires,
wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed
sensitive. Also referred to as a shimmy or wobble.
Shimmy
An abnormal vibration or wobbling, felt as a side- to-side motion of the steering wheel in the driveshaft
rotation. Also described as waddle.
Shudder
A low- frequency vibration that is felt through the steering wheel or seat during light brake application.
Slap
A resonance from flat surfaces, such as safety belt webbing or door trim panels.
Slip Yoke/Slip Spline
The driveshaft coupling that allows length changes to occur while the suspension articulates and while
the driveshaft rotates.
Squeak
A high- pitched transient sound, similar to rubbing fingers against a clean window.
Squeal
A long- duration, high- pitched noise.
Static Balance
The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can
cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear.
Tap
A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge.
Thump
A dull beat caused by two items striking together. Tick Klj . 9 ba
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glass
zAir traveling up
windshield molding
along A- pillar. z
INSTALL foam rope the
full length of the A- pillar.
z Windshield/backlite
misaligned or not
installed correctly. z
REINSTALL the
windshield/backlite.
z Rear hood seal at base
of windshield
misaligned/damaged. z
REALIGN or INSTALL a
new seal as necessary.
z Air leak at cowl zCowl gasket
misaligned/damaged. z
REALIGN or INSTALL a
new seal as necessary.
z Air leak around
liftgate perimeter z
Loose fit seal. zPINCH the seal carrier to
improve retention on the
seal flange or INSERT
foam in the carrier.
z Seal misaligned. zREINSTALL the seal.
z Liftgate misaligned. zREALIGN the liftgate.
CHECK the liftgate fit in
the body opening and
ADJUST as necessary.
z Scuff plate misaligned. zREINSTALL the scuff
plate.
z Seal or seal push pins
damaged. z
INSTALL a new seal.
z Air leak around
the liftgate flip
window
perimeter z
Loose fit seal. zPINCH the seal carrier to
improve the retention to
the seal flange.
z Seal misaligned. zREINSTALL the seal.
z Glass misaligned. zREALIGN the glass.
z Seal damaged. zINSTALL a new seal.
z Wind noise from
antenna z
Shape of antenna. zINSTALL an antenna boot
or a spiral antenna.
z Air leak around
antenna cable access
hole. z
INSPECT the antenna
access hole grommet.
REPAIR as necessary.
z Air leak from
closed roof
opening panel z
Seal installed
incorrectly. z
REINSTALL the seal.
z Roof opening panel
glass/door misaligned. z
REALIGN the roof
opening panel glass/door.
z Roof opening panel
damaged. z
INSTALL a new roof
opening panel.
z Buffeting from an
open roof
opening panel z
Wind deflector
inoperative/damaged. z
REPAIR or INSTALL a
new wind deflector as
necessary.
z Wind deflector height
incorrect. z
ADJUST the wind
deflector higher.
z Wind noise
created by
airflow over or
behind body
panels z
Fender splash shield
misaligned. z
REALIGN the fender
splash shield. Klj . 14 ba
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5. In the following steps, the movement of the contact pattern along the length is indicated as
toward the" heel" or "toe" of the differential ring gear.
6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is
obtained. Inspect the contact patterns on the ring gear teeth.
7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always be some clearance between the contact pattern and the top of the tooth.
z Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. Item Description
1 Heel
2 Toe Klj . 65 ba
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Repair the axle as necessary. Make sure the axle lubricant is at the correct level. Refer to
Specifications in this section.
Axle Vent
NOTE:
If a plugged vent cannot be cleared, install a new one.
A plugged vent will cause excessive seal lip wear due to internal pressure buildup. If a leak occurs,
check the vent. Make sure the vent hose is not kinked. Remove the hose from the vent nipple and
clear the hose of any foreign material. While the hose is removed, pass a length of mechanics wire in
and out of the vent to clean it. Connect the hose when done.
Flange Yoke Seal
Leaks at the axle drive pinion seal originate for the following reasons:
zSeal was not correctly installed.
z Poor quality seal journal surface.
Any damage to the seal bore (dings, dents, gouges, or other imperfections) will distort the seal casing
and allow leakage past the outer edge of the axle drive pinion seal.
The axle drive pinion seal can be torn, cut, or gouged if it is not installed carefully. The spring that
holds the axle drive pinion seal against the pinion flange may be knocked out and allow leakage past
the lip.
The rubber lips can occasionally become hard (like plastic) with cracks at the oil lip contact point. The
contact point on the pinion flange may blacken, indicating excessive heat. Marks, nicks, gouges, or
rough surface texture on the seal journal of the pinion flange will also cause leaks.
When a seal leak occurs, install a new seal and check the vent and the vent hose to make sure they
are clean and free of foreign material.
Axle Shaft Seals
Axle shaft oil seals are susceptible to the same kinds of damage as axle drive pinion seals if incorrectly
installed. The seal bore must be clean and the lip handled carefully to avoid cutting or tearing it. The
axle shaft journal surface must be free of nicks, gouges, and rough surface texture.
Differential Seals
Refer to Section 205 - 02A or
Section 205 - 02B .
Analysis of Vibration 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
off the floor.
Few vibration conditions are caused by the rear axle. On a vibration concern, follow the diagnosis
procedure in Section 100 - 04 unless there is a good reason to suspect the axle.
Tires Klj . 3 ba
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crayon or chalk.
6. While holding the crayon or chalk against the tire, rotate the wheel slowly in the opposite direction until the feeling of driving the rear axle is encountered again.
7. Measure the length of the crayon or chalk mark on the tire. zIf the length of the mark is 25.4 mm (1 inch) or less, the rear axle backlash is within
allowable limits.
z If the chalk mark is greater than 25.4 mm (1 inch), check for these conditions:
„Elongation of the differential pinion shaft and holes in the differential case (4204).
„ Missing differential pinion thrust washer (4230) or differential side gear thrust
washer (4228).
„ Galling of the differential pinion shaft (4211) and bore.
„ Excessive ring gear and pinion backlash. Follow the procedure for the type of rear
axle to check backlash.
Axle Shaft Bearing Noise
Axle bearing shaft noise is similar to gear noise and differential pinion bearing whine. Axle shaft
bearing noise will usually distinguish itself from gear noise by occurring in all driving modes (drive,
coast, and float), and will persist with the transmission in NEUTRAL while the vehicle is moving at the
speed in which the concern is occurring. If the vehicle makes this noise, remove the suspect axle
shaft, install a new bearing and a new axle seal. Re- evaluate the vehicle for noise before removing any
internal components.
Bearing Rumble
Bearing rumble sounds like marbles being tumbled. This condition is usually caused by a
worn/damaged wheel bearing. The lower pitch is because the wheel bearing turns at only about one-
third of the driveshaft speed. Wheel bearing noise also may be high- pitched, similar to gear noise, but
will be evident in all four driving modes.
Symptom Chart
Symptom Chart Condition
Possible Sources Action
z Traction- Lok®
does not work in
snow, mud or on
ice z
Differential. zCARRY OUT the Traction-
Lok® Differential Operation
Check in this section. REPAIR
as necessary. REFER to
Section 205 - 02A or
Section 205 - 02B .
z Lubricant leaking
from the pinion
seal, axle shaft oil
seals z
Vent.
z Damage in the
seal contact area
or damaged or
worn seal. z
CLEAN the axle housing vent.
z INSTALL a new seal if
damage is found.
z Differential side
gears/pinion
gears are scored z
Insufficient
lubrication. z
INSTALL new gears. REFER
to Section 205 - 02A or
Section 205 - 02B . FILL the axle to
specification.
z Incorrect or
contaminated z
INSTALL new gears. REFER
to Section 205 - 02A or
Section Klj . 10 ba
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6. Remove the outer differential pinion bearing.
7. Remove and discard the collapsible spacer (4662).
8. Using the special tool and a suitable press, remove the inner differential pinion bearing (4630).
9.
NOTE: Do not remove the pinion bearing cups from the differential housing unless the cups are
damaged.
To remove the bearing cups, tap alternately (with a brass drift of suitable length) on opposite Klj . 4 ba
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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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REMOVAL AND INSTALLATION
Brake Caliper Anchor Plate
Removal
1. Remove the pads. For additional information, refer to Pads in this section.
2. Remove the anchor plate (2B292). 1. Remove and discard the anchor plate bolts.
2. Remove the anchor plate.
Installation 1. CAUTION: Use correct type and length bolts.
Follow the removal procedure in reverse order. zInstall new anchor plate bolts.
SECTION 206-
03: Front Disc Brake 2003 Mustang Workshop Manual Klj . 1 ba
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Brake Pressure Control Valve
The brake pressure control valve proportions the pressure to the rear brakes.
zWhen the brake pedal is applied, brake fluid pressure passes through the proportioning valves
to the rear brake system until the valve split point is reached.
z Above its split point, the proportioning valve begins to reduce the hydraulic pressure to the rear
brakes, creating a balanced braking condition between the front and rear brakes.
Brake Tubes and Hoses CAUTION: Never use copper tubing. It is subject to fatigue, cracking and corrosion which
could result in brake tube failure.
Steel tubing is used throughout the brake hydraulic system. All brake tube fittings must be correctly
double flared to provide strong leakproof connections. When bending the tubing to fit the underbody or
rear axle contours, be careful not to kink or crack the tube.
If a section of brake tube is damaged, the entire section must be removed and a new tube of the same
type, size, shape and length installed.
When replacing hydraulic brake tubing, hoses, or connectors, tighten all connections securely. After
installation, bleed the brake system. For additional information, refer to Section 206 - 00 . Klj . 3 ba
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