differential FORD MUSTANG 2003 Workshop Manual

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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z
The differential housing (4010) consists of a cast aluminum housing and a cast aluminum
differential housing cover (4033). The differential housing cover uses silicone sealant as a
gasket.
z The hypoid- design gearset consists of a 8.8- inch differential ring gear and a drive pinion gear.
Two opposed pinion bearings (4621) (4630) support the drive pinion gear in the differential
housing.
z A differential drive pinion collapsible spacer (4662), located on the drive pinion gear shaft,
maintains pinion bearing preload. The pinion nut adjusts the preload.
z Differential bearing shims (4067), located between the differential bearing cups (4222) and the
differential housing, adjust the differential ring gear backlash and the differential bearing
preload.
z The differential case (4204) is a one- piece design with two openings to allow for assembly of
the internal components and lubricant flow. Two opposed differential bearings (4221) support
the differential case in the differential housing. Removable differential bearing caps retain the
differential assembly in the differential housing.
z Inside the differential case, the differential pinion shaft (4211) supports two differential pinion
gears (4215). The pinion gears engage the differential side gears (4236), to which the halfshafts 10 4033 Differential housing cover
11 4B416 Inboard CV joint stub shaft pilot bearing housing
seal
12 4B413 Inboard CV joint stub shaft pilot bearing
13 4010 Differential housing
14 4662 Differential drive pinion collapsible spacer
15 4670 Rear axle drive pinion shaft oil slinger
16 4851 Rear axle pinion flange
17 389546-
S100 Pinion nut
18 4859 Drive pinion oil seal deflector
19 4676 Rear axle drive pinion seal
20 4621 Pinion bearing
21 4616 Differential drive pinion bearing cup
22 56187-
S Bolt
23 — Drive pinion gear (part of 4209)
24 — Differential bearing cap
(part of 4010)
25 4628 Rear axle pinion bearing cup
26 4630 Pinion bearing
27 4663 Drive pinion bearing adjustment shim
28 4A321 Rear axle differential clutch shim
29 — Clutch plate (part of 4947)
30 — Clutch disc (part of 4947)
31 4236 Differential side gear
32 4214 Differential clutch spring
33 4215 Differential pinion gear
34 4947 Differential clutch pack Klj . 2 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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IN-
VEHICLE REPAIR
Stub Shaft Pilot Bearing and Seal
Removal 1. Remove the halfshaft assembly. zThe knuckle and halfshaft are removable as an assembly. For additional information,
refer to Axle Housing in this section. If it is necessary to remove the halfshaft from the
knuckle, refer to Section 205 - 05 .
2. NOTE: If only removing the inboard CV joint stub shaft pilot bearing housing seal (4B416),
SECTION 205-
02C: Rear Drive Axle/Differential — Ford 8.8-Inch IRS 2003 Mustang Workshop Manual Special Tool(s)
Remover, Bearing Cup
308-
047 (T77F-1102- A) Protector, Differential Seal
(Pair)
205-
461 Installer, Differential Oil Seal
205-
293 (T89P-4850- A) Adapter for 303-
224 (Handle)
205- 153 (T80T-4000- W) Slide Hammer
100-
001 (T50T-100- A) Installer, Needle Bearing
205-
288 (T89P-1244- A) Klj . 1 ba
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IN-
VEHICLE REPAIR
Drive Pinion Flange
Removal 1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. Remove the rear wheel and tire assemblies. For additional information, refer to Section 204 - 04 .
3. CAUTION: Remove the rear brake calipers to prevent drag during the drive pinion
bearing preload adjustment.
CAUTION: Do not allow the calipers to hang from the brake hoses.
Remove the rear brake caliper and support bracket from the knuckle as an assembly. Wire the
caliper and support bracket assembly out of the way. For additional information, refer to Section 206 - 04 .
4. CAUTION: Index- mark the driveshaft flange and rear axle pinion flange (4851) to
maintain initial balance during installation.
CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion
flange pilot. Never hammer on the driveshaft (4602) 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.
Disconnect and position the driveshaft out of the way. For additional information, refer to
Section 205 - 01 .
SECTION 205-
02C: Rear Drive Axle/Differential — Ford 8.8-Inch IRS 2003 Mustang Workshop Manual Special Tool(s)
2-
Jaw Puller
205- D072 (D97L-4221- A) or
equivalent Holding Fixture, Drive Pinion
Flange
205-
126 (T78P-4851- A) Installer, Drive Pinion Flange
205-
002 (TOOL- 4858-E) or
equivalent Klj . 1 ba
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5.
CAUTION: Do not under any circumstance loosen the nut to reduce preload. If it is
necessary to reduce preload, install a new differential drive pinion collapsible spacer
(4662) and nut.
Tighten the nut to set the preload.
zRotate the pinion occasionally to make sure the pinion bearings (4630) (4621) seat
correctly. Take frequent pinion bearing torque preload readings by rotating the drive
pinion gear with a Nm (inch/pound) torque wrench.
z If the preload recorded prior to disassembly is lower than the specification for used
bearings, then tighten the nut to specification. 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.
z Refer to the torque specification for used pinion bearings in the Specifications portion of
this section.
6. 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 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.
Connect the driveshaft. For additional information, refer to Section 205 - 01 . Klj . 4 ba
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IN-
VEHICLE REPAIR
Pinion Seal
Removal 1. Remove the pinion flange (4851). For additional information, refer to Drive Pinion Flange in this
section.
2. Force up the metal flange of the rear axle drive pinion seal (4676). zInstall gripping pliers and strike with a hammer to remove the seal.
Installation 1. Lubricate the new rear axle drive pinion seal. zUse Premium Long- Life Grease XG-1-C or equivalent meeting Ford specification ESA-
M1C75- B.
2. CAUTION: Installation without the proper tool can result in early seal failure. SECTION 205-
02C: Rear Drive Axle/Differential — Ford 8.8-Inch IRS 2003 Mustang Workshop Manual Special Tool(s)
Installer, Drive Pinion Oil Seal
205-
133 (T79P-4676- A) Klj . 1 ba
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REMOVAL AND INSTALLATION
Axle Housing
Removal
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 component fasteners.
SECTION 205-
02C: Rear Drive Axle/Differential — Ford 8.8-Inch IRS 2003 Mustang Workshop Manual Special Tool(s)
Plug Set, Differential
205-
294 (T89P-4850- B) Protector, Differential Seal
(Pair)
205-
461 Remover, Halfshaft
205-
475 Remover, Steering Arm
211-
003 (T64P-3590- F) Klj . 1 ba
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17.
NOTE: Mark the new cam bolt in the same position as the old one for assembly reference
before discarding the old bolt.
Disconnect the knuckle from upper suspension arm and bushing. 1. Remove and discard the nut and bolt.
2. Disconnect the knuckle from the upper suspension arm and bushing.
18. CAUTION: The crown on the tool forks must face away from the differential
housing. Position the special tool correctly between the CV joint and the differential
housing so as not to damage the differential seal.
Using the special tool, exert enough pressure to overcome the circlip and separate the CV joint
from the differential side gear.
19. Install the special tool.
20. Remove the halfshaft and knuckle assembly from the vehicle. Klj . 5 ba
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