differential FORD MUSTANG 2003 Workshop Manual

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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8.
CAUTION: Differential seal damage will occur if installing the halfshaft without the
special tool.
Install the special tool.
9. Position the halfshaft for installation.
10. Seat the CV joint stub shaft in the differential side gear. 1. Slide the stub shaft into the differential housing until the shaft splines are past the differential seal.
2. Remove the special tool.
3. Align the stub shaft splines and the side gear splines, and slide the stub shaft into the gear until it seats.
„When seated, the axle circlip will lock the stub shaft in the differential side gear.
Check the circlip engagement by attempting to pull the inboard CV joint out of the
differential side gear. If the circlip has not seated, push the CV joint inward until
the circlip is fully engaged in the differential side gear. Klj . 9 ba
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DISASSEMBLY AND ASSEMBLY
Axle
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 Adapter for 205-
S127
205- 105 (T76P-4020- A3) Bearing Preload Tool
205-
395 (T93P-4220- A) Plate, Bearing/Oil Seal
205-
090 (T75L-1165- B) Gauge, Clutch Housing
308-
021 (T75L-4201- A) Holding Fixture, Drive Pinion
Flange
205-
126 (T78P-4851- A) Installer, Drive Pinion Flange
205-
002 (TOOL- 4858-E) or
equivalent Dial Indicator Gauge
100-
D005 (D78P-4201- G) or
equivalent Klj . 1 ba
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Dial Indicator Gauge with
Holding Fixture
100-
002 (TOOL- 4201-C) or
equivalent Spreader, Differential Carrier
205-
001 (TOOL- 4000-E) or
equivalent Installer, Differential Side
Bearing
205-
010 (T57L-4221- A2) Adapter for 205-
S127
205- 110 (T76P-4020- A10) Adapter for 205-
S127
205- 129 (T79P-4020- A18) Gauge Tube, Drive Pinion
205-
336 (T93P-4020- A) Adapter for 205-
S127
205- 111 (T76P-4020- A11) Spreader, Differential Housing
(Plate)
205-
335 (T93P-4000- A) Klj . 2 ba
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Gauge, Differential Bearing
205-
338 (T93P-4222- A) Installer, Drive Pinion Bearing
Cone
205-
005 (T53T-4621- C) Installer, Drive Pinion Bearing
Cup
205-
024 (T67P-4616- A) Protector, Drive Pinion Thread
205-
460 Installer, Drive Pinion Oil Seal
205-
133 (T79P-4676- A) Gauge, Differential Bearing
205-
339 (T93P-4222- B) Adapter for 205-
S127
205- 109 (T76P-4020- A9) Step Plate
205-
D061 (D83T-4205- C2) or
equivalent Klj . 3 ba
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Disassembly
Initial disassembly
1. Remove the differential housing cover (4033) and drain the lubricant into a suitable container.
2. Wipe the lubricant from the internal working parts and inspect the parts for wear and damage.
3. Using the special tool, measure and note the differential ring gear backface runout. zRemove the special tool. Gauge, Differential Clutch
205-
135 (T80P-4946- A) Gauge, Differential Clutch
Torque
205-
013 (T59L-4204- A) Remover, Bearing
205-
055 (T71P-4621- B) Holding Fixture, Transmission
307-
003 (T57L- 500-B) Klj . 4 ba
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4.
CAUTION: Do not damage the aluminum differential housing (4010) while carrying
out these procedures.
Using the special tools, mount the differential housing to a work bench. 1. Attach the special tools to the differential housing with four bolts that retain the differential housing cover to the differential housing.
2. Attach the special tools together with two 3/8 inch x 1- 1/2 inch bolts.
5. Install the special tool by placing the spreader pins in the hole in the Housing Spreader Adapters.
6. Assemble the special tool. 1. Install the special tool.
2. Attach the special tool and position the tip in the Housing Spreader Adapter hole.
7. CAUTION: Overspreading can damage the differential housing.
NOTE: Tighten and loosen the Differential Carrier Spreader screw to normalize the Housing
Spreader Adapters prior to taking the final Dial Indicator reading.
Spread the differential housing to the specification. Klj . 5 ba
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1. Adjust the special tool to zero.
2. Tighten the screw until the differential housing is spread to the specification.
3. Remove the special tools.
8. CAUTION: Mark the position and location of the differential bearing caps as the
arrows may not be visible. Always install the differential bearing caps in their identical
location and position.
Remove the differential bearing caps. 1. Remove the bolts.
2. Remove the differential bearing caps.
9. CAUTION: Use wood blocks to avoid damaging the differential housing.
Remove the differential assembly. 1. Position wood blocks at the top and bottom of the differential case (4204).
2. Pry the differential assembly and the differential bearing shims (4067) out of the
differential housing.
3. Remove the special tool.
10. CAUTION: Record the torque necessary to maintain rotation of the drive pinion gear Klj . 6 ba
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through several revolutions prior to removing the rear axle pinion flange (4851).
Remove the rear axle pinion flange. For additional information, refer to
Drive Pinion Flange in
this section.
11. Using a screwdriver, force the rear axle drive pinion seal metal flange up and strike it with a hammer.
12. Using gripping pliers and a hammer, remove the rear axle drive pinion seal (4676).
13. Remove the rear axle drive pinion shaft oil slinger (4670).
14. Using the special tool and a soft- faced hammer, drive the drive pinion gear out of the front
pinion bearing (4621) and remove it through the rear of the differential housing.
15. Remove and discard the differential drive pinion collapsible spacer (4662). Klj . 7 ba
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16. Using the special tool and a suitable press, remove the pinion bearing (4630).
1. Position the special tool under the pinion bearing.
2. Using a press, remove the pinion bearing.
17. NOTE: Using a micrometer, measure the drive pinion bearing adjustment shim thickness. Use
this measurement as a reference to compare to the shim gauge reading taken prior to installing
the pinion bearing.
Remove the drive pinion bearing adjustment shim (4663).
18. Using a brass drift and a hammer, remove any damaged differential drive pinion bearing cup (4616) (4628) from the differential housing. Tap alternately on each side of the cup to prevent it
from cocking in the bore. Klj . 8 ba
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