differential FORD MUSTANG 2003 Workshop Manual

19. If the differential ring gear backface runout measurement, taken at the beginning of this
procedure, did not exceed the specification, proceed to Final disassembly in this procedure. If
the differential ring gear backface runout measurement, taken at the beginning of this
procedure, exceeded the specification, the cause may be a warped differential ring gear, a
damaged differential case, or loss of differential bearing preload. Proceed to Excessive
differential ring gear backface runout in this procedure to verify the cause of the excessive
runout.
Excessive differential ring gear backface runout 20. Place the differential assembly with the differential bearings (4221) and the differential bearing cups (4222) in the differential housing.
21. Install a differential bearing shim of the thickness shown on the LH side of the differential case.
22. Install the LH differential bearing cap finger- tight. Klj . 9 ba
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23.
NOTE: Apply pressure toward the left side to fully seat the differential bearing cup.
Install progressively larger differential bearing shims on the RH side until the largest differential
bearing shim selected can be assembled with a slight drag feel.
24. Install the RH differential bearing cap. zTighten both bearing caps to specification.
25. Rotate the differential assembly to make sure it turns freely. Klj . 10 ba
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26. Using the special tool, measure and record the differential ring gear backface runout.
zIf the runout does not exceed the specification, the cause of the original excessive runout
was due to a loss of differential bearing preload. Proceed to Final disassembly in this
procedure.
z If the runout exceeds the specification, proceed as follows.
„Remove the special tool.
27. Remove the differential assembly.
28. Remove the bolts.
29. CAUTION: Do not damage the bolt hole threads.
Insert a punch in the bolt holes and drive off the differential ring gear. Klj . 11 ba
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30. Install the differential case. Rotate the differential case to seat the differential bearings.
31. Using the special tool, measure the differential case flange runout.
zIf the runout does not exceed the specification, the cause of the original excessive runout
is the differential ring gear. Remove the differential case. Discard the differential ring gear
and the drive pinion gear. Proceed to Final disassembly in this procedure.
z If the runout exceeds the specification, the differential ring gear is true and the concern is
due to either differential case/differential bearing damage. Remove the differential case.
Discard the differential bearings/differential case. Proceed to Final disassembly in this
procedure.
„Remove the special tool.
Final disassembly 32. If not done previously, remove the bolts. Klj . 12 ba
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33.
CAUTION: Do not damage the bolt hole threads.
If not done previously, insert a punch in the bolt holes and drive off the differential ring gear.
34. Using the special tools, remove the differential bearing. zRepeat for the other side.
35. Remove the bolt and remove the differential pinion shaft (4211). Klj . 13 ba
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36.
WARNING: The differential clutch spring (4214) is under tension. Remove the spring
carefully. Failure to follow these instructions may result in personal injury.
Remove the differential clutch spring.
37. Remove the differential gears. 1. Remove the two differential pinion gears (4215) and pinion thrust washers (4230).
2. Remove the two differential side gears (4236) with the clutch packs (4947) and the shims and tag them "left" and "right."
38. CAUTION: Keep the differential clutch packs in order. Do not mix them. Always
reassemble them in the same sequence.
Remove the differential clutch packs and shims from the differential side gears.
zClean and inspect the remaining differential components for wear and damage. Install
new parts as necessary. Klj . 14 ba
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39.
CAUTION: Do not use acids or solvents when cleaning the differential clutch packs.
Wipe the components only with a clean, lint- free cloth.
Clean and inspect the differential clutch packs for wear and damage. Install new parts as
necessary.
Assembly
Initial assembly 1. Coat the new differential drive pinion bearing cup(s) with lubricant. zUse SAE 75W- 140 High Performance Rear Axle Lubricant F1TZ-19580- B or equivalent
meeting Ford specification WSL- M2C192-A.
2. Using the special tool, install the differential drive pinion bearing cup(s). 1. Position the bearing cup(s) on the special tool.
2. Position the special tool and the bearing cup(s) in the differential housing.
3. Tighten the special tool to fully seat the bearing cup(s) in the bore(s).
3. NOTE: Apply a light film of SAE 75W- 140 High Performance Rear Axle Lubricant F1TZ-19580-
B or equivalent meeting Ford specification WSL-M2C192- A on the front and rear pinion Klj . 15 ba
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Rotate the special tool several half turns to seat the pinion bearings. Position the special tool as
shown.
6. Install the special tool. 1. Position the special tool on the differential housing differential bearing seat.
2. Install the differential bearing caps.
3. Install the bolts.
7. Use a drive pinion bearing adjustment shim as a gauge for shim selection. Check the drive pinion bearing adjustment shim thickness between the Gauge Block and the Gauge Tube. A
slight drag indicates correct shim selection.
8. Remove all of the special tools.
9. CAUTION: Use the same pinion bearings and drive pinion bearing adjustment shim
from the drive pinion bearing adjustment shim selection procedure for final assembly.
Position the drive pinion bearing adjustment shim and the pinion bearing on the drive pinion
gear stem.
10. Using the special tools and a suitable press, firmly seat the drive pinion bearing adjustment shim and pinion bearing on the drive pinion gear stem. Klj . 17 ba
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11. Install the front pinion bearing and the rear axle drive pinion shaft oil slinger in the differential
housing.
12. CAUTION: Installation without the correct tool can result in early seal failure.
CAUTION: If the seal becomes misaligned during installation, remove it and install a
new one.
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.
Using the special tool, install the new rear axle drive pinion seal.
13. CAUTION: Make sure the splines on the drive pinion gear stem are free of burrs. If
burrs are evident, remove them using a fine crocus cloth, work in a rotational motion.
Place a new differential drive pinion collapsible spacer on the drive pinion gear stem against the
pinion stem shoulder. 14. Install the drive pinion gear with the differential drive pinion collapsible spacer in the differential Klj . 18 ba
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housing.
15. NOTE: Disregard the index marks if installing a new rear axle pinion flange.
Position the rear axle pinion flange. 1. Lubricate the rear axle pinion flange splines.
„Use SAE 75W- 140 High Performance Rear Axle Lubricant F1TZ-19580- B or
equivalent meeting Ford specification WSL-M2C192- A.
2. Position the rear axle pinion flange.
16. Using the special tool, install the rear axle pinion flange.
17. 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 and
nut.
Tighten the nut to set the preload.
zRotate the pinion occasionally to make sure the pinion bearings seat correctly. Take
frequent pinion bearing torque preload readings by rotating the drive pinion gear with a
Nm (inch/pound) torque wrench.
z For new pinion bearings, tighten the nut to specification. Refer to torque specifications for Klj . 19 ba
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