FORD MUSTANG 2003 Workshop Manual

IN-
VEHICLE REPAIR
Differential Case
Removal 1. Remove the differential housing cover (4033) and drain the rear axle (4001). For additional information, refer to Differential Housing Cover in this section.
2. CAUTION: Reinstall the differential pinion shaft (4211) and the bolt in the differential
case (4204) after removing the axle shafts (4234).
SECTION 205-
02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring
Gear 2003 Mustang Workshop
Manual Special Tool(s)
2-
Jaw Puller
205- D072 (D97L-4221- A) or
equivalent Dial Indicator Gauge with
Holding Fixture
100-
002 (TOOL- 4201-C) or
equivalent Gauge, Clutch Housing
308-
021 (T75L-4201- A) or
equivalent Installer, Differential Shim
205-
220 (T85L-4067- AH) Installer, Differential Side
Bearing
205-
009 (T57L-4221- A1) Step Plate
205-
D016 (D80L-630- 5) or
equivalent Klj . 1 ba
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Remove the axle shafts. For additional information, refer to
Axle Shaft in this section.
3. Wipe the lubricant from the internal working parts and inspect the parts for wear and damage.
4. Rotate the differential assembly to check for roughness indicating bearing/gear damage.
5. Using a suitable dial indicator and the special tool, measure and note the ring gear backface runout.
6. CAUTION: Mark the position and location of the bearing caps, as the arrows may
not be visible. Always install the bearing caps in their identical locations and positions.
Remove the bearing caps. 1. Remove the bolts.
2. Remove the bearing caps.
7. WARNING: Do not allow the differential assembly to fall. Failure to follow these
instructions may result in personal injury and component damage. CAUTION: Place a wood block between the pry bar and the differential housing Klj . 2 ba
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(4010) to protect the machined surface from damage.
Using a pry bar and a wood block, remove the differential assembly from the differential
housing.
8. Remove the 10 bolts.
9. CAUTION: Do not damage the threads in the bolt holes.
Insert a punch in the bolt holes, and drive off the ring gear.
10. If the ring gear backface runout measurement, taken at the beginning of this procedure, did not exceed the specification, proceed to the appropriate procedure as necessary: Drive Pinion ,
Differential Case and Ring Gear in this section, or to Installation in this procedure. If the ring
gear backface runout measurement, taken at the beginning of this procedure, exceeds the
specification, the cause may be a warped ring gear, differential case/differential bearing
damage. Proceed as follows to verify the cause of the excessive runout.
11. Position the differential assembly, including the differential bearing cups (4222) and differential bearing shims (4067), in the differential housing. Install the bearing caps and bolts. Klj . 3 ba
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12. Position the special tool.
1. Rotate the differential case to verify that the differential bearings (4221) have seated correctly.
2. Position the special tool.
13. Measure and note the differential case runout. 1. Rotate the differential case.
2. Note the runout.
„If the runout does not exceed the specification, install a new ring gear and drive
pinion gear. For additional information, refer to Drive Pinion in this section and to
Installation in this procedure.
„ If the runout exceeds the specification, the ring gear is true and the concern is due
to either differential case/differential bearing damage. Proceed as follows.
14. Remove the differential assembly from the differential housing.
15. Using the special tools, remove the differential bearings. Klj . 4 ba
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16. Using the special tool, install the new differential bearings.
17. Position the differential assembly, including the differential bearing cups and differential bearing
shims, in the differential housing. Install the bearing caps and bolts.
18. Position the special tool. 1. Rotate the differential case to verify that the differential bearings have seated correctly.
2. Position the special tool.
19. Measure the differential case runout. Klj . 5 ba
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z
If the runout does not exceed the specification, use the new differential bearings for
assembly.
z If the runout exceeds the specification, install a new differential case. For additional
information, refer to Differential Case and Ring Gear in this section.
20. Remove the differential assembly from the differential housing.
Installation
All axles
1. Position the ring gear and the differential case. Align the bolt holes by starting two bolts through the holes in the differential case and the ring gear. Press the ring gear on the differential case.
2. Install the bolts. zApply Stud and Bearing Mount EOAZ-19554- BA or equivalent meeting Ford specification
WSK- M2G349- A1 to the bolt threads.
3. With the pinion depth set and the pinion installed, place the differential assembly in the differential housing. Klj . 6 ba
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4. Install a differential bearing shim on the left side.
5.
CAUTION: Always install the bearing caps in their identical locations and positions.
NOTE: Apply pressure toward the left side to make sure the left differential bearing cup seats
correctly.
Install the left bearing cap and loosely install the bolts.
6. Install progressively larger differential bearing shims on the right side until the largest shim selected is installed by hand. Klj . 7 ba
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7. Install the right side bearing cap and tighten the left side and right side bolts to specification.
8. Rotate the differential assembly several times to verify that the differential bearings have seated
correctly.
Measuring backlash 9. Using the special tools, measure the ring gear backlash. zIf backlash is within the specification, refer to Backlash within specification in this
procedure. The specification shown is the full allowable range. For the preferred range,
refer to Specifications in this section.
z If a zero backlash condition occurs, refer to Zero backlash in this procedure.
z If backlash is not within the specification, refer to Backlash not within specification in this
procedure. Backlash Change Required Thickness Change Required
mm Inch mm Inch
0.025 0.001 0.050 0.002
0.050 0.002 0.050 0.002 Klj . 8 ba
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Zero backlash
10. If a zero backlash condition occurs, remove the bearing caps and add 0.51 mm (0.020 inch) to the RH side and subtract 0.51 mm (0.020 inch) from the LH side to allow backlash indication.
11. Install the bearing caps and the bolts. 0.076 0.003 0.101 0.004
0.101 0.004 0.152 0.006
0.127 0.005 0.152 0.006
0.152 0.006 0.203 0.008
0.177 0.007 0.254 0.010
0.203 0.008 0.254 0.010
0.228 0.009 0.304 0.012
0.254 0.010 0.355 0.014
0.279 0.011 0.355 0.014
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 Klj . 9 ba
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12. Rotate the differential assembly several times to verify that the differential bearings seated
correctly.
13. Measure the backlash. Refer to Measuring backlash in this procedure.
Backlash not within specification 14. To increase or decrease the backlash, remove the bearing caps and install a thicker shim and thinner shim accordingly.
zIf backlash is not within the specification, increase the thickness of one differential
bearing shim and decrease the thickness of the other differential bearing shim by the
same amount.
15. Install the bearing caps and the bolts. Klj . 10 ba
132003 Mustang Workshop Manual
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