clutch FORD MUSTANG 2003 Owner's Guide

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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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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new pinion bearings in the Specifications portion of this section.
z For used pinion bearings, if the preload recorded prior to disassembly is lower than the
specification for used bearings, then tighten the nut to specification. Refer to torque
specifications for used pinion bearings in the Specifications portion of this section.
z For used pinion bearings, 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.
18. CAUTION: 118 ml (4 oz) of Additive Friction Modifier C8AZ- 19B546-A or equivalent
meeting Ford specification EST- M2C118-A must be used in the axle.
Lubricate each steel clutch plate and soak all friction plates for no less than 15 minutes. zUse Additive Friction Modifier C8AZ- 19B546-A or equivalent meeting Ford specification
EST- M2C118- A.
19. CAUTION: Do not mix the clutch plates, clutch discs or shim from one side with the
other.
Assemble the differential clutch packs (without the shims) on their respective differential side gear. Klj . 20 ba
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20. Place the base portion of the special tool in a vise.
21. Install the differential clutch pack and differential side gear (without the shim) on the special tool.
22. Position the special tool hand-
tight on top of the differential clutch pack. Klj . 21 ba
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23. Install the special tool over the disc and differential clutch pack.
24. Install the nut.
25. Select and insert the thickest feeler gauge blade that will enter between the tool and the
differential clutch pack. The reading will be the thickness of the new clutch shim. Selective Shims
Part Number Description
EOAZ-
4A324- G 0.025 Inch
EOAZ-
4A324- H 0.030 Inch
EOAZ-
4A324- C 0.035 Inch
EOAZ-
4A324- D 0.040 Inch
EOAZ-
4A324- F 0.045 Inch Klj . 22 ba
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26. Remove the special tool from the differential clutch pack and differential side gear assembly.
27. Install the shim(s) on the differential clutch pack and differential side gear assembly.
28. Install the differential side gear assemblies in the differential case.
29. Install the differential pinion gear and differential pinion thrust washer assemblies in the
differential case.
30. Using a soft- faced hammer, install the differential clutch spring. Klj . 23 ba
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31.
NOTE: If a new bolt is unavailable, coat the original bolt threads with Threadlock and Sealer
EOAZ- 19554- AA or equivalent meeting Ford specification WSK-M2G351- A5 prior to final
installation.
Install the differential pinion shaft and install a new bolt finger- tight.
32. Mount the differential case and the special tool in a vise. Using the special tool, check the torque necessary to rotate one differential side gear.
zIf reusing the original clutch plates, the initial minimum break- away torque must be no
less than the specification. The minimum rotating torque necessary to keep the
differential side gear turning with new clutch plates may vary.
33. CAUTION: The Master bearings are marked LH and RH. Install them as shown.
Install the special tools on the differential case. Klj . 24 ba
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GENERAL PROCEDURES
Valve Spring Strength
1. Use a Valve/Clutch Spring Pressure Gauge to check the valve spring for correct strength at the specified valve spring length.
zRefer to the appropriate section in Group 303 for the procedure.
z If out of specification, install new components as necessary. Refer to the appropriate
section in Group 303 for the procedure.
SECTION 303-
00: Engine System — General Information 2003 Mustang Workshop Manual Special Tool(s)
Pressure Gauge, Valve/Clutch
Spring
303-
006 (TOOL- 6513-DD) or
equivalent Klj . 1 ba
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IN-
VEHICLE REPAIR
Cylinder Head RH
Removal 1. Disconnect the battery negative cable. For additional information, refer to Section 414 - 01 .
2. Drain the engine cooling system. For additional information, refer to Section 303 - 03A .
3. Remove the RH exhaust manifold. For additional information, refer to Exhaust Manifold RH in
this section.
4. Remove the lower intake manifold. For additional information, refer to Lower Intake Manifold in
this section.
5. Remove the push rods. For additional information, refer to Push Rod in this section.
6. Remove the drive belt. For additional information, refer to Section 303 - 05 .
7. Disconnect the A/C manifold and tube assembly. For additional information, refer to Section 412 - 03 .
8. Disconnect the A/C compressor clutch electrical connector.
9. Remove the A/C compressor bracket.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Material
Item Specification
SAE 5W-
20 Premium Synthetic
Blend Motor Oil
XO- 5W20-QSP or equivalent WSS-
M2C153-
H Klj . 1 ba
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