light FORD MUSTANG 2003 Owner's Guide

Setting pinion depth
7. NOTE: Apply only a light oil film on the differential pinion bearings before assembling the tools.
Assemble and position the following in the differential housing. 1. Position the Adapter for 205- S127.
2. Position the Adapter for 205- S127.
3. Position the inner pinion bearing.
4. Position the Adapter for 205- S127.
5. Position the Adapter for 205- S127.
6. Position the outer pinion bearing.
7. Thread on the Adapter for 205- S127.
8. NOTE: This step duplicates final differential pinion bearing preload.
Using a Nm (inch/pound) torque wrench, tighten the special tool to specification. Klj . 7 ba
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2. Install the bearing caps.
3. Install the four bolts.
11. NOTE: Use only flat, clean drive pinion bearing adjustment shims (4663).
NOTE: Selection of too thick a shim results in a deep tooth contact at final assembly. Do not
attempt to force the shim between the special tools. A slight drag indicates correct shim
selection.
Use a drive pinion bearing adjustment shim as a gauge for shim selection.
zAfter determining the correct shim thickness, remove the special tools.
12. Position the correct thickness drive pinion bearing adjustment shim and the differential pinion bearing on the drive pinion gear. Using a suitable press and the special tools, press the
differential pinion bearing until it seats firmly against the drive pinion gear.
13. Place a new collapsible spacer on the pinion shaft against the pinion stem shoulder. Klj . 9 ba
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8. Remove and discard the nuts and bolts retaining the shock absorbers to the axle.
9. Remove and discard the nuts and bolts retaining the upper suspension arm and bushings to the
differential housing.
10. Lower the axle slightly, and remove the springs.
11. Remove and discard the nuts and bolts retaining the lower suspension arm and bushings to the axle. Klj . 3 ba
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Setting pinion depth
7. NOTE: Apply only a light oil film on the differential pinion bearings before assembling the tools.
Assemble and position the following in the differential housing.
8. NOTE: This step duplicates final differential pinion bearing preload. Item Part
Number Description
1 205-109 Adapter for 205-
S127 (T76P-4020- A9) 2 205-105 Adapter for 205-
S127 (T76P-4020- A3) (1.612 inch
O.D.) 3 4630 Rear (inner) pinion bearing
4 205-129 Adapter for 205-
S127 (T79P-4020- A18) (1.1884
inch thick) 5 205-110 Adapter for 205-
S127 (T76P-4020- A10) (1.7 inch
thick) 6 4621 Front (outer) pinion bearing
7 205-111 Adapter for 205-
S127 (T76P-4020- A11) Klj . 7 ba
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Tighten the special tool to specification.
9. NOTE: Offset the special tool to obtain an accurate reading.
Rotate the special tool several half- turns to make sure the differential pinion bearings seat
correctly and position the special tool as shown.
10. Install the special tool. 1. Position the special tool.
2. Install the bearing caps.
3. Install the four bolts.
11. NOTE: Use only flat, clean drive pinion bearing adjustment shims (4663).
NOTE: Selection of too thick a shim results in a deep tooth contact at final assembly. Do not
attempt to force the shim between the special tools. A slight drag indicates correct shim
selection.
Use a drive pinion bearing adjustment shim as a gauge for shim selection.
zAfter determining the correct shim thickness, remove the special tools. Klj . 8 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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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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50.
CAUTION: Overspreading may 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.
1. Adjust the special tool to zero.
2. Tighten the screw until spreading the differential housing to the specification.
3. Remove the special tools.
51. NOTE: Select the correct size differential bearing shims by completing the differential bearing
shim selection chart.
NOTE: Apply a light coating of Premium Long- Life Grease XG-1-C, or equivalent meeting Ford
specification ESA- M1C75-B to the differential bearing shim to help hold in place.
Place the differential bearing shims in the differential housing.
52. Install the differential case. 1. Position the differential bearing cups on the differential bearings.
2. Lower the differential case in place between the differential bearing shims. Klj . 30 ba
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not machine a new brake disc.
7. For vehicles with a two- piece hub and brake disc assembly:
z Match-mark before disassembly.
z Remove the brake disc.
z Using a die grinder with a mild abrasive (Scotch Brite® type), remove any rust or
corrosion from the hub and brake disc mounting surfaces.
z Align the match- marks and reinstall the brake disc on the hub.
8. CAUTION: Do not use a bench lathe to machine brake discs.
NOTE: The depth of cut must be between 0.10 and 0.20 mm (0.004 and 0.008 inch). Lighter
cuts will cause heat and wear. Heavier cuts will cause poor brake disc surface finish.
Using on- vehicle brake lathe, machine the brake discs. Follow the manufacturer's instructions.
After machining, make sure the brake disc still meets the thickness specification.
9. Using a dial indicator, verify that the brake disc lateral runout is now within vehicle specification.
10. Remove any metal chips.
11. Remove the hub adapter.
12. Remove any remaining metal chips from the machining operation.
13. CAUTION: Do not carry out this step on rear drum- in-hat brake discs.
For vehicles with a two- piece hub and a non drum- in-hat brake disc assembly:
z Remove the brake disc from the hub.
z Remove any remaining metal chips from hub and brake disc mounting surfaces and from
the ABS sensor.
z Apply High Temperature Nickel Anti- Seize Lubricant F6AZ-9L494-AA to the mounting
surfaces.
z Using the match- marks, mount the brake disc on the hub.
14. Install the caliper and check brake operation.
Symptom Chart Symptom Chart
Condition
Possible Sources Action
z The Brakes Pull or
Drift z
Tire air pressure.
z Wheel alignment.
z Brake pads.
z Brake components.
z Suspension
component. z
Go To Pinpoint Test A .
z The Red Brake
Warning Indicator Is z
Instrument cluster.
z Circuit. z
Go To Pinpoint Test B . Klj . 4 ba
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