oil FORD MUSTANG 2003 Owner's Guide

crayon or chalk.
6. While holding the crayon or chalk against the tire, rotate the wheel slowly in the opposite direction until the feeling of driving the rear axle is encountered again.
7. Measure the length of the crayon or chalk mark on the tire. zIf the length of the mark is 25.4 mm (1 inch) or less, the rear axle backlash is within
allowable limits.
z If the chalk mark is greater than 25.4 mm (1 inch), check for these conditions:
„Elongation of the differential pinion shaft and holes in the differential case (4204).
„ Missing differential pinion thrust washer (4230) or differential side gear thrust
washer (4228).
„ Galling of the differential pinion shaft (4211) and bore.
„ Excessive ring gear and pinion backlash. Follow the procedure for the type of rear
axle to check backlash.
Axle Shaft Bearing Noise
Axle bearing shaft noise is similar to gear noise and differential pinion bearing whine. Axle shaft
bearing noise will usually distinguish itself from gear noise by occurring in all driving modes (drive,
coast, and float), and will persist with the transmission in NEUTRAL while the vehicle is moving at the
speed in which the concern is occurring. If the vehicle makes this noise, remove the suspect axle
shaft, install a new bearing and a new axle seal. Re- evaluate the vehicle for noise before removing any
internal components.
Bearing Rumble
Bearing rumble sounds like marbles being tumbled. This condition is usually caused by a
worn/damaged wheel bearing. The lower pitch is because the wheel bearing turns at only about one-
third of the driveshaft speed. Wheel bearing noise also may be high- pitched, similar to gear noise, but
will be evident in all four driving modes.
Symptom Chart
Symptom Chart Condition
Possible Sources Action
z Traction- Lok®
does not work in
snow, mud or on
ice z
Differential. zCARRY OUT the Traction-
Lok® Differential Operation
Check in this section. REPAIR
as necessary. REFER to
Section 205 - 02A or
Section 205 - 02B .
z Lubricant leaking
from the pinion
seal, axle shaft oil
seals z
Vent.
z Damage in the
seal contact area
or damaged or
worn seal. z
CLEAN the axle housing vent.
z INSTALL a new seal if
damage is found.
z Differential side
gears/pinion
gears are scored z
Insufficient
lubrication. z
INSTALL new gears. REFER
to Section 205 - 02A or
Section 205 - 02B . FILL the axle to
specification.
z Incorrect or
contaminated z
INSTALL new gears. REFER
to Section 205 - 02A or
Section Klj . 10 ba
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SPECIFICATIONS
a
In- vehicle repair refill capacities are determined by filling the rear axle with the specified lubricant to
6.4- 14.3- mm (1/4- 9/16-in) below the bottom of the fill hole.
SECTION 205-
02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring
Gear 2003 Mustang Workshop
Manual General Specifications
Item Specification
Lubes and Sealers
SAE 80W-
90 Premium Rear Axle Lubricant XY-
80W90- QL WSP-
M2C197- A Premium Long-
Life Grease XG -1-C ESA-
M1C75- B Rust Penetrant and Inhibitor F2AZ-19A501-
A ESR-
M99C56- A High Temperature Nickel Anti-
Sieze Lubricant
F6AZ- 9L494- AA ESE-
M124A- A Clear Silicone Rubber F7AZ-
19554-CA ESB-
M4G92- A Threadlock and Sealer EOAZ-19554-
AA WSK-
M2G351- A5 Lubricant Fill Level Checks
Approximate axle fill capacity
a 1.54-1.66-
liters (3.25-3.50- pints)
6.4-14.3- mm (1/4-9/16- in) below the bottom of
the fill hole Clearance, Tolerance and Adjustments
Maximum ring gear back face runout 0.102 mm (0.004 in)
Maximum differential case runout 0.076 mm (0.003 in)
Differential side gear thrust washer thickness 0.762 mm -
0.813 mm (0.030 in - 0.032 in) Differential pinion gear thrust washer thickness 0.762 mm -
0.813 mm (0.030 in - 0.032 in) Maximum axle shaft end play 0.762 mm (0.030 in)
Ring gear backlash 0.203 mm-
0.381 mm
(0.008 in- 0.015 in)
[(0.305 mm- 0.381 mm
(0.012 in- 0.015 in) preferred] Variation between teeth maximum backlash 0.102 mm (0.004 in)
Pinion flange runout 0.25 mm (0.010 in) T.I.R.
Torque Specifications Description Nm lb-
ft lb-
in Bolt retaining the differential pinion shaft to the differential case 30 22 —
Bolt retaining the driveshaft yoke to the pinion flange 112 83 —
Bolt retaining the differential housing cover to the differential housing 44 32 —
Oil filler plug 30 22 —
Pinion bearing preload (used pinion bearings) 0.9-
1.5 — 8-
14 Pinion bearing preload (new pinion bearings) 1.8-
3.3 — 16-
29 Adapter for 205-
S127 2.2 — 20 Klj . 1 ba
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4 4222 Differential bearing cup
5 4067 Differential bearing shim
6 4216 Rear axle differential gear case bolt
7 4204 Differential case
8 — Ring gear (part of 4209)
9 — Bearing cap (part of 4010)
10 4010 Rear axle housing
11 373098-
S Filler plug
12 4662 Collapsible spacer
13 4670 Rear axle drive pinion shaft oil slinger
14 4676 Rear axle drive pinion seal
15 4851 Pinion flange
16 389546-S100 Pinion nut
17 4621 Differential pinion bearing
18 2C026 Rear brake disc
19 — Axle shaft flange (part of 4234)
20 2C189 Rear brake anti-
lock sensor indicator 21 2552 Rear disc brake caliper
22 N601951-S2 Bolt
23 N804361-S100 Clip
24 — Bolt
25 2C190 Rear brake anti-
lock sensor 26 2C101 Left hand rear disc brake adapter
27 2C100 Right hand rear disc brake adapter
28 N8015163-S190 Caliper anchor bolt
29 2C028 Rear wheel brake disc shield
30 N602726-S2 Bolt (3 req'd)
31 4616 Differential drive pinion bearing cup
32 4628 Rear axle pinion bearing cup
33 4630 Differential pinion bearing
34 — Drive pinion gear
(part of 4209)
35 4663 Drive pinion bearing adjustment shim
36 — Bolt (part of 4010)
37 4241 Differential pinion shaft lock bolt
38 4211 Differential pinion shaft
39 4N237 U-
washer 40 383548 Bolt
41 — Rear axle identification tag
42 4033 Differential housing cover
43 4230 Differential pinion thrust washer
44 4215 Differential pinion gear Klj . 2 ba
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206 - 09A .
8. CAUTION: Do not damage the wheel bearing oil seal.
Remove the axle shaft.
Installation 1. Lubricate the lip of the wheel bearing oil seal zUse Premium Long- Life Grease XG-1-C or equivalent meeting Ford specification ESA-
M1C75- B.
2. CAUTION: Do not damage the wheel bearing oil seal.
Install the two axle shafts.
3. CAUTION: Do not damage the rubber O- ring in the axle shaft groove.
Install the U- washer. Klj . 2 ba
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IN-
VEHICLE REPAIR
Rear Wheel Bearing and Axle Shaft Oil Seal
Removal 1. Remove the axle shaft (4234). For additional information, refer to Axle Shaft in this section.
2. NOTE: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged.
Using the special tools, remove the rear wheel bearing and wheel bearing oil seal.
SECTION 205-
02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring
Gear 2003 Mustang Workshop
Manual Special Tool(s)
Adapter for 303-
224
205- 153 (T80T-4000- W) Installer, Axle Shaft Bearing
205-
124 (T78P-1225- A) Installer, Rear Axle Oil Seal
205-
390 (T97T-1177- B) Remover, Axle Bearing
205-
219 (T85L-1225- AH) Slide Hammer
100-
001 (T50T-100- A) Klj . 1 ba
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Installation
1. Lubricate the new rear wheel bearing with the specified lubricant.
2. Using the special tools, install the new rear wheel bearing.
3. Lubricate the lip of the new wheel bearing oil seal. zUse Premium Long- Life Grease XG-1-C or equivalent meeting Ford specification ESA-
M1C75- B.
4. Using the special tools, install the new wheel bearing oil seal.
5. Install the axle shaft. For additional information, refer to Axle Shaft in this section. Klj . 2 ba
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IN-
VEHICLE REPAIR
Differential Housing Cover
Removal 1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. NOTE: Empty the lubricant into a clean container for reuse.
Remove the differential housing cover (4033). 1. Remove the 10 bolts and drain the lubricant from the differential housing (4010).
2. Remove the differential housing cover.
Installation 1. CAUTION: Make sure the machined surfaces on both the differential housing and
the differential housing cover are clean and free of oil before applying the new silicone
sealant. To prevent contamination, cover the inside of the rear axle (4001) prior to
cleaning the machined surface.
Clean the differential housing and the differential housing cover gasket mating surfaces.
2. CAUTION: Install the differential housing cover within 15 minutes of applying the
silicone, or it will be necessary to remove and reapply new sealant.
Apply a continuous bead of sealant of the specified thickness to the differential housing cover.
zUse Clear Silicone Rubber F7AZ- 19554-CA or equivalent meeting Ford specifications
ESB- M4G92- A.
SECTION 205-
02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring
Gear 2003 Mustang Workshop
Manual Klj . 1 ba
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equivalent
Holding Fixture, Drive Pinion
Flange
205-
126 (T78P-4851- A) Installer, Drive Pinion Bearing
Cone
205-
005 (T53T-4621- C) Installer, Drive Pinion Bearing
Cup
205-
054 (T71P-4616- A) Installer, Drive Pinion Flange
205-
002 (TOOL- 4858-E) or
equivalent Installer, Drive Pinion Oil Seal
205-
133 (T79P-4676- A) Plate, Bearing/Oil Seal
205-
090 (T75L-1165- B) Protector, Drive Pinion Thread
205-
460 Puller, Bearing
205-
D064 (D84L-1123- A) or
equivalent Klj . 2 ba
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Removal
1. Remove the differential assembly from the differential housing. For additional information, refer to Differential Case in this section.
2. CAUTION: Record the torque necessary to maintain rotation of the drive pinion gear
through several revolutions prior to removing the pinion flange (4851).
Remove the pinion flange. For additional information, refer to Drive Pinion Flange and Drive Pinion Seal in this section.
3. Force the rear axle drive pinion seal metal flange up. Install gripping pliers and strike with a hammer to remove the seal.
4. Remove the rear axle drive pinion shaft oil slinger (4670).
5. Using the special tool and a soft-faced hammer, drive the pinion assembly out of the outer differential pinion bearing (4621) and remove the drive pinion through the rear of the differential
housing (4010). 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. 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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