FORD MUSTANG 2003 Workshop Manual

16. Install the drive pinion assembly (drive pinion, shims, bearing, and the collapsible spacer) into
the differential housing bore.
17. 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.
Place the rear axle drive pinion seal on the special tool.
18. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation,
remove it and install a new one.
Position the rear axle drive pinion seal in the seal bore, and use the special tool to drive the seal
into place. Klj . 10 ba
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19. Lubricate the pinion flange splines.
zUse SAE 75W- 140 High Performance Rear Axle Lubricant F1TZ-19580- B or equivalent
meeting Ford specification WSL- M2C192-A.
20. NOTE: Disregard the index marks if installing a new pinion flange.
Position the pinion flange.
21. Using the special tools, install the pinion flange.
22. CAUTION: Do not under any circumstance loosen the nut to reduce preload. If it is
necessary to reduce preload, install a new collapsible spacer and nut.
CAUTION: Remove the special tool while taking readings with the Nm (inch- pound)
torque wrench.
Tighten the nut to set the preload.
zRotate the drive pinion occasionally to make sure the differential pinion bearings seat
correctly. Take frequent differential pinion bearing torque preload readings by rotating the
drive pinion with a Nm (inch- pound) torque wrench. Klj . 11 ba
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z
For new differential pinion bearings, tighten the nut to specification. Refer to torque
specifications for new differential pinion bearings in the Specifications portion of this
section.
z For used differential 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 differential pinion bearings in the Specifications portion of
this section.
z For used differential 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.
Final assembly 23. Install the differential assembly in the differential housing. For additional information, refer to Differential Case in this section.
24. CAUTION: Align the index marks.
CAUTION: Install the driveshaft with new bolts. If new bolts are not available, apply
Threadlock and Sealer EOAZ-19554- AA or equivalent meeting Ford specification WSK-
M2G351- A5 to the threads of the original bolts.
CAUTION: The driveshaft centering socket yoke fits tightly on the pinion flange
pilot. To make sure that the yoke seats squarely on the flange, tighten the bolts evenly in
a cross pattern as shown.
Connect the driveshaft. For additional information, refer to Section 205 - 01 .
25. Lower the vehicle. Klj . 12 ba
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Klj . 13 ba
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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-
02B: Rear Drive Axle/Differential — Ford 8.8-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-
010 (T57L-4221- A2) Step Plate
205-
D061 (D83T-4205- C2) 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 — Conventional or
Differential Case and Ring Gear — Traction -
Lok ® in this section, or to Installation in this procedure. If the ring gear backface runout
measurement, taken at the beginning of this procedure, exceeded 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 — Conventional or
Differential Case and Ring Gear — Traction - Lok ® 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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