FORD MUSTANG 2003 Workshop Manual

26.
CAUTION: Do not damage the axle vent hose.
Lower the rear axle assembly from the vehicle.
27. If removal of the mounting bushings is necessary, remove them by hand.
Installation 1. Install the bushings, if removed.
2. Using the transmission jack, raise the rear axle assembly into position.
3. Install the bolts and nuts.
4. Install the bolts. Klj . 7 ba
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5.
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 rear axle 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 and install the bolts.
6. Install the pinion nose crossmember.
7. NOTE: The following halfshaft and knuckle assembly installation steps apply to both sides of
the vehicle.
Remove the special tool. Klj . 8 ba
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8.
CAUTION: Differential seal damage will occur if installing the halfshaft without the
special tool.
Install the special tool.
9. Position the halfshaft for installation.
10. Seat the CV joint stub shaft in the differential side gear. 1. Slide the stub shaft into the differential housing until the shaft splines are past the differential seal.
2. Remove the special tool.
3. Align the stub shaft splines and the side gear splines, and slide the stub shaft into the gear until it seats.
„When seated, the axle circlip will lock the stub shaft in the differential side gear.
Check the circlip engagement by attempting to pull the inboard CV joint out of the
differential side gear. If the circlip has not seated, push the CV joint inward until
the circlip is fully engaged in the differential side gear. Klj . 9 ba
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11.
CAUTION: Do not tighten the fastener at this time.
Connect the knuckle to the upper suspension arm and bushing. 1. Position the knuckle.
2. Install the new cam bolt and nut.
12. CAUTION: Do not tighten the fastener at this time.
Connect the knuckle to the lower suspension arm and bushing. 1. Position the knuckle.
2. Install the new bolt and nut.
13. Connect the toe link to the knuckle. 1. Position the toe link.
2. Install the new nut.
3. Install the new cotter pin. Klj . 10 ba
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14.
CAUTION: Install the hardened washer between the lower suspension arm and
bushing and the shock absorber. Failure to do so can result in damage and failure of the
lower suspension arm and bushing.
Position the shock absorber, and install the bolt and the new nut.
15. Install the other halfshaft and knuckle assembly, toe link, and shock absorber as described in the previous steps.
16. Raise the suspension until the shock absorbers compress to the previously established alignment mark (curb height).
17. Tighten the nut. Klj . 11 ba
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18. Align the marks on the cam bolt and the upper suspension arm and bushing, and tighten the
nut.
19. Repeat the two previous steps for the other knuckle.
20. Lower the suspension and remove the jack stands.
21. Apply Anti- Seize Lubricant to the rear brake anti- lock sensors where they contact the axle
housing and install the anti- lock sensors.
z Use High Temperature Nickel Anti- Seize Lubricant F6AZ-9L494-AA or equivalent
meeting Ford specification ESE- M12A4-A.
22. Install the brake disc, and the rear disc brake caliper and support bracket assembly. For additional information, refer to Section 206 - 04 .
23. Position the parking brake cable and conduit. Klj . 12 ba
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24. Connect the parking brake cable and conduit to the caliper and parking brake lever. For
additional information, refer to Section 206 - 05 .
25. Repeat the three previous steps for the brake components on the other side of the vehicle.
26. Install the exhaust system. For additional information, refer to Section 309 - 00 .
27. Install the wheels and tires. For additional information, refer to Section 204 - 04 .
28. CAUTION: If refilling the rear axle (4001), first add 118 ml (4 oz) of Additive Friction
Modifier C8AZ- 19B546-A or equivalent meeting Ford specification EST- M2C118-A.
Check the lubricant level. zIf necessary, fill the rear axle housing to the level shown with SAE 75W- 140 High
Performance Rear Axle Lubricant F1TZ-19580- B or equivalent meeting Ford
specification WSL- M2C192-A. The refill capacity is 1.23- 1.37 liters (2.6-2.9 pints).
29. Lower the vehicle.
30. Check, and adjust the wheel alignment as necessary. For additional information, refer to Section 204 - 00 . Klj . 13 ba
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Klj . 14 ba
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DISASSEMBLY AND ASSEMBLY
Axle
SECTION 205-
02C: Rear Drive Axle/Differential — Ford 8.8-Inch IRS 2003 Mustang Workshop Manual Special Tool(s)
2-
Jaw Puller
205- D072 (D97L-4221- A) or
equivalent Adapter for 205-
S127
205- 105 (T76P-4020- A3) Bearing Preload Tool
205-
395 (T93P-4220- A) Plate, Bearing/Oil Seal
205-
090 (T75L-1165- B) Gauge, Clutch Housing
308-
021 (T75L-4201- A) Holding Fixture, Drive Pinion
Flange
205-
126 (T78P-4851- A) Installer, Drive Pinion Flange
205-
002 (TOOL- 4858-E) or
equivalent Dial Indicator Gauge
100-
D005 (D78P-4201- G) or
equivalent Klj . 1 ba
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Dial Indicator Gauge with
Holding Fixture
100-
002 (TOOL- 4201-C) or
equivalent Spreader, Differential Carrier
205-
001 (TOOL- 4000-E) or
equivalent Installer, Differential Side
Bearing
205-
010 (T57L-4221- A2) Adapter for 205-
S127
205- 110 (T76P-4020- A10) Adapter for 205-
S127
205- 129 (T79P-4020- A18) Gauge Tube, Drive Pinion
205-
336 (T93P-4020- A) Adapter for 205-
S127
205- 111 (T76P-4020- A11) Spreader, Differential Housing
(Plate)
205-
335 (T93P-4000- A) Klj . 2 ba
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