FORD MUSTANG 2003 Workshop Manual

33.
CAUTION: Do not damage the bolt hole threads.
If not done previously, insert a punch in the bolt holes and drive off the differential ring gear.
34. Using the special tools, remove the differential bearing. zRepeat for the other side.
35. Remove the bolt and remove the differential pinion shaft (4211). Klj . 13 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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bearings.
Install the pinion bearings and special tools as shown.
4. NOTE: This step duplicates pinion bearing preload.
Thread the special tool onto the Screw and tighten to the specification shown.
5. CAUTION: Offset the special tool to obtain an accurate reading. Item Part Number Description
1 205-
109 Adapter for 205-
S127 2 205-
105 Adapter for 205-
S127 3 4630 Rear (inner) pinion bearing
4 205-
129 Adapter for 205-
S127 5 205-
110 Adapter for 205-
S127 6 4621 Front (outer) pinion bearing
7 205-
111 Adapter for 205-
S127 Klj . 16 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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11. Install the front pinion bearing and the rear axle drive pinion shaft oil slinger in the differential
housing.
12. CAUTION: Installation without the correct tool can result in early seal failure.
CAUTION: If the seal becomes misaligned during installation, remove it and install a
new one.
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.
Using the special tool, install the new rear axle drive pinion seal.
13. CAUTION: Make sure the splines on the drive pinion gear stem are free of burrs. If
burrs are evident, remove them using a fine crocus cloth, work in a rotational motion.
Place a new differential drive pinion collapsible spacer on the drive pinion gear stem against the
pinion stem shoulder. 14. Install the drive pinion gear with the differential drive pinion collapsible spacer in the differential Klj . 18 ba
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housing.
15. NOTE: Disregard the index marks if installing a new rear axle pinion flange.
Position the rear axle pinion flange. 1. Lubricate the rear axle pinion flange splines.
„Use SAE 75W- 140 High Performance Rear Axle Lubricant F1TZ-19580- B or
equivalent meeting Ford specification WSL-M2C192- A.
2. Position the rear axle pinion flange.
16. Using the special tool, install the rear axle pinion flange.
17. CAUTION: Do not under any circumstance loosen the nut to reduce preload. If it is
necessary to reduce preload, install a new differential drive pinion collapsible spacer and
nut.
Tighten the nut to set the preload.
zRotate the pinion occasionally to make sure the pinion bearings seat correctly. Take
frequent pinion bearing torque preload readings by rotating the drive pinion gear with a
Nm (inch/pound) torque wrench.
z For new pinion bearings, tighten the nut to specification. Refer to torque specifications for Klj . 19 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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