FORD MUSTANG 2003 Workshop Manual

26. Remove the special tool from the differential clutch pack and differential side gear assembly.
27. Install the shim(s) on the differential clutch pack and differential side gear assembly.
28. Install the differential side gear assemblies in the differential case.
29. Install the differential pinion gear and differential pinion thrust washer assemblies in the
differential case.
30. Using a soft- faced hammer, install the differential clutch spring. Klj . 23 ba
352003 Mustang Workshop Manual
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31.
NOTE: If a new bolt is unavailable, coat the original bolt threads with Threadlock and Sealer
EOAZ- 19554- AA or equivalent meeting Ford specification WSK-M2G351- A5 prior to final
installation.
Install the differential pinion shaft and install a new bolt finger- tight.
32. Mount the differential case and the special tool in a vise. Using the special tool, check the torque necessary to rotate one differential side gear.
zIf reusing the original clutch plates, the initial minimum break- away torque must be no
less than the specification. The minimum rotating torque necessary to keep the
differential side gear turning with new clutch plates may vary.
33. CAUTION: The Master bearings are marked LH and RH. Install them as shown.
Install the special tools on the differential case. Klj . 24 ba
352003 Mustang Workshop Manual
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34.
CAUTION: Do not damage the aluminum differential housing while carrying out
these procedures.
Place the differential case with the special tools in the differential housing.
35. Position the special tool on the outside mounting hole.
36. NOTE: Repeat this step until obtaining a consistent reading.
Measure the total end play. 1. Attach the special tool and position the indicator tip on the machined surface of the differential case flange.
2. Move the differential case to the left and the right (as far as possible).
3. Record the reading on the differential bearing shim selection procedure line A. Differential Bearing Shim Selection Chart
8.8-
inch Aluminum Axle Example Actual
Line-
A End play without ring gear 0.498
Line-
B End play with ring gear (ring gear side) -
0.245 Minus (-
) Line-
C Subtract Line-B from Line- A, also record on Line C, below 0.253 Klj . 25 ba
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a
Round off initial thickness to the nearest shim thickness as in example for final shim
thickness.
37. Remove the Dial Indicator and the differential case from the differential housing. 38. Draw - file the differential ring gear mounting surface to remove any nicks or burrs. 8.8-
inch Aluminum
Axle Left Differential Bearing
Height Right Differential Bearing
Height Example Actual Example Actual
Master bearing height 0.8695 0.8695 0.8695 0.8695
Line-
D Actual bearing
height -0.8478 Minus (-
) -0.8491 Minus (-)
Line-
E Difference 0.0217 0.0204
8.8-
inch Aluminum
Axle Left Side
8.8-
inch Aluminum
Axle Right Side
Example Actual Example Actual
Line-
B End play
Line- E Bearing height 0.2450
+0.0217 + Line-
C End play
Line- E Bearing height 0.2530
+0.0204 +
TOTAL Lines B and E
Backlash (subtract) 0.2667
-0.0060 -0.006 TOTAL Lines C and E
Backlash/preload (add) 0.2734
+0.020 +0.020
Initial thickness
a 0.2607 Initial thickness 0.2934
Final shim thickness
—
left 0.261 Final shim thickness —
right 0.293 Klj . 26 ba
352003 Mustang Workshop Manual
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39. Install the differential ring gear.
1. Place the differential ring gear on the differential case.
2. Hand start three bolts to align the holes in the differential ring gear and the differential case.
3. Place the differential case and differential ring gear onto the press bed blocks with the differential ring gear teeth facing downward.
4. Press the differential ring gear into place.
40. Install the remaining bolts.
41. Place the differential case with the special tools into the differential housing. Klj . 27 ba
352003 Mustang Workshop Manual
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42.
NOTE: The bolts retaining the differential ring gear to the differential case may interfere while
carrying out this procedure. If so, remove three to five bolts to provide clearance.
Measure the end play. 1. Attach the special tool and position the indicator tip on the machined surface of the differential case flange.
2. Rock the differential ring gear to allow full mesh with the drive pinion gear.
3. With the gears in full mesh, set the special tool to zero.
4. Move the differential case as far as possible to the left and note the reading.
5. Record the reading on the differential bearing shim selection procedure line B.
„Remove the special tool.
43. Remove the differential case from the differential housing.
44. Remove the bolts. Apply Stud and Bearing Mount EOAZ-19554- BA or equivalent meeting Ford
specification WSK-M2G349- A1 to the bolt threads, and reinstall the bolts.
45. NOTE: Measure the stand height of both differential bearings prior to installation.
NOTE: Mark the differential bearings left and right before measuring them.
Install the special tool. Klj . 28 ba
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1. Place the special tool base in a soft-
jawed vise with the bearing mounting surface above
the vise jaws.
2. Position the differential bearing on the special tool base.
3. Attach the bolt, spring, washers and spacer.
4. Tighten the bolt.
46. Measure the differential bearing stand height. 1. Invert the special tool and clamp the bolt head in a vise.
2. Position a depth micrometer flat on the differential bearing.
47. Measure both differential bearings stand height. Record the measurement on the differential bearing shim selection procedure line D.
48. Press the left and right differential bearing on the differential case.
49. Install the special tools. Klj . 29 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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53.
NOTE: Tighten the bolts prior to releasing the carrier spreader.
Install the differential bearing caps in their original locations and positions and tighten the bolts.
54. Remove the special tool.
55. Install the special tool at the 12 o'clock position.
56. Using the special tools, measure the differential ring gear backlash at four equally spaced points. Klj . 31 ba
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1. Attach the special tool.
2. Position the special tool tip centrally on a drive tooth.
3. Zero the indicator.
4. Turn the differential ring gear without turning the drive pinion gear. Record the indicator
reading. The allowable backlash is 0.203 mm ( 0.008 in) to 0.330 mm ( 0.013 in) and
must not very more than 0.1016 mm (0.004 in) between points measured. A backlash
variation of more than 0.1016 mm (0.004 in) between points checked indicates gear/case
runout.
„If backlash is within specifications, proceed to Final assembly in this procedure.
„ To correct for a high or low backlash proceed as follows.
57. To correct for high or low backlash increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount. Refer to the
following tables when adjusting the backlash. When the backlash is within specifications,
proceed to Final assembly in this procedure. Backlash Change Required Thickness Change Required
mm Inch mm Inch
0.025 0.001 0.050 0.002
0.050 0.002 0.050 0.002
0.076 0.003 0.101 0.004
0.101 0.004 0.152 0.006
0.127 0.005 0.152 0.006
0.152 0.006 0.203 0.008
0.177 0.007 0.254 0.010
0.203 0.008 0.254 0.010
0.228 0.009 0.304 0.012
0.254 0.010 0.355 0.014
0.279 0.011 0.355 0.014 Klj . 32 ba
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