differential FORD MUSTANG 2003 Service Manual

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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6. Remove the outer differential pinion bearing.
7. Remove and discard the collapsible spacer (4662).
8. Using the special tool and a suitable press, remove the inner differential pinion bearing (4630).
9.
NOTE: Do not remove the pinion bearing cups from the differential housing unless the cups are
damaged.
To remove the bearing cups, tap alternately (with a brass drift of suitable length) on opposite Klj . 4 ba
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sides of the cup to prevent the cup from cocking in the casting.
Installation
Using special tool 205- 054
NOTE: This is the preferred method for installing the pinion bearing cups. If necessary, proceed to
Using special tools 205- 153, 205-054, and 205-D055 in this procedure for an alternate method.
1. Position the special tools and the inner and outer pinion bearing cups in their respective bores. 1. After placing the inner and outer bearing cups in their bores, place the special tool on the inner bearing cup.
2. Place the special tool on the outer bearing cup.
3. Install the special tool.
2. Tighten the special tool to seat the pinion bearing cups in their bores.
3. CAUTION: Always install new differential pinion bearings when installing new
pinion bearing cups.
NOTE: If the feeler gauge can fit between a cup and the bottom of its bore at any point around
the cup, remove and reseat the cup. Klj . 5 ba
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Check that the cups have seated correctly in their bores.
Using special tools 205-153, 205- 054, and 205-D055
NOTE: This is an alternate method for installing the pinion bearing cups. Carry out this procedure if
pinion bearing cup installation was not done in the previous steps.
4. Using the special tools, drive the outer differential drive pinion bearing cup (4616) into the differential housing.
5. Using the special tools, drive the inner rear axle pinion bearing cup (4628) into the differential housing.
6. CAUTION: Always install new differential pinion bearings when installing new
pinion bearing cups.
NOTE: If the feeler gauge can fit between a cup and the bottom of its bore at any point around
the cup, remove and reseat the cup. Check that the cups have seated correctly in their bores. Klj . 6 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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9.
NOTE: Offset the special tool to obtain an accurate reading.
Rotate the special tool several half- turns to make sure the differential pinion bearings seat
correctly and position the special tool as shown.
10. Install the special tool. 1. Position the special tool. Item Part
Number Description
1 205-109 Adapter for 205-S127 (T76P-4020-
A9) 2 205-105 Adapter for 205-S127 (T76P-4020-
A3) (1.612
inch O.D.) 3 4630 Rear (inner) pinion bearing
4 205-125 Adapter for 205-S127 (T78P-4020-
A15) (0.894
inch thick) 5 205-110 Adapter for 205-S127 (T76P-4020-
A10) (1.7 inch
thick) 6 4621 Front (outer) pinion bearing
7 205-111 Adapter for 205-S127 (T76P-4020-
A11) Klj . 8 ba
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2. Install the bearing caps.
3. Install the four bolts.
11. NOTE: Use only flat, clean drive pinion bearing adjustment shims (4663).
NOTE: Selection of too thick a shim results in a deep tooth contact at final assembly. Do not
attempt to force the shim between the special tools. A slight drag indicates correct shim
selection.
Use a drive pinion bearing adjustment shim as a gauge for shim selection.
zAfter determining the correct shim thickness, remove the special tools.
12. Position the correct thickness drive pinion bearing adjustment shim and the differential pinion bearing on the drive pinion gear. Using a suitable press and the special tools, press the
differential pinion bearing until it seats firmly against the drive pinion gear.
13. Place a new collapsible spacer on the pinion shaft against the pinion stem shoulder. Klj . 9 ba
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14. Install the outer differential pinion bearing.
15. Install the rear axle drive pinion shaft oil slinger.
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. Klj . 10 ba
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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.
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- Klj . 12 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-
02A: Rear Drive Axle/Differential — Ford 7.5-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-
009 (T57L-4221- A1) Step Plate
205-
D016 (D80L-630- 5) or
equivalent Klj . 1 ba
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