torque FORD MUSTANG 2003 Service Manual

SPECIFICATIONS
SECTION 204-
04: Wheels and Tires 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants
Silicone Dielectric Compound D7AZ-
19A331-
A ESE-
M1C171- A Cleaners
Liquid Soap ESR-
M99B135- A Professional Choke and Linkage Cleaner
E8AZ-
19A501- AA ESR-
M14P10- A Custom Bright Metal Cleaner
8A-19522-
A ESR-
M5B194- B Aluminum Wheel Repair Compound E7AZ-
19554-
A ESA-
M4G280- A Tire Balance Weight
Max tire balance weight 140g (5 oz) per wheel
70g (2.5 oz) per flange Tire inflation
Tires See safety certification sticker located inside glove
compartment door
Torque Specifications Description Nm lb-
ft Wheel nuts 129 95 Klj . 1 ba
22003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

DIAGNOSIS AND TESTING
Driveline System
SECTION 205-
00: Driveline System — General Information 2003 Mustang Workshop Manual Special Tool(s)
Clamp Plate
205-
320 (T92L-4851- C) Clutch Housing Alignment
Adapter
308-
021 (T75L-4201- A) Companion Flange Holding
Tool
205-
126 (T78P-4851- A) Companion Flange Runout
Gauge
205-
319 (T92L-4851- B) Dial Indicator with Bracketry
100-
002 (TOOL- 4201-C) or
equivalent Dial Indicator/Magnetic Base
100-
D002 (D78P-4201- B) or
equivalent Vibration Analyzer
100-
F027 (014- 00344) Traction-Lok® Torque Tool
205- 022 (T66L-4204- A) Klj . 1 ba
192003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

2.
NOTE: Measure the end play with a Dial Indicator with Bracketry and not by feel.
Knock is also caused by excessive end play in the axle shafts. Up to 0.762 mm (0.030 inch) is
allowed in semi- float axles. The frequency of the knock will be less because the axle shaft
speed is slower than the driveshaft.
Clunk
Clunk is a metallic noise heard when the automatic transmission is engaged in REVERSE or DRIVE.
The noise may also occur when throttle is applied or released. It is caused by backlash somewhere in
the driveline or loose suspension components; it is felt or heard in the axle. Refer to Total Backlash
Check in this section.
Additionally, clunk may be heard upon initial drive- away. This occurs as engine torque shifts vehicle
weight, forcing changes in driveline angles, preventing the driveshaft slip- yoke from sliding on the
output shaft. To correct for this condition, lubricate the slip- yoke splines.
Total Backlash Check 1. Raise and support the vehicle. Refer to Section 100 - 02 .
2. Remove the driveshaft. Refer to Section 205 - 01 .
3. Install the special tool. zClamp a rigid bar or pipe to the tool. Clamp the other end of the bar or pipe to the frame
or a body member in order to prevent movement of the rear axle pinion flange.
4. Lower the vehicle so that one rear wheel is resting on a wheel chock to prevent it from turning. The other rear wheel will be used to measure total rear axle backlash.
5. Rotate the free wheel slowly, by hand, until the feeling of driving the rear axle is encountered. Place a mark on the side of the tire, 305 mm (12 inches) from the center of the wheel, with a Klj . 9 ba
192003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

off the floor.
With the engine off, raise only one rear wheel. Install the special tool on the wheel nuts.
Use a torque wrench with a capacity of at least 271 Nm (200 lb-
ft) to rotate the axle shaft. Be sure that
the transmission is in NEUTRAL, and that one rear wheel is on the floor while the other rear wheel is
raised off the floor. The breakaway torque required to start rotation must be at least 27 Nm (20 lb- ft).
The initial breakaway torque may be higher than the continuous turning torque.
The axle shaft must turn with even pressure throughout the check without slipping or binding. If the
torque reading is less than specified, check the differential case. Refer to Section 205 - 02A or
Section 205 - 02B .
Traction- Lok® Differential Check Road Test
1. Place one wheel on a dry surface and the other wheel on ice, mud or snow.
2. Gradually open the throttle to obtain maximum traction prior to break away. The ability to move the vehicle demonstrates correct operation of a Traction- Lok® rear axle assembly.
3. When starting with one wheel on an excessively slippery surface, a slight application of the parking brake may be necessary to help energize the Traction- Lok® feature of the differential.
Release the brake when traction is established. Use light throttle on starting to provide
maximum traction.
4. If, with unequal traction, both wheels slip, the limited slip rear axle has done all it can possibly do.
5. In extreme cases of differences in traction, the wheel with the least traction may spin after the Traction-Lok® has transferred as much torque as possible to the non- slipping wheel. Klj . 15 ba
192003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

SPECIFICATIONS
SECTION 205-
01: Driveshaft 2003 Mustang Workshop Manual Torque Specifications
Description Nm lb-
ft Pinion flange bolts 112 83 Klj . 1 ba
12003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

DESCRIPTION AND OPERATION
Driveshaft
NOTE:
All driveshaft assemblies are balanced. If undercoating the vehicle, protect the driveshaft to
prevent overspray of any undercoating material.
The driveshaft has the following features:
zA tubular shaft used to transfer engine torque from the transmission output shaft to the
differential in the rear axle housing, which transmits torque through the axle shafts to the drive
SECTION 205-
01: Driveshaft 2003 Mustang Workshop Manual Item Part Number Description
1 N800594-S100 Bolt (4 req'd)
2 4635 Universal joint (U-
joint) 3 4602 Driveshaft
4 — Grease seal (part of 4635)
5 — Needle bearings (part of 4635)
6 — Bearing cup (part of 4635)
7 — Thrust washer (part of 4635)
8 — Spider (part of 4635)
9 4841 Driveshaft slip yoke
10 — Snap ring (4 req'd)
(part of 4635)
11 4782 Driveshaft centering socket yoke
12 4851 Rear axle universal joint flange Klj . 1 ba
22003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

SPECIFICATIONS
a
In- vehicle repair refill capacities are determined by filling the rear axle with the specified lubricant to
6.4- 14.3- mm (1/4- 9/16-in) below the bottom of the fill hole.
SECTION 205-
02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring
Gear 2003 Mustang Workshop
Manual General Specifications
Item Specification
Lubes and Sealers
SAE 80W-
90 Premium Rear Axle Lubricant XY-
80W90- QL WSP-
M2C197- A Premium Long-
Life Grease XG -1-C ESA-
M1C75- B Rust Penetrant and Inhibitor F2AZ-19A501-
A ESR-
M99C56- A High Temperature Nickel Anti-
Sieze Lubricant
F6AZ- 9L494- AA ESE-
M124A- A Clear Silicone Rubber F7AZ-
19554-CA ESB-
M4G92- A Threadlock and Sealer EOAZ-19554-
AA WSK-
M2G351- A5 Lubricant Fill Level Checks
Approximate axle fill capacity
a 1.54-1.66-
liters (3.25-3.50- pints)
6.4-14.3- mm (1/4-9/16- in) below the bottom of
the fill hole Clearance, Tolerance and Adjustments
Maximum ring gear back face runout 0.102 mm (0.004 in)
Maximum differential case runout 0.076 mm (0.003 in)
Differential side gear thrust washer thickness 0.762 mm -
0.813 mm (0.030 in - 0.032 in) Differential pinion gear thrust washer thickness 0.762 mm -
0.813 mm (0.030 in - 0.032 in) Maximum axle shaft end play 0.762 mm (0.030 in)
Ring gear backlash 0.203 mm-
0.381 mm
(0.008 in- 0.015 in)
[(0.305 mm- 0.381 mm
(0.012 in- 0.015 in) preferred] Variation between teeth maximum backlash 0.102 mm (0.004 in)
Pinion flange runout 0.25 mm (0.010 in) T.I.R.
Torque Specifications Description Nm lb-
ft lb-
in Bolt retaining the differential pinion shaft to the differential case 30 22 —
Bolt retaining the driveshaft yoke to the pinion flange 112 83 —
Bolt retaining the differential housing cover to the differential housing 44 32 —
Oil filler plug 30 22 —
Pinion bearing preload (used pinion bearings) 0.9-
1.5 — 8-
14 Pinion bearing preload (new pinion bearings) 1.8-
3.3 — 16-
29 Adapter for 205-
S127 2.2 — 20 Klj . 1 ba
22003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

Section 205 - 01 .
5. Install an Nm (inch/pound) torque wrench on the nut and record the torque necessary to maintain rotation of the drive pinion gear through several revolutions.
6. CAUTION: After removing the nut, discard it. Use a new nut for installation.
Use the special tool to hold the pinion flange while removing the nut.
7. Index- mark the pinion flange and drive pinion gear stem to maintain initial balance during Klj . 2 ba
52003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

5.
CAUTION: Do not under any circumstance loosen the nut to reduce preload. If it is
necessary to reduce preload, install a new collapsible spacer (4662) and nut.
CAUTION: Remove the special tool while taking preload 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 (4630)
(4621) seat correctly. Take frequent differential pinion bearing torque preload readings by
rotating the drive pinion with a Nm (inch/pound) torque wrench.
z If the preload recorded prior to disassembly is lower than the specification for used
bearings, then tighten the nut to specification. 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.
z Refer to the torque specification for used differential pinion bearings in the Specifications
portion of this section.
6. 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 . Klj . 4 ba
52003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

IN-
VEHICLE REPAIR
Axle Housing Bushing
Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure can result in major service expense. A new part with
the same part number must be installed if installation becomes necessary. If substitution is
necessary, the part must be of the same finish and property class. Torque values must be used
as specified during reassembly to make sure of correct retention of these parts.
1. Remove the upper arm and bushing (5500). For additional information, refer to Section 204 - 02 .
2. Using the special tools, remove the bushing.
Installation 1. Using the special tools, install the bushing.
SECTION 205-
02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring
Gear 2003 Mustang Workshop
Manual Special Tool(s)
Axle Suspension Bushing Set
204-
S030 (T78P-5638- A) Klj . 1 ba
22003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...