lock FORD MUSTANG 2003 Repair Manual

5.
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
(4662) and nut.
Tighten the nut to set the preload.
zRotate the pinion occasionally to make sure the pinion bearings (4630) (4621) seat
correctly. Take frequent pinion bearing torque preload readings by rotating the drive
pinion gear 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 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 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. For additional information, refer to Section 205 - 01 . Klj . 4 ba
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Disconnect the parking brake cable and conduit from the parking brake lever and the caliper.
For additional information, refer to
Section 206 - 05 .
8. Separate the parking brake cable and conduit from the knuckle.
9. Remove the rear brake disc. For additional information, refer to Section 206 - 04 .
z Remove the rear brake caliper and support bracket from the knuckle as an assembly.
Wire the caliper and support bracket assembly out of the way.
10. Remove the rear brake anti- lock sensor and position it aside.
11. Support the lower suspension arm and bushing with a jack stand.
12. Remove and discard the nut and bolt.
13. Remove and discard the cotter pin and nut. Klj . 3 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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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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1. Adjust the special tool to zero.
2. Tighten the screw until the differential housing is spread to the specification.
3. Remove the special tools.
8. CAUTION: Mark the position and location of the differential bearing caps as the
arrows may not be visible. Always install the differential bearing caps in their identical
location and position.
Remove the differential bearing caps. 1. Remove the bolts.
2. Remove the differential bearing caps.
9. CAUTION: Use wood blocks to avoid damaging the differential housing.
Remove the differential assembly. 1. Position wood blocks at the top and bottom of the differential case (4204).
2. Pry the differential assembly and the differential bearing shims (4067) out of the
differential housing.
3. Remove the special tool.
10. CAUTION: Record the torque necessary to maintain rotation of the drive pinion gear Klj . 6 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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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
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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
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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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