oil FORD MUSTANG 2003 Repair Manual

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.
14. Install the outer differential pinion bearing.
15. Install the rear axle drive pinion shaft oil slinger. Klj . 9 ba
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z
The differential housing (4010) consists of a cast aluminum housing and a cast aluminum
differential housing cover (4033). The differential housing cover uses silicone sealant as a
gasket.
z The hypoid- design gearset consists of a 8.8- inch differential ring gear and a drive pinion gear.
Two opposed pinion bearings (4621) (4630) support the drive pinion gear in the differential
housing.
z A differential drive pinion collapsible spacer (4662), located on the drive pinion gear shaft,
maintains pinion bearing preload. The pinion nut adjusts the preload.
z Differential bearing shims (4067), located between the differential bearing cups (4222) and the
differential housing, adjust the differential ring gear backlash and the differential bearing
preload.
z The differential case (4204) is a one- piece design with two openings to allow for assembly of
the internal components and lubricant flow. Two opposed differential bearings (4221) support
the differential case in the differential housing. Removable differential bearing caps retain the
differential assembly in the differential housing.
z Inside the differential case, the differential pinion shaft (4211) supports two differential pinion
gears (4215). The pinion gears engage the differential side gears (4236), to which the halfshafts 10 4033 Differential housing cover
11 4B416 Inboard CV joint stub shaft pilot bearing housing
seal
12 4B413 Inboard CV joint stub shaft pilot bearing
13 4010 Differential housing
14 4662 Differential drive pinion collapsible spacer
15 4670 Rear axle drive pinion shaft oil slinger
16 4851 Rear axle pinion flange
17 389546-
S100 Pinion nut
18 4859 Drive pinion oil seal deflector
19 4676 Rear axle drive pinion seal
20 4621 Pinion bearing
21 4616 Differential drive pinion bearing cup
22 56187-
S Bolt
23 — Drive pinion gear (part of 4209)
24 — Differential bearing cap
(part of 4010)
25 4628 Rear axle pinion bearing cup
26 4630 Pinion bearing
27 4663 Drive pinion bearing adjustment shim
28 4A321 Rear axle differential clutch shim
29 — Clutch plate (part of 4947)
30 — Clutch disc (part of 4947)
31 4236 Differential side gear
32 4214 Differential clutch spring
33 4215 Differential pinion gear
34 4947 Differential clutch pack Klj . 2 ba
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IN-
VEHICLE REPAIR
Stub Shaft Pilot Bearing and Seal
Removal 1. Remove the halfshaft assembly. zThe knuckle and halfshaft are removable as an assembly. For additional information,
refer to Axle Housing in this section. If it is necessary to remove the halfshaft from the
knuckle, refer to Section 205 - 05 .
2. NOTE: If only removing the inboard CV joint stub shaft pilot bearing housing seal (4B416),
SECTION 205-
02C: Rear Drive Axle/Differential — Ford 8.8-Inch IRS 2003 Mustang Workshop Manual Special Tool(s)
Remover, Bearing Cup
308-
047 (T77F-1102- A) Protector, Differential Seal
(Pair)
205-
461 Installer, Differential Oil Seal
205-
293 (T89P-4850- A) Adapter for 303-
224 (Handle)
205- 153 (T80T-4000- W) Slide Hammer
100-
001 (T50T-100- A) Installer, Needle Bearing
205-
288 (T89P-1244- A) Klj . 1 ba
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IN-
VEHICLE REPAIR
Pinion Seal
Removal 1. Remove the pinion flange (4851). For additional information, refer to Drive Pinion Flange in this
section.
2. Force up the metal flange of the rear axle drive pinion seal (4676). zInstall gripping pliers and strike with a hammer to remove the seal.
Installation 1. Lubricate the new rear axle drive pinion seal. zUse Premium Long- Life Grease XG-1-C or equivalent meeting Ford specification ESA-
M1C75- B.
2. CAUTION: Installation without the proper tool can result in early seal failure. SECTION 205-
02C: Rear Drive Axle/Differential — Ford 8.8-Inch IRS 2003 Mustang Workshop Manual Special Tool(s)
Installer, Drive Pinion Oil Seal
205-
133 (T79P-4676- A) Klj . 1 ba
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DISASSEMBLY AND ASSEMBLY
Axle
SECTION 205-
02C: Rear Drive Axle/Differential — Ford 8.8-Inch IRS 2003 Mustang Workshop Manual Special Tool(s)
2-
Jaw Puller
205- D072 (D97L-4221- A) or
equivalent Adapter for 205-
S127
205- 105 (T76P-4020- A3) Bearing Preload Tool
205-
395 (T93P-4220- A) Plate, Bearing/Oil Seal
205-
090 (T75L-1165- B) Gauge, Clutch Housing
308-
021 (T75L-4201- A) Holding Fixture, Drive Pinion
Flange
205-
126 (T78P-4851- A) Installer, Drive Pinion Flange
205-
002 (TOOL- 4858-E) or
equivalent Dial Indicator Gauge
100-
D005 (D78P-4201- G) or
equivalent Klj . 1 ba
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Gauge, Differential Bearing
205-
338 (T93P-4222- A) Installer, Drive Pinion Bearing
Cone
205-
005 (T53T-4621- C) Installer, Drive Pinion Bearing
Cup
205-
024 (T67P-4616- A) Protector, Drive Pinion Thread
205-
460 Installer, Drive Pinion Oil Seal
205-
133 (T79P-4676- A) Gauge, Differential Bearing
205-
339 (T93P-4222- B) Adapter for 205-
S127
205- 109 (T76P-4020- A9) Step Plate
205-
D061 (D83T-4205- C2) or
equivalent Klj . 3 ba
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through several revolutions prior to removing the rear axle pinion flange (4851).
Remove the rear axle pinion flange. For additional information, refer to
Drive Pinion Flange in
this section.
11. Using a screwdriver, force the rear axle drive pinion seal metal flange up and strike it with a hammer.
12. Using gripping pliers and a hammer, remove the rear axle drive pinion seal (4676).
13. Remove the rear axle drive pinion shaft oil slinger (4670).
14. Using the special tool and a soft- faced hammer, drive the drive pinion gear out of the front
pinion bearing (4621) and remove it through the rear of the differential housing.
15. Remove and discard the differential drive pinion collapsible spacer (4662). Klj . 7 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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Final assembly
58. CAUTION: The machined surfaces on the differential housing and the differential
housing cover must be clean and free of oil before applying the new silicone sealant.
Cover the inside of the axle before cleaning the machined surface to prevent
contamination.
CAUTION: Install the differential housing cover within 15 minutes of applying the
silicone material.
CAUTION: Allow the sealant to cure for one hour before filling the axle with
lubricant.
Apply a continuous bead of sealant, of the specified thickness, to the differential housing cover
mounting surface.
zUse Clear Silicone Rubber F7AZ- 19554-CA or equivalent meeting Ford specification
ESB- M4G92- A.
59. Install the differential housing cover.
60. CAUTION: First fill the rear axle (4001) with 118 ml (4 oz) of Additive Friction
Modifier C8AZ- 19B546-A or equivalent meeting Ford specification EST- M2C118-A.
Install the rear axle assembly in the vehicle. Fill the axle with the specified lubricant. For
additional information, refer to Axle Housing in this section. Klj . 34 ba
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PINPOINT TEST F: HYDRO-
BOOST ERRATIC OPERATION, STICKS,
BINDS OR GRABS z
Check accessory drive belt tension and
condition. Refer to Section 303 - 05 .
z Is the accessory drive belt OK? Yes
GO to
E3 .
No
INSTALL a new accessory drive belt.
REFER to Section 303 - 05 .
E3 CHECK POWER STEERING HOSES
z
Check power steering pressure hoses, power
steering gear pressure hoses and power
steering return hose for cracks or leaks.
z Do power steering pressure hose, power
steering gear hose and power steering
return hose check OK? Yes
GO to
E4 .
No
INSTALL new hoses as necessary.
REFER to Section 211 - 00 .
E4 CHECK BRAKE PEDAL LINKAGE
z
Check brake pedal linkage for binding or
sticking operation.
z Does pedal linkage check OK? Yes
GO to
E5 .
No
INSTALL new pedal linkage as necessary.
REFER to Section 206 - 06 .
E5 CHECK POWER STEERING PUMP SPEED
z
Check engine idle speed against
specifications.
z Is engine idle speed OK? Yes
GO to
E6 .
No
SET engine idle speed to specification.
REFER to Powertrain Control/Emissions
Diagnosis (PC/ED) manual. E6 CHECK FOR PLUGGED RETURN HOSE
z
NOTE: The return hose from the oil cooler to
the power steering reservoir has an in- line
filter in the hose.
z Disconnect power steering return hose from
power steering fluid cooler and power
steering pump reservoir.
z Pass air through hose from the oil cooler end.
z Is hose plugged? Yes
INSTALL a new power steering return
hose.
No
GO to
E7 .
E7 CHECK POWER STEERING PUMP FLOW
AND RELIEF z
Test power steering pump for correct flow
and relief pressure. Refer to Section 211 - 00 .
z Is power steering pump operating
correctly? Yes
INSTALL a new power brake hydro-
boost
unit. REFER to Section 206 - 07 .
No
INSTALL a new power steering pump.
REFER to Section 211 - 02 .
Test Step Result / Action to
Take F1 CHECK SUPPLY HOSE
z
Check for obstructions in power steering return hose and Yes Klj . 11 ba
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