torque FORD MUSTANG 2003 Repair 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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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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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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SPECIFICATIONS
a
If it is necessary to refill a Traction- Lok® axle with new lubricant, add 118 ml (4 oz) of Additive
Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST- M2C118-A before
filling the axle with the new lubricant.
b 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-
02B: Rear Drive Axle/Differential — Ford 8.8-Inch Ring
Gear 2003 Mustang Workshop
Manual General Specifications
Item Specification
Lubes and Sealers
SAE 75W-
140 High Performance Rear Axle
Lubricant
F1TZ- 19580- B WSL-
M2C192- 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 Additive Friction Modifier C8AZ-
19B546-A EST-
M2C118- A Clear Silicone Rubber D6AZ-
19562-AA ESB-
M4G92- A Threadlock and Sealer EOAZ-19554-
AA WSK-
M2G351- A5 Lubricant Fill Level Checks
Additive Friction Modifier 118 ml (4 oz)
Approximate axle fill capacity
a b 1.66-1.77-
liters (3.5-3.75-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
(0.305 mm - 0.381 mm preferred)
0.008 in - 0.015 in
(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 — Klj . 1 ba
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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-
02B: Rear Drive Axle/Differential — Ford 8.8-Inch Ring
Gear 2003 Mustang Workshop
Manual Special Tool(s)
Axle Suspension Bushing Set
204-
S030 (T78P-5638- A) Klj . 1 ba
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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). Puller, Bearing
205-
D064 (D84L-1123- A) or
equivalent Klj . 3 ba
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19. Lubricate the pinion flange splines.
zUse SAE 75W- 140 High Performance Rear Axle Lubricant F1TZ-19580- B or equivalent
meeting Ford specification WSL- M2C192-A.
20. NOTE: Disregard the index marks if installing a new pinion flange.
Position the pinion flange.
21. Using the special tools, install the pinion flange.
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. Klj . 11 ba
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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-
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 .
25. Lower the vehicle. Klj . 12 ba
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14. 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.
15. Using the special tool, install the differential bearings, if removed.
16. Position the differential ring gear and the differential case. Align the bolt holes by starting two bolts through the holes in the differential case and the differential ring gear. Press the
differential ring gear on the differential case. Klj . 8 ba
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SPECIFICATIONS
SECTION 205-
02C: Rear Drive Axle/Differential — Ford 8.8-Inch IRS 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants/Adhesive/Sealants
Premium Long-
Life Grease XG -1-C ESA-
M1C75- B SAE 75W-
140 High Performance Rear Axle Lubricant F1TZ-
19580- B WSL-
M2C192- A Additive Friction Modifier C8AZ-
19B546-A EST-
M2C118- A Clear Silicone Rubber F7AZ-
19554-CA ESB-
M4G92- A Stud and Bearing Mount EOAZ-19554-
BA WSK-
M2G349- A1 Threadlock and Sealer EOAZ-19554-
AA WSK-
M2G351- A5 High Temperature Nickel Anti-
Seize Lubricant F6AZ-9L494-
AA ESE-
M12A4-A Capacity
Additive Friction Modifier 118 ml (4 oz)
Rear axle lubricant 1.23-
1.37 liters (2.6- 2.9 pints) Rear axle lubricant level 6.35 mm (1/4 inch) from the bottom of
the fill hole Clearance, Tolerance and Adjustments
Maximum carrier spread 0.762 mm (0.030 in)
Maximum differential ring gear backface runout 0.076 mm (0.003 in)
Maximum differential case runout 0.076 mm (0.003 in)
Backlash between differential ring gear and pinion teeth 0.203 mm (0.008 in)-
0.330 mm (0.013
in) Preferred backlash 0.254 mm (0.010 in)
Maximum backlash variation between teeth 0.1016 mm (0.004 in)
Maximum radial runout of rear axle pinion flange in
assembly TIR 0.254 mm (0.010 in)
Available drive pinion bearing adjustment shim in steps of:
0.0254 mm (0.001 in) 0.254 mm (0.010 in)-
0.965 mm (0.038
in) Lubricant deflector to differential housing cover 5.08 mm (0.200 in)-
6.35 mm (0.250 in)
Torque Specifications Description Nm lb-
ft lb-
in Rear axle wheel hub retainer 340 251 —
Driveshaft to pinion flange bolt 112 83 —
Rear axle differential front lower insulator nut and bolt 70 52 —
Rear axle differential rear insulator bolt 103 76 —Klj . 1 ba
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