2003 FORD MUSTANG differential

50.
CAUTION: Overspreading may damage the differential housing.
NOTE: Tighten and loosen the Differential Carrier Spreader screw to normalize the Housing
Spreader Adapters prior to taking the final Dial Indicator reading.
Spread the differential housing to the specification.
1. Adjust the special tool to zero.
2. Tighten the screw until spreading the differential housing to the specification.
3. Remove the special tools.
51. NOTE: Select the correct size differential bearing shims by completing the differential bearing
shim selection chart.
NOTE: Apply a light coating of Premium Long- Life Grease XG-1-C, or equivalent meeting Ford
specification ESA- M1C75-B to the differential bearing shim to help hold in place.
Place the differential bearing shims in the differential housing.
52. Install the differential case. 1. Position the differential bearing cups on the differential bearings.
2. Lower the differential case in place between the differential bearing shims. Klj . 30 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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1. Attach the special tool.
2. Position the special tool tip centrally on a drive tooth.
3. Zero the indicator.
4. Turn the differential ring gear without turning the drive pinion gear. Record the indicator
reading. The allowable backlash is 0.203 mm ( 0.008 in) to 0.330 mm ( 0.013 in) and
must not very more than 0.1016 mm (0.004 in) between points measured. A backlash
variation of more than 0.1016 mm (0.004 in) between points checked indicates gear/case
runout.
„If backlash is within specifications, proceed to Final assembly in this procedure.
„ To correct for a high or low backlash proceed as follows.
57. To correct for high or low backlash increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount. Refer to the
following tables when adjusting the backlash. When the backlash is within specifications,
proceed to Final assembly in this procedure. Backlash Change Required Thickness Change Required
mm Inch mm Inch
0.025 0.001 0.050 0.002
0.050 0.002 0.050 0.002
0.076 0.003 0.101 0.004
0.101 0.004 0.152 0.006
0.127 0.005 0.152 0.006
0.152 0.006 0.203 0.008
0.177 0.007 0.254 0.010
0.203 0.008 0.254 0.010
0.228 0.009 0.304 0.012
0.254 0.010 0.355 0.014
0.279 0.011 0.355 0.014 Klj . 32 ba
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0.304 0.012 0.406 0.016
0.330 0.013 0.457 0.018
0.335 0.014 0.457 0.018
0.381 0.015 0.508 0.020
Differential Shim Size Chart — 4067 —Numbers of Stripes and Color Code Dimension A
mm Inch
2—C-
COAL 7.7978-7.8105 0.3070-0.3075
1—C-
COAL 7.7470-7.7597 0.3050-0.3055
5—
BLU 7.6962-
7.7089 0.3030-0.3035
4—
BLU 7.6454-
7.6581 0.3010-0.3015
3—
BLU 7.5946-
7.6073 0.2990-0.2995
2—
BLU 7.5458-
7.5565 0.2970-0.2975
5—
PINK 7.4422-
7.4549 0.2930-0.2935
4—
PINK 7.3914-
7.4041 0.2910-0.2915
3—
PINK 7.3406-
7.3533 0.2890-0.2895
2—
PINK 7.2898-
7.3025 0.2870-0.2875
1—
PINK 7.2390-
7.2517 0.2850-0.2855
5—
GRN 7.1882-
7.2009 0.2830-0.2835
4—
GRN 7.1374-
7.1501 0.2810-0.2815
3—
GRN 7.0866-
7.0993 0.2790-0.2795
2—
GRN 7.0358-
7.0485 0.2770-0.2775
1—
GRN 6.9850-
7.0485 0.2750-0.2755
5—
WH 6.9342-
6.9469 0.2730-0.2735
4—
WH 6.8834-
6.8961 0.2710-0.2715
3—
WH 6.8326-
6.8453 0.2690-0.2695
2—
WH 6.7818-
6.7945 0.2670-0.2675
1—
WH 6.7310-
6.7437 0.2650-0.2655
5—YEL 6.6802-6.6929 0.2630-0.2635
4—YEL 6.6294-6.6421 0.2610-0.2615
3—YEL 6.5786-6.5913 0.2590-0.2595
2—YEL 6.5278-6.5405 0.2570-0.2575
1—YEL 6.4770-6.4897 0.2550-0.2555
5—
ORNG 6.4262-
6.4389 0.2530-0.2535
4—
ORNG 6.3754-
6.3881 0.2510-0.2515
3—
ORNG 6.3246-
6.3373 0.2490-0.2495
2—
ORNG 6.2738-
6.2865 0.2470-0.2475
1—
ORNG 6.2223-
6.2357 0.2450-0.2455
2—
RED 6.1722-
6.1849 0.2430-0.2435
1—
RED 6.1214-
6.1341 0.2410-0.2415 Klj . 33 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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DESCRIPTION AND OPERATION
Rear Drive Halfshafts
The rear wheel drive halfshaft system consists of and operates as follows:
zHalfshafts (4K138) transmit engine torque from the rear axle housing to the rear wheels.
z Halfshafts rotate at approximately one- third the speed of a driveshaft and do not contribute to
rotational vibration disturbances.
z A constant velocity (CV) joint is a mechanism for transmitting uniform torque and rotary motion
while operating through a range of angles.
z CV joints at both inboard (differential) and outboard (wheel) ends provide operating
smoothness.
z The inboard CV joints are plunge- type joints that provide the axial movement necessary to
affect shaft length changes.
z The outboard CV joints have a higher angle capability than the inboard CV joints to
accommodate suspension travel.
z Inboard and outboard CV joints connect to a splined shaft.
z A driveshaft bearing retainer circlip retains the splined inboard CV joint to the differential side
gear. Install a new circlip every time you remove the halfshaft from the vehicle.
z A rear axle wheel hub retainer secures the interconnecting shaft and outboard CV joint to the
rear hub.
z The lubed-for- life CV joints use special CV joint grease. They require no periodic lubrication.
z To separate the halfshaft from the rear hub, press the outboard CV joint from the rear hub.
z To separate the halfshaft from the differential, apply a load to the back face of the inboard CV
joint assembly to overcome the circlip.
z The halfshaft assemblies are not repairable. Install a new assembly if worn/damaged.
SECTION 205-
05: Rear Drive Halfshafts 2003 Mustang Workshop Manual Klj . 1 ba
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z
Do not drop assembled halfshafts. The impact will cut the boots from the inside without
evidence of external damage.
z Inspect all machined surfaces and splines for damage.
Wheel and Tire Balancing, Rear
WARNING: Do not balance the rear wheels and tires while mounted on the vehicle.
Possible tire disintegration, differential or halfshaft failure can result, causing personal injury
or extensive component damage. Use an off- vehicle wheel and tire balancer only.
Hoisting
CAUTION: Use a frame- contact hoist only. Vehicle or component damage can result if
other types of hoists are used.
Never raise the vehicle using the halfshafts as lift points.
Undercoating and Rustproofing
During undercoating and rustproofing procedures, protect the boots from the coating materials.
Foreign materials on the rubber boots will cause extreme advanced wear. Klj . 3 ba
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REMOVAL AND INSTALLATION
Halfshaft
Removal
NOTE:
This procedure applies to both the LH and RH halfshafts.
1. CAUTION: The vehicle must be on level ground and at curb height.
Mark the rear shock absorber relative to the protective sleeve. zDuring installation, raise the suspension to this reference mark before tightening the
suspension component fasteners.
SECTION 205-
05: Rear Drive Halfshafts 2003 Mustang Workshop Manual Special Tool(s)
Differential Plug
205-
294 (T89P-4850- B) Differential Seal Protector
205-
461 Front Hub Remover
205-
D070 (D93P-1175- B) or
Equivalent Halfshaft Removal Tool
205-
475 Steering Arm Remover
211-
003 (T64P-3590- F) Klj . 1 ba
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