2003 FORD MUSTANG Mounting

GENERAL PROCEDURES
Driveline Angle Inspection
NOTE:
An incorrect driveline angle can cause a vibration or shudder. For additional information, refer
to Section 100 - 04 .
1. Check the vehicle for evidence or overload or sagging. Check for specified air pressures information in all four tires.
2. Normalize the suspension.
3. Drive the vehicle onto a drive- on hoist or back onto a front-end alignment rack.
4. Inspect the suspension and chassis. Verify that the vehicle curb position ride height is within specification. For additional information, refer to Section 204 - 00 .
z Measure the curb position ride height with the vehicle empty and all fluids full.
5. Place the Inclinometer flush against the bottom of the driveshaft. After the tool has been held on the driveshaft surface for 5 seconds, push the ALT ZERO button to calibrate to zero degrees.
Remove the tool.
6. To check the pinion angle, rotate the driveshaft so that the rear axle pinion flange yoke ear is parallel to the floor. Remove the U- joint snap ring, then install the special tool. Check and record
the pinion angle reading.
zIf the angle is not within specification, repair or adjust to obtain the correct angle. Inspect
the rear suspension, rear axle, rear axle mounting or the frame for wear or damage.
SECTION 205-
00: Driveline System — General Information 2003 Mustang Workshop Manual Special Tool(s)
Anglemaster II Driveline
Inclinometer
164-
R2402 or equivalent Klj . 1 ba
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26.
CAUTION: Do not damage the axle vent hose.
Lower the rear axle assembly from the vehicle.
27. If removal of the mounting bushings is necessary, remove them by hand.
Installation 1. Install the bushings, if removed.
2. Using the transmission jack, raise the rear axle assembly into position.
3. Install the bolts and nuts.
4. Install the bolts. Klj . 7 ba
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34.
CAUTION: Do not damage the aluminum differential housing while carrying out
these procedures.
Place the differential case with the special tools in the differential housing.
35. Position the special tool on the outside mounting hole.
36. NOTE: Repeat this step until obtaining a consistent reading.
Measure the total end play. 1. Attach the special tool and position the indicator tip on the machined surface of the differential case flange.
2. Move the differential case to the left and the right (as far as possible).
3. Record the reading on the differential bearing shim selection procedure line A. Differential Bearing Shim Selection Chart
8.8-
inch Aluminum Axle Example Actual
Line-
A End play without ring gear 0.498
Line-
B End play with ring gear (ring gear side) -
0.245 Minus (-
) Line-
C Subtract Line-B from Line- A, also record on Line C, below 0.253 Klj . 25 ba
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a
Round off initial thickness to the nearest shim thickness as in example for final shim
thickness.
37. Remove the Dial Indicator and the differential case from the differential housing. 38. Draw - file the differential ring gear mounting surface to remove any nicks or burrs. 8.8-
inch Aluminum
Axle Left Differential Bearing
Height Right Differential Bearing
Height Example Actual Example Actual
Master bearing height 0.8695 0.8695 0.8695 0.8695
Line-
D Actual bearing
height -0.8478 Minus (-
) -0.8491 Minus (-)
Line-
E Difference 0.0217 0.0204
8.8-
inch Aluminum
Axle Left Side
8.8-
inch Aluminum
Axle Right Side
Example Actual Example Actual
Line-
B End play
Line- E Bearing height 0.2450
+0.0217 + Line-
C End play
Line- E Bearing height 0.2530
+0.0204 +
TOTAL Lines B and E
Backlash (subtract) 0.2667
-0.0060 -0.006 TOTAL Lines C and E
Backlash/preload (add) 0.2734
+0.020 +0.020
Initial thickness
a 0.2607 Initial thickness 0.2934
Final shim thickness
—
left 0.261 Final shim thickness —
right 0.293 Klj . 26 ba
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1. Place the special tool base in a soft-
jawed vise with the bearing mounting surface above
the vise jaws.
2. Position the differential bearing on the special tool base.
3. Attach the bolt, spring, washers and spacer.
4. Tighten the bolt.
46. Measure the differential bearing stand height. 1. Invert the special tool and clamp the bolt head in a vise.
2. Position a depth micrometer flat on the differential bearing.
47. Measure both differential bearings stand height. Record the measurement on the differential bearing shim selection procedure line D.
48. Press the left and right differential bearing on the differential case.
49. Install the special tools. Klj . 29 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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For low or spongy brake pedal concerns:
zcheck and, if necessary, refill the brake master cylinder reservoir.
z bleed the brake system and retest the brake pedal feel.
z if the brake pedal is still low or feels spongy, check the brake pedal mounting for looseness and
correct installation. Check the power brake booster and the brake master cylinder for loose
mounting. Correct as necessary and retest the system for normal operation.
For a slow or incomplete brake pedal return concern:
zinspect for binding, damage, correct installation or interference at the brake pedal.
z check the power brake booster for binding, damage and correct installation.
Vibration When Brakes are Applied
For vibration concerns when brakes are applied, perform the following procedure.
Visually inspect: ztire condition and pressure.
z suspension bushings and ball joints.
Correct as necessary. 1. Verify and isolate the concern. Brake roughness can be felt in: zthe steering wheel.
z the seat.
z the brake pedal.
2. After verifying the concern, check for related concerns in the: zOn- Line Automotive Service Information System (OASIS).
z Technical Service Bulletins.
3. Check wheel bearing end- play and correct as necessary.
4. NOTE: Begin at the front of the vehicle unless the vibration has been isolated to the rear.
Remove the tire and wheel.
5. Remove the brake caliper.
6. Measure and record the brake disc thickness. Install a new brake disc if the thickness after machining will be at or below specification. The specification is molded into the brake disc. Do z
Power brake booster
z Brake pedal linkage
z Vacuum booster hose
z Tires
z Foreign material Klj . 3 ba
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not machine a new brake disc.
7. For vehicles with a two- piece hub and brake disc assembly:
z Match-mark before disassembly.
z Remove the brake disc.
z Using a die grinder with a mild abrasive (Scotch Brite® type), remove any rust or
corrosion from the hub and brake disc mounting surfaces.
z Align the match- marks and reinstall the brake disc on the hub.
8. CAUTION: Do not use a bench lathe to machine brake discs.
NOTE: The depth of cut must be between 0.10 and 0.20 mm (0.004 and 0.008 inch). Lighter
cuts will cause heat and wear. Heavier cuts will cause poor brake disc surface finish.
Using on- vehicle brake lathe, machine the brake discs. Follow the manufacturer's instructions.
After machining, make sure the brake disc still meets the thickness specification.
9. Using a dial indicator, verify that the brake disc lateral runout is now within vehicle specification.
10. Remove any metal chips.
11. Remove the hub adapter.
12. Remove any remaining metal chips from the machining operation.
13. CAUTION: Do not carry out this step on rear drum- in-hat brake discs.
For vehicles with a two- piece hub and a non drum- in-hat brake disc assembly:
z Remove the brake disc from the hub.
z Remove any remaining metal chips from hub and brake disc mounting surfaces and from
the ABS sensor.
z Apply High Temperature Nickel Anti- Seize Lubricant F6AZ-9L494-AA to the mounting
surfaces.
z Using the match- marks, mount the brake disc on the hub.
14. Install the caliper and check brake operation.
Symptom Chart Symptom Chart
Condition
Possible Sources Action
z The Brakes Pull or
Drift z
Tire air pressure.
z Wheel alignment.
z Brake pads.
z Brake components.
z Suspension
component. z
Go To Pinpoint Test A .
z The Red Brake
Warning Indicator Is z
Instrument cluster.
z Circuit. z
Go To Pinpoint Test B . Klj . 4 ba
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