2003 FORD MUSTANG clip

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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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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Halfshaft Handling
CAUTION: Never pick up or hold the halfshaft by the outboard joint.
Handle all halfshaft components carefully during removal and installation.
zDo not over- angle the CV joints.
z Damage will occur to an assembled inboard CV joint if it is over- plunged outward from the joint
housing.
z Never use a hammer to remove or install the halfshafts.
z Never use the halfshaft assembly as a lever to position other components. Always support the
free end of the halfshaft.
z Do not allow the boots to contact sharp edges or hot exhaust components. Item Part Number Description
1 4B422 Driveshaft bearing retainer circlip
2 2C189 Rear brake anti-
lock sensor indicator 3 — Retaining ring (part of 4B402)
4 4B478 Boot clamp (large inboard)
5 — Rear axle shaft inner boot (part of 4B402)
6 4B478 Boot clamp (small inboard)
7 4B478 Boot clamp (small outboard)
8 — Rear axle shaft outer boot (part of 4B402)
9 4B478 Boot clamp (large outboard)
10 2217 Dust seal assembly
11 4B402 Halfshaft assembly Klj . 2 ba
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12. Using the special tool, press the outboard CV joint until it is loose in the hub.
13.
CAUTION: Do not over- angulate the outboard CV joint or damage the boot.
While lowering the knuckle, remove the CV joint from the hub.
14. CAUTION: The crown on the tool forks must face away from the axle housing.
Position the special tool correctly between the CV joint and the axle housing so as not to
damage the differential seal.
Using the special tool, exert enough pressure to overcome the circlip and separate the CV joint
(4K326) from the differential side gear.
15. CAUTION: Do not damage the differential seal.
Carefully remove the halfshaft (4K138) with both hands.
16. Install the special tool. Klj . 4 ba
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Installation
1. NOTE: This procedure applies to both the LH and RH halfshafts.
Install a new driveshaft bearing retainer circlip.
2. Remove the special tool.
3. CAUTION: Differential seal damage will occur if installing the halfshaft without the
special tool installed.
Install the special tool. Klj . 5 ba
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4. Position the halfshaft for installation.
5. Seat the CV joint stub shaft in the differential side gear.
1. Slide the stub shaft into the axle 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.
6. Connect the axle shaft to the hub. 1. Making sure the serrations on the shaft line up with the serrations in the hub, install the axle shaft into the hub.
2. Install a new retainer. Do not tighten the retainer at this time. Klj . 6 ba
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REMOVAL AND INSTALLATION
Brake Pads —
Cobra
Removal 1. Remove brake fluid in the master cylinder reservoir until the reservoir is half full.
2. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
3. Remove the tire and wheel assembly. For additional information, refer to Section 204 - 04 .
4. CAUTION: Install new pads if worn to or past the specified thickness above the
metal backing plate or rivets. Install new pads in complete axle sets.
Inspect the pads for wear and contamination.
5. Remove the caliper locating pin E- clip.
6. Remove the caliper locating pin.
SECTION 206-
03: Front Disc Brake 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Brake Caliper —
Cobra
Removal 1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. Remove the tire and wheel assembly. For additional information, refer to Section 204 - 04 .
3. Remove the caliper locating pin E- clip.
4. Remove the caliper locating pin.
5. Remove the front brake flow bolt. 6. Remove the caliper. SECTION 206-
03: Front Disc Brake 2003 Mustang Workshop Manual Klj . 1 ba
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