2003 FORD MUSTANG clutch

GENERAL PROCEDURES
Brake Disc Machining
WARNING: The electrical power to the air suspension system must be shut off prior to
hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off
the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the
air springs, which can result in shifting of the vehicle during these operations.
CAUTION: Do not install brake discs that are less than the minimum thickness specified.
Do not machine a brake disc below the minimum thickness specification.
1. Check wheel bearing end- play and correct as necessary.
2. NOTE: Begin at the front of the vehicle unless the vibration has been isolated to the rear.
Remove the tire and wheel assembly.
3. Remove the brake caliper and the brake caliper anchor plate. Refer to the appropriate section in Group 206 for the procedure.
4. Inspect the brake linings. Install new brake linings if below specification. For additional information, refer to the appropriate brake section.
5. 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.
zDo not machine a new brake disc.
SECTION 100-
04: Noise, Vibration and Harshness 2003 Mustang Workshop Manual Special Tool(s)
Gauge, Clutch Housing
308-
021 (T75L-4201- A) Dial Indicator Gauge with
Holding Fixture
100-
002 (TOOL- 4201-C) or
equivalent
Material Item Specification
Metal Surface Cleaner
F4AZ-
19A536- RA or equivalent WSE-
M5B392-
A High Temperature Nickel Anti-
Seize Lubricant
F6AZ-
9L494- AA or equivalent ESE-
M12A4-A Klj . 1 ba
32003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

DIAGNOSIS AND TESTING
Driveline System
SECTION 205-
00: Driveline System — General Information 2003 Mustang Workshop Manual Special Tool(s)
Clamp Plate
205-
320 (T92L-4851- C) Clutch Housing Alignment
Adapter
308-
021 (T75L-4201- A) Companion Flange Holding
Tool
205-
126 (T78P-4851- A) Companion Flange Runout
Gauge
205-
319 (T92L-4851- B) Dial Indicator with Bracketry
100-
002 (TOOL- 4201-C) or
equivalent Dial Indicator/Magnetic Base
100-
D002 (D78P-4201- B) or
equivalent Vibration Analyzer
100-
F027 (014- 00344) Traction-Lok® Torque Tool
205- 022 (T66L-4204- A) Klj . 1 ba
192003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

IN-
VEHICLE REPAIR
Differential Case
Removal 1. Remove the differential housing cover (4033) and drain the rear axle (4001). For additional information, refer to Differential Housing Cover in this section.
2. CAUTION: Reinstall the differential pinion shaft (4211) and the bolt in the differential
case (4204) after removing the axle shafts (4234).
SECTION 205-
02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring
Gear 2003 Mustang Workshop
Manual Special Tool(s)
2-
Jaw Puller
205- D072 (D97L-4221- A) or
equivalent Dial Indicator Gauge with
Holding Fixture
100-
002 (TOOL- 4201-C) or
equivalent Gauge, Clutch Housing
308-
021 (T75L-4201- A) or
equivalent Installer, Differential Shim
205-
220 (T85L-4067- AH) Installer, Differential Side
Bearing
205-
009 (T57L-4221- A1) Step Plate
205-
D016 (D80L-630- 5) or
equivalent Klj . 1 ba
132003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

IN-
VEHICLE REPAIR
Differential Case
Removal 1. Remove the differential housing cover (4033) and drain the rear axle (4001). For additional information, refer to Differential Housing Cover in this section.
2. CAUTION: Reinstall the differential pinion shaft (4211) and the bolt in the differential
case (4204) after removing the axle shafts (4234).
SECTION 205-
02B: Rear Drive Axle/Differential — Ford 8.8-Inch Ring
Gear 2003 Mustang Workshop
Manual Special Tool(s)
2-
Jaw Puller
205- D072 (D97L-4221- A) or
equivalent Dial Indicator Gauge with
Holding Fixture
100-
002 (TOOL- 4201-C) or
equivalent Gauge, Clutch Housing
308-
021 (T75L-4201- A) or
equivalent Installer, Differential Shim
205-
220 (T85L-4067- AH) Installer, Differential Side
Bearing
205-
010 (T57L-4221- A2) Step Plate
205-
D061 (D83T-4205- C2) or
equivalent Klj . 1 ba
132003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

DISASSEMBLY AND ASSEMBLY
Differential Case and Ring Gear —
Traction-Lok®
Disassembly 1. Remove the differential assembly from the differential housing. For additional information, refer to Differential Case in this section.
2. Remove the 10 bolts.
SECTION 205-
02B: Rear Drive Axle/Differential — Ford 8.8-Inch Ring
Gear 2003 Mustang Workshop
Manual Special Tool(s)
2-
Jaw Puller
205- D072 (D97L-4221- A) or
equivalent Gauge, Differential Clutch
205-
022 (T66L-4204- A) Gauge, Differential Clutch
205-
135 (T80P-4946- A) Installer, Differential Side
Bearing
205-
010 (T57L-4221- A2) Step Plate
205-
D061 (D83T-4205- C2) or
equivalent Klj . 1 ba
92003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

clutch spring (4214). Failure to follow these instructions may result in personal injury.
Remove the differential clutch spring.
7. Remove the differential gears. 1. Remove the two differential pinion gears (4215).
2. Remove the two differential side gears (4236).
3. Remove the two differential pinion thrust washers (4230).
8. CAUTION: Keep the differential clutch packs (4947) in order. Do not mix them.
Always reassemble them in the same sequence.
Separate the differential clutch packs and shims from the differential side gears and tag them
"right" and "left".
zClean and inspect the remaining differential components for wear and damage and install
new parts as necessary. Klj . 3 ba
92003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

9.
CAUTION: Do not use acids or solvents when cleaning the differential clutch pack.
Wipe components only with a clean, lint- free cloth.
Clean and inspect the differential clutch packs for wear and damage and install new parts as
necessary.
Assembly
1. CAUTION: 118 ml (4 oz) of the specified Ford Friction Modifier must be used in the
axle.
Lubricate each steel clutch plate and soak all friction plates for no less than 15 minutes.
zUse Additive Friction Modifier C8AZ- 19B546-A or equivalent meeting Ford specification
EST- M2C118- A
2. CAUTION: Do not mix the differential clutch packs or shims from one side with the
other.
Assemble the differential clutch packs (without the shims) on their respective differential side
gears. Klj . 4 ba
92003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

3. Place the base portion of the special tool in a vise. Install the differential differential side gear
and differential clutch pack (without the shim) on the tool.
4. Position the special tool hand- tight on top of the differential clutch pack.
5. Install the special tool over the disc and differential clutch pack. Klj . 5 ba
92003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...