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7. Position the special tool as shown. Turn the Companion Flange Runout Gauge, and locate and
mark the high spot on the pinion flange with yellow paint.
If the flange runout exceeds 0.25 mm (0.010 inch), remove the pinion flange, reindex the flange one-
half turn on the pinion, and reinstall it. Refer to Section 205 - 02A or
Section 205 - 02B .
8. Check the runout again. If necessary, rotate the flange until an acceptable runout is obtained. If the flange runout is still more than 0.25 mm (0.010 inch), install a new pinion flange.
9. If excessive runout is still evident after installing a new pinion flange, install a new ring and pinion. Repeat the above checks until the runout is within specifications.
10. Install the driveshaft. Refer to Section 205 - 01 .
Tooth Contact Pattern Check — Gearset
1. To check the gear tooth contact, paint the gear teeth with the special marking compound. A mixture that is too wet will run and smear; a mixture that is too dry cannot be pressed out from
between the teeth. Klj . 17 ba
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2. Use a box wrench on the ring gear bolts as a lever to rotate the ring gear several complete
revolutions in both directions or until a clear tooth contact pattern is obtained.
3. Certain types of gear tooth contact patterns on the ring gear indicate incorrect adjustment. Incorrect adjustment can be corrected by readjusting the ring gear or the pinion.
Contact Pattern Location
In general, desirable ring gear tooth patterns must have the following characteristics:
zdrive pattern on the drive side ring gear well centered on the tooth
z coast pattern on the coast side ring gear well centered on the tooth
z clearance between the pattern and the top of the tooth
z no hard lines where the pressure is high
Acceptable ring gear tooth patterns for all axles.
Correct backlash with a thinner pinion position shim required.
Correct backlash with a thicker pinion position shim required. Klj . 18 ba
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Correct pinion position shim that requires a decrease in backlash.
Correct pinion position shim that requires an increase in backlash. Klj . 19 ba
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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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7. To check the engine angle, rotate the driveshaft so that the slip yoke ear is parallel to the floor.
Remove the U- joint snap ring, then install the special tool. Check and record the engine angle
reading.
zIf the angle is not within specifications, repair or adjust to obtain the correct angles.
Inspect the powertrain/drivetrain mounts or frame rails for wear or damage. Klj . 2 ba
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GENERAL PROCEDURES
Axle Housing Casting Porosity (Holes in Casting) Repair
CAUTION: To keep the axle's sound characteristics, do not disassemble the carrier.
NOTE: Casting porosity is a condition where occasionally gas bubbles will form during the casting
process leaving small pockets in the metal that will cause the axle housing to leak.
1. To fill small pockets, peen in a small amount of body lead.
2. Seal the pocket. zUse epoxy sealer meeting Ford specification M- 3D35A(E).
3. To fill large pockets, drill and tap a shallow hole for a small setscrew. Install the setscrew and seal it.
zUse epoxy sealer meeting Ford specification M- 3D35A(E).
SECTION 205-
00: Driveline System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
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GENERAL PROCEDURES
Axle Housing Weld Leaks Repair
1. CAUTION: To keep the axle's sound characteristics, do not disassemble the carrier.
CAUTION: Rear axle housing straightness is too critical for field repair. Install a new
axle housing if a weld is broken.
NOTE: Most minor weld leaks are repairable. This includes the puddle and fill welds that join
the axle shaft tube to the axle housing on integral axles.
Seal the weld.
zUse Devcon Aluminum Liquid F2 or equivalent meeting Ford specification M- 3D35A(E).
SECTION 205-
00: Driveline System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
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SPECIFICATIONS
SECTION 205-
01: Driveshaft 2003 Mustang Workshop Manual Torque Specifications
Description Nm lb-
ft Pinion flange bolts 112 83 Klj . 1 ba
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