2003 FORD MUSTANG Workshop Manual

air suspension key fob radio controls glove box heater ignition

Page 305 of 4378

FORD MUSTANG 2003 Workshop Manual Check the U-
joints for freedom of movement.
�z If binding, strike the yoke with a brass or plastic hammer.
6. Install the driveshaft. For additional information, refer to Driveshaft in this secti

Page 306 of 4378

FORD MUSTANG 2003 Workshop Manual SPECIFICATIONS
a
In- vehicle repair refill capacities are determined by filling the rear axle with the specified lubricant to
6.4- 14.3- mm (1/4- 9/16-in) below the bottom of the fill hole.
SECTIO

SPECIFICATIONS
a
In- vehicle repair refill capacities are determined by filling the rear axle with the specified lubricant to
6.4- 14.3- mm (1/4- 9/16-in) below the bottom of the fill hole.
SECTION 205-
02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring
Gear 2003 Mustang Workshop
Manual General Specifications
Item Specification
Lubes and Sealers
SAE 80W-
90 Premium Rear Axle Lubricant XY-
80W90- QL WSP-
M2C197- A Premium Long-
Life Grease XG -1-C ESA-
M1C75- B Rust Penetrant and Inhibitor F2AZ-19A501-
A ESR-
M99C56- A High Temperature Nickel Anti-
Sieze Lubricant
F6AZ- 9L494- AA ESE-
M124A- A Clear Silicone Rubber F7AZ-
19554-CA ESB-
M4G92- A Threadlock and Sealer EOAZ-19554-
AA WSK-
M2G351- A5 Lubricant Fill Level Checks
Approximate axle fill capacity
a 1.54-1.66-
liters (3.25-3.50- pints)
6.4-14.3- mm (1/4-9/16- in) below the bottom of
the fill hole Clearance, Tolerance and Adjustments
Maximum ring gear back face runout 0.102 mm (0.004 in)
Maximum differential case runout 0.076 mm (0.003 in)
Differential side gear thrust washer thickness 0.762 mm -
0.813 mm (0.030 in - 0.032 in) Differential pinion gear thrust washer thickness 0.762 mm -
0.813 mm (0.030 in - 0.032 in) Maximum axle shaft end play 0.762 mm (0.030 in)
Ring gear backlash 0.203 mm-
0.381 mm
(0.008 in- 0.015 in)
[(0.305 mm- 0.381 mm
(0.012 in- 0.015 in) preferred] Variation between teeth maximum backlash 0.102 mm (0.004 in)
Pinion flange runout 0.25 mm (0.010 in) T.I.R.
Torque Specifications Description Nm lb-
ft lb-
in Bolt retaining the differential pinion shaft to the differential case 30 22 —
Bolt retaining the driveshaft yoke to the pinion flange 112 83 —
Bolt retaining the differential housing cover to the differential housing 44 32 —
Oil filler plug 30 22 —
Pinion bearing preload (used pinion bearings) 0.9-
1.5 — 8-
14 Pinion bearing preload (new pinion bearings) 1.8-
3.3 — 16-
29 Adapter for 205-
S127 2.2 — 20 Klj . 1 ba
22003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

Page 307 of 4378

FORD MUSTANG 2003 Workshop Manual Bolt retaining the bearing cap to the differential case 105 77 —
Bolt retaining the ring gear to the differential case 105 77 — Klj . 2 ba
22003 Mustang Workshop Manual
17. 11. 2011f

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FORD MUSTANG 2003 Workshop Manual DESCRIPTION AND OPERATION
Rear Drive Axle and Differential
SECTION 205-
02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring
Gear 2003 Mustang Workshop
Manual Item Part Number Description

Page 309 of 4378

FORD MUSTANG 2003 Workshop Manual 4 4222 Differential bearing cup
5 4067 Differential bearing shim
6 4216 Rear axle differential gear case bolt
7 4204 Differential case
8 — Ring gear (part of 4209)
9 — Bearing cap (

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FORD MUSTANG 2003 Workshop Manual �z
The axle housing assembly consists of a cast center section with two steel tube assemblies and
a stamped differential housing cover (4033). The differential housing cover uses silicone sealant
as

Page 311 of 4378

FORD MUSTANG 2003 Workshop Manual IN-
VEHICLE REPAIR
Axle Shaft
Removal 1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. Remove the wheel and tire assembly. For additional information,

Page 312 of 4378

FORD MUSTANG 2003 Workshop Manual 206 - 09A .
8. CAUTION: Do not damage the wheel bearing oil seal.
Remove the axle shaft.
Installation 1. Lubricate the lip of the wheel bearing oil seal �zUse Premium Long- Life Grease XG-1-C o

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