2003 FORD MUSTANG clutch

6. Install the nut.
7.
NOTE: Clutch Pack Rebuild Kit F5AZ- 4947-A is available for this application.
Select and insert the thickest feeler gauge blade that will enter between the tool and the
differential clutch pack. The reading will be the thickness of the new clutch shim.
8. Remove the special tools from the differential clutch pack and differential side gear assembly.
9. Install shim(s) on the differential clutch pack and differential side gear assembly.
10. Install the differential side gear assemblies in the differential case. Selective Shims
Part Number Description
EOAZ-
4A324- G 0.025 Inch
EOAZ-
4A324- H 0.030 Inch
EOAZ-
4A324- C 0.035 Inch
EOAZ-
4A324- D 0.040 Inch
EOAZ-
4A324- F 0.045 Inch Klj . 6 ba
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11. Install the differential pinion gear and differential pinion thrust washer assemblies in the
differential case.
12. Using a soft- faced hammer, install the differential clutch spring.
13. Install the differential pinion shaft and install a new bolt finger- tight. Klj . 7 ba
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14. Mount the differential case and the special tool in a vise. Using the special tool, check the
torque necessary to rotate one differential side gear.
zIf reusing the original clutch plates, the initial minimum break- away torque must be no
less than the specification. The minimum rotating torque necessary to keep the
differential side gear turning with new clutch plates may vary.
15. Using the special tool, install the differential bearings, if removed.
16. Position the differential ring gear and the differential case. Align the bolt holes by starting two bolts through the holes in the differential case and the differential ring gear. Press the
differential ring gear on the differential case. Klj . 8 ba
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a
Use Stud and Bearing Mount EOAZ-19554- BA or equivalent meeting Ford specification WSK-
M2G349- A1.
b With pinion flange yoke seal. Pinion nose crossmember nut 250 184 —
Toe link nut 47 35 —
Shock absorber to lower suspension arm and bushing 133 98 —
Knuckle to lower suspension arm and bushing 115 85 —
Knuckle to upper suspension arm and bushing 90 66 —
Filler plug 34 25 —
Ring gear bolt
a 105 77 —
Differential pinion shaft lock bolt 30 22 —
Bearing cap bolt 105 77 —
Differential housing cover bolt 32 24 —
Pinion bearing preload
—(drive pinion collapsible spacer) used bearings b 0.9-
1.16 — 8-14
New pinion bearings 1.8-
3.2 — 16-
29 Traction-
Lok® clutch gauge nut 6.7 — 60
Initial minimum breakaway torque 27 20 —Klj . 2 ba
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z
The differential housing (4010) consists of a cast aluminum housing and a cast aluminum
differential housing cover (4033). The differential housing cover uses silicone sealant as a
gasket.
z The hypoid- design gearset consists of a 8.8- inch differential ring gear and a drive pinion gear.
Two opposed pinion bearings (4621) (4630) support the drive pinion gear in the differential
housing.
z A differential drive pinion collapsible spacer (4662), located on the drive pinion gear shaft,
maintains pinion bearing preload. The pinion nut adjusts the preload.
z Differential bearing shims (4067), located between the differential bearing cups (4222) and the
differential housing, adjust the differential ring gear backlash and the differential bearing
preload.
z The differential case (4204) is a one- piece design with two openings to allow for assembly of
the internal components and lubricant flow. Two opposed differential bearings (4221) support
the differential case in the differential housing. Removable differential bearing caps retain the
differential assembly in the differential housing.
z Inside the differential case, the differential pinion shaft (4211) supports two differential pinion
gears (4215). The pinion gears engage the differential side gears (4236), to which the halfshafts 10 4033 Differential housing cover
11 4B416 Inboard CV joint stub shaft pilot bearing housing
seal
12 4B413 Inboard CV joint stub shaft pilot bearing
13 4010 Differential housing
14 4662 Differential drive pinion collapsible spacer
15 4670 Rear axle drive pinion shaft oil slinger
16 4851 Rear axle pinion flange
17 389546-
S100 Pinion nut
18 4859 Drive pinion oil seal deflector
19 4676 Rear axle drive pinion seal
20 4621 Pinion bearing
21 4616 Differential drive pinion bearing cup
22 56187-
S Bolt
23 — Drive pinion gear (part of 4209)
24 — Differential bearing cap
(part of 4010)
25 4628 Rear axle pinion bearing cup
26 4630 Pinion bearing
27 4663 Drive pinion bearing adjustment shim
28 4A321 Rear axle differential clutch shim
29 — Clutch plate (part of 4947)
30 — Clutch disc (part of 4947)
31 4236 Differential side gear
32 4214 Differential clutch spring
33 4215 Differential pinion gear
34 4947 Differential clutch pack Klj . 2 ba
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DISASSEMBLY AND ASSEMBLY
Axle
SECTION 205-
02C: Rear Drive Axle/Differential — Ford 8.8-Inch IRS 2003 Mustang Workshop Manual Special Tool(s)
2-
Jaw Puller
205- D072 (D97L-4221- A) or
equivalent Adapter for 205-
S127
205- 105 (T76P-4020- A3) Bearing Preload Tool
205-
395 (T93P-4220- A) Plate, Bearing/Oil Seal
205-
090 (T75L-1165- B) Gauge, Clutch Housing
308-
021 (T75L-4201- A) Holding Fixture, Drive Pinion
Flange
205-
126 (T78P-4851- A) Installer, Drive Pinion Flange
205-
002 (TOOL- 4858-E) or
equivalent Dial Indicator Gauge
100-
D005 (D78P-4201- G) or
equivalent Klj . 1 ba
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Disassembly
Initial disassembly
1. Remove the differential housing cover (4033) and drain the lubricant into a suitable container.
2. Wipe the lubricant from the internal working parts and inspect the parts for wear and damage.
3. Using the special tool, measure and note the differential ring gear backface runout. zRemove the special tool. Gauge, Differential Clutch
205-
135 (T80P-4946- A) Gauge, Differential Clutch
Torque
205-
013 (T59L-4204- A) Remover, Bearing
205-
055 (T71P-4621- B) Holding Fixture, Transmission
307-
003 (T57L- 500-B) Klj . 4 ba
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36.
WARNING: The differential clutch spring (4214) is under tension. Remove the spring
carefully. Failure to follow these instructions may result in personal injury.
Remove the differential clutch spring.
37. Remove the differential gears. 1. Remove the two differential pinion gears (4215) and pinion thrust washers (4230).
2. Remove the two differential side gears (4236) with the clutch packs (4947) and the shims and tag them "left" and "right."
38. CAUTION: Keep the differential clutch packs in order. Do not mix them. Always
reassemble them in the same sequence.
Remove the differential clutch packs and shims from the differential side gears.
zClean and inspect the remaining differential components for wear and damage. Install
new parts as necessary. Klj . 14 ba
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