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5.
CAUTION: Do not under any circumstance loosen the nut to reduce preload. If it is
necessary to reduce preload, install a new collapsible spacer (4662) and nut.
CAUTION: Remove the special tool while taking preload readings with the Nm
(inch/pound) torque wrench.
Tighten the nut to set the preload.
zRotate the drive pinion occasionally to make sure the differential pinion bearings (4630)
(4621) seat correctly. Take frequent differential pinion bearing torque preload readings by
rotating the drive pinion with a Nm (inch/pound) torque wrench.
z If the preload recorded prior to disassembly is lower than the specification for used
bearings, then tighten the nut to specification. If the preload recorded prior to
disassembly is higher than the specification for used bearings, then tighten the nut to the
original reading as recorded.
z Refer to the torque specification for used differential pinion bearings in the Specifications
portion of this section.
6. CAUTION: Align the index marks.
CAUTION: Install the driveshaft with new bolts. If new bolts are not available, apply
Threadlock and Sealer EOAZ-19554- AA or equivalent meeting Ford specification WSK-
M2G351- A5 to the threads of the original bolts.
CAUTION: The driveshaft centering socket yoke fits tightly on the pinion flange
pilot. To make sure that the yoke seats squarely on the flange, tighten the bolts evenly in
a cross pattern as shown.
Connect the driveshaft. For additional information, refer to Section 205 - 01 . Klj . 4 ba
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7. Install the rear brake calipers. For additional information, refer to
Section 206 - 04 .
8. Install the rear wheel and tire assemblies. For additional information, refer to Section 204 - 04 .
9. Lower the vehicle. Klj . 5 ba
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IN-
VEHICLE REPAIR
Differential Housing Cover
Removal 1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. NOTE: Empty the lubricant into a clean container for reuse.
Remove the differential housing cover (4033). 1. Remove the 10 bolts and drain the lubricant from the differential housing (4010).
2. Remove the differential housing cover.
Installation 1. CAUTION: Make sure the machined surfaces on both the differential housing and
the differential housing cover are clean and free of oil before applying the new silicone
sealant. To prevent contamination, cover the inside of the rear axle (4001) prior to
cleaning the machined surface.
Clean the differential housing and the differential housing cover gasket mating surfaces.
2. CAUTION: Install the differential housing cover within 15 minutes of applying the
silicone, or it will be necessary to remove and reapply new sealant.
Apply a continuous bead of sealant of the specified thickness to the differential housing cover.
zUse Clear Silicone Rubber F7AZ- 19554-CA or equivalent meeting Ford specifications
ESB- M4G92- A.
SECTION 205-
02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring
Gear 2003 Mustang Workshop
Manual Klj . 1 ba
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3.
NOTE: If possible, allow one hour before filling the axle with lubricant to make sure the silicone
sealant has cured.
Install the differential housing cover. 1. Install the differential housing cover.
2. Install the 10 bolts.
4. NOTE: 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.
Fill the rear axle to the level shown, approximately 1.54-1.66- liters (3.25-3.50-pints) of lubricant,
and install the filler plug.
zUse SAE 80W- 90 Premium Rear Axle Lubricant XY-80W90- QL or equivalent meeting
Ford specification WSP- M2C197-A.
5. Lower the vehicle. Klj . 2 ba
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Klj . 3 ba
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IN-
VEHICLE REPAIR
Axle Housing Bushing
Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure can result in major service expense. A new part with
the same part number must be installed if installation becomes necessary. If substitution is
necessary, the part must be of the same finish and property class. Torque values must be used
as specified during reassembly to make sure of correct retention of these parts.
1. Remove the upper arm and bushing (5500). For additional information, refer to Section 204 - 02 .
2. Using the special tools, remove the bushing.
Installation 1. Using the special tools, install the bushing.
SECTION 205-
02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring
Gear 2003 Mustang Workshop
Manual Special Tool(s)
Axle Suspension Bushing Set
204-
S030 (T78P-5638- A) Klj . 1 ba
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2. Using a suitable calibrated micrometer, measure the bushing as shown. If not within
specifications, adjust as necessary.
3. Install the upper arm and bushing. For additional information, refer to Section 204 - 02 . Klj . 2 ba
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IN-
VEHICLE REPAIR
Drive Pinion SECTION 205-
02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring
Gear 2003 Mustang Workshop
Manual Special Tool(s)
Adapter for 205-
S127
205- 105 (T76P-4020- A3) Adapter for 205-
S127
205- 109 (T76P-4020- A9) Adapter for 205-
S127
205- 110 (T76P-4020- A10) Adapter for 205-
S127
205- 111 (T76P-4020- A11) Adapter for 205-
S127
205- 125 (T78P-4020- A15) Adapter for 303-
224
205- 153 (T80T-4000- W) Gauge Tube
205-
D034 (D80T-4020- F49) or
equivalent Handle (Long)
205-
D055 (D81L-4000- A) or Klj . 1 ba
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