2003 FORD MUSTANG Workshop Manual

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Page 361 of 4378

FORD MUSTANG 2003 Workshop Manual 8. Remove the differential side gears (4236) and the differential side gear thrust washers (4228).
Assembly 1. Lubricate the differential side gear thrust washers and the differential side gear jour

Page 362 of 4378

FORD MUSTANG 2003 Workshop Manual 3. Position the differential side gear and thrust washer assemblies in the differential case.
4. Engage the differential pinion gears with the differential side gears and rotate the pinion gears
to

Page 363 of 4378

FORD MUSTANG 2003 Workshop Manual installation.
Install a new bolt finger-
tight.
7. Using the special tool, install the new differential bearings, if removed.
8. Position the ring gear and the differential case. Align the bolt hol

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FORD MUSTANG 2003 Workshop Manual 10. Install the differential case. For additional information, refer to
Differential Case in this section. Klj . 6 ba
62003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/t

Page 365 of 4378

FORD MUSTANG 2003 Workshop Manual SPECIFICATIONS
a
If it is necessary to refill a Traction- Lok® axle with new lubricant, add 118 ml (4 oz) of Additive
Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-

SPECIFICATIONS
a
If it is necessary to refill a Traction- Lok® axle with new lubricant, add 118 ml (4 oz) of Additive
Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST- M2C118-A before
filling the axle with the new lubricant.
b 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-
02B: Rear Drive Axle/Differential — Ford 8.8-Inch Ring
Gear 2003 Mustang Workshop
Manual General Specifications
Item Specification
Lubes and Sealers
SAE 75W-
140 High Performance Rear Axle
Lubricant
F1TZ- 19580- B WSL-
M2C192- 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 Additive Friction Modifier C8AZ-
19B546-A EST-
M2C118- A Clear Silicone Rubber D6AZ-
19562-AA ESB-
M4G92- A Threadlock and Sealer EOAZ-19554-
AA WSK-
M2G351- A5 Lubricant Fill Level Checks
Additive Friction Modifier 118 ml (4 oz)
Approximate axle fill capacity
a b 1.66-1.77-
liters (3.5-3.75-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
(0.305 mm - 0.381 mm preferred)
0.008 in - 0.015 in
(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 — Klj . 1 ba
22003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

Page 366 of 4378

FORD MUSTANG 2003 Workshop Manual 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

Page 367 of 4378

FORD MUSTANG 2003 Workshop Manual DESCRIPTION AND OPERATION
Rear Drive Axle and Differential
SECTION 205-
02B: Rear Drive Axle/Differential — Ford 8.8-Inch Ring
Gear 2003 Mustang Workshop
Manual Item Part Number Description

Page 368 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 gearset)
9 — Beari

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