2003 FORD MUSTANG lock

(4010) to protect the machined surface from damage.
Using a pry bar and a wood block, remove the differential assembly from the differential
housing.
8. Remove the 10 bolts.
9. CAUTION: Do not damage the threads in the bolt holes.
Insert a punch in the bolt holes, and drive off the ring gear.
10. If the ring gear backface runout measurement, taken at the beginning of this procedure, did not exceed the specification, proceed to the appropriate procedure as necessary: Drive Pinion ,
Differential Case and Ring Gear in this section, or to Installation in this procedure. If the ring
gear backface runout measurement, taken at the beginning of this procedure, exceeds the
specification, the cause may be a warped ring gear, differential case/differential bearing
damage. Proceed as follows to verify the cause of the excessive runout.
11. Position the differential assembly, including the differential bearing cups (4222) and differential bearing shims (4067), in the differential housing. Install the bearing caps and bolts. Klj . 3 ba
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5.
NOTE: If necessary, use Rust Penetrant and Inhibitor F2AZ-19A501- A meeting Ford
specification ESR-M99C56- A to loosen the sensor for removal.
Remove the rear anti- lock brake sensors from the rear disc brake adapters. For additional
information, refer to Section 206 - 09A .
6. CAUTION: Index- mark the brake discs and the wheel studs prior to brake disc
removal.
CAUTION: Do not allow the calipers to hang from the brake hoses.
Remove the rear brake discs. For additional information, refer to Section 206 - 04 .
7. CAUTION: Secure the differential housing (4010) to the jack with a suitable strap.
Support the differential housing with a suitable hi- lift jack. Klj . 2 ba
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12. Disconnect the lower suspension arm and bushings from the axle.
13. Remove the axle from the vehicle.
14.
CAUTION: Align the index marks on the driveshaft centering socket yoke and the
pinion flange.
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.
CAUTION: Raise the suspension to the reference marks on the rear shock
absorbers before tightening the suspension fasteners.
NOTE: Apply High Temperature Nickel Anti- Sieze Lubricant F6AZ-9L494-AA meeting Ford
specification ESE-M124A- A to the rear anti-lock brake sensor body where it will make contact
when installed.
To install, reverse the removal procedure.
zRefer to Section 204 - 02 for rear suspension fastener tightening specifications.
z Refer to Section 204 - 04 for wheel nut tightening specification.
z Check and, if necessary, fill the axle with the specified lubricant to the specified level. For
additional information, refer to Specifications in this section. Klj . 4 ba
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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 align with the differential pinion shaft bore.
5. Insert the differential pinion shaft. zAlign the hole in the differential pinion shaft with the hole in the differential case.
6. NOTE: If a new bolt is unavailable, coat the original bolt threads with Threadlock and Sealer
EOAZ- 19554- AA or equivalent meeting Ford specifications WSK-M2G351- A5 prior to Klj . 4 ba
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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
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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 — Bearing cap (part of 4010)
10 4010 Rear axle housing
11 373098-
S Filler plug
12 4662 Collapsible spacer
13 4670 Rear axle drive pinion shaft oil slinger
14 4676 Rear axle drive pinion seal
15 4851 Pinion flange
16 389546-S100 Pinion nut
17 4621 Differential pinion bearing
18 2C026 Rear brake disc
19 — Axle shaft flange (part of 4234)
20 2C189 Rear brake anti-
lock sensor indicator 21 2552 Rear disc brake caliper
22 N601951-S2 Bolt
23 N804361-S100 Clip
24 — Bolt (part of 4010)
25 2C190 Rear brake anti-
lock sensor 26 2C101 Left hand rear disc brake adapter
27 2C100 Right hand rear disc brake adapter
28 N8015163-S190 Caliper anchor bolt
29 2C028 Rear wheel brake disc shield
30 N602726-S2 Bolt (3 req'd)
31 4616 Differential drive pinion bearing cup
32 4628 Rear axle pinion bearing cup
33 4630 Differential pinion bearing
34 — Drive pinion gear (part of 4209 gearset)
35 4663 Drive pinion bearing adjustment shim
36 — Bolt (part of 4010)
37 4241 Differential pinion shaft lock bolt
38 4211 Differential pinion shaft
39 4N237 U-
washer 40 383548 Bolt
41 — Rear axle identification tag (part of 4001)
42 4033 Differential housing cover
43 4230 Differential pinion thrust washer
44 4215 Differential pinion gear Klj . 2 ba
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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 a gasket.
z The hypoid- design gearset consists of 8.8- inch ring gear (4209) and a drive pinion gear (4209).
Two opposed tapered roller bearings support the drive pinion in the axle housing (4010).
z A collapsible spacer (4662), located on the differential pinion shaft, maintains pinion bearing
preload. The pinion nut (389546- S100) adjusts the preload.
z Differential bearing shims (4067), located between the differential bearing cups (4222) and the
rear axle housing, adjust the differential bearing preload and the ring gear backlash.
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 tapered roller bearings (differential
bearings) (4221) support the differential case in the axle housing. Removable bearing caps
(4010) retain the differential assembly in the axle 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 axle
shafts (4234) are splined. The differential pinion shaft lock bolt (4241) retains the differential
pinion shaft in the differential case.
z An embossed metal tag, bolted to the differential housing cover, contains rear axle
identification. Klj . 3 ba
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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, refer to Section 204 - 04 .
3. Remove the rear brake disc (2C026). For additional information, refer to Section 206 - 04 .
4. Remove the differential housing cover (4033) and drain the lubricant. For additional information, refer to Differential Housing Cover in this section.
5. Remove the differential pinion shaft (4211). 1. Remove the differential pinion shaft lock bolt (4241).
2. Remove the differential pinion shaft.
6. CAUTION: Do not damage the rubber O- ring in the axle shaft groove.
Remove the U- washer (4N237).
1. Push the axle shafts (4234) inboard.
2. Remove the U- washer.
7. CAUTION: Damage to the rear brake anti- lock sensor (2C190) may occur if it is not
removed before the axle shaft.
Carefully remove the rear brake anti- lock sensor. For additional information, refer to Section SECTION 205-
02B: Rear Drive Axle/Differential — Ford 8.8-Inch Ring
Gear 2003 Mustang Workshop
Manual Klj . 1 ba
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