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53.
NOTE: Tighten the bolts prior to releasing the carrier spreader.
Install the differential bearing caps in their original locations and positions and tighten the bolts.
54. Remove the special tool.
55. Install the special tool at the 12 o'clock position.
56. Using the special tools, measure the differential ring gear backlash at four equally spaced points. Klj . 31 ba
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1. Attach the special tool.
2. Position the special tool tip centrally on a drive tooth.
3. Zero the indicator.
4. Turn the differential ring gear without turning the drive pinion gear. Record the indicator
reading. The allowable backlash is 0.203 mm ( 0.008 in) to 0.330 mm ( 0.013 in) and
must not very more than 0.1016 mm (0.004 in) between points measured. A backlash
variation of more than 0.1016 mm (0.004 in) between points checked indicates gear/case
runout.
„If backlash is within specifications, proceed to Final assembly in this procedure.
„ To correct for a high or low backlash proceed as follows.
57. To correct for high or low backlash increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount. Refer to the
following tables when adjusting the backlash. When the backlash is within specifications,
proceed to Final assembly in this procedure. Backlash Change Required Thickness Change Required
mm Inch mm Inch
0.025 0.001 0.050 0.002
0.050 0.002 0.050 0.002
0.076 0.003 0.101 0.004
0.101 0.004 0.152 0.006
0.127 0.005 0.152 0.006
0.152 0.006 0.203 0.008
0.177 0.007 0.254 0.010
0.203 0.008 0.254 0.010
0.228 0.009 0.304 0.012
0.254 0.010 0.355 0.014
0.279 0.011 0.355 0.014 Klj . 32 ba
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0.304 0.012 0.406 0.016
0.330 0.013 0.457 0.018
0.335 0.014 0.457 0.018
0.381 0.015 0.508 0.020
Differential Shim Size Chart — 4067 —Numbers of Stripes and Color Code Dimension A
mm Inch
2—C-
COAL 7.7978-7.8105 0.3070-0.3075
1—C-
COAL 7.7470-7.7597 0.3050-0.3055
5—
BLU 7.6962-
7.7089 0.3030-0.3035
4—
BLU 7.6454-
7.6581 0.3010-0.3015
3—
BLU 7.5946-
7.6073 0.2990-0.2995
2—
BLU 7.5458-
7.5565 0.2970-0.2975
5—
PINK 7.4422-
7.4549 0.2930-0.2935
4—
PINK 7.3914-
7.4041 0.2910-0.2915
3—
PINK 7.3406-
7.3533 0.2890-0.2895
2—
PINK 7.2898-
7.3025 0.2870-0.2875
1—
PINK 7.2390-
7.2517 0.2850-0.2855
5—
GRN 7.1882-
7.2009 0.2830-0.2835
4—
GRN 7.1374-
7.1501 0.2810-0.2815
3—
GRN 7.0866-
7.0993 0.2790-0.2795
2—
GRN 7.0358-
7.0485 0.2770-0.2775
1—
GRN 6.9850-
7.0485 0.2750-0.2755
5—
WH 6.9342-
6.9469 0.2730-0.2735
4—
WH 6.8834-
6.8961 0.2710-0.2715
3—
WH 6.8326-
6.8453 0.2690-0.2695
2—
WH 6.7818-
6.7945 0.2670-0.2675
1—
WH 6.7310-
6.7437 0.2650-0.2655
5—YEL 6.6802-6.6929 0.2630-0.2635
4—YEL 6.6294-6.6421 0.2610-0.2615
3—YEL 6.5786-6.5913 0.2590-0.2595
2—YEL 6.5278-6.5405 0.2570-0.2575
1—YEL 6.4770-6.4897 0.2550-0.2555
5—
ORNG 6.4262-
6.4389 0.2530-0.2535
4—
ORNG 6.3754-
6.3881 0.2510-0.2515
3—
ORNG 6.3246-
6.3373 0.2490-0.2495
2—
ORNG 6.2738-
6.2865 0.2470-0.2475
1—
ORNG 6.2223-
6.2357 0.2450-0.2455
2—
RED 6.1722-
6.1849 0.2430-0.2435
1—
RED 6.1214-
6.1341 0.2410-0.2415 Klj . 33 ba
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Final assembly
58. CAUTION: The machined surfaces on the differential housing and the differential
housing cover must be clean and free of oil before applying the new silicone sealant.
Cover the inside of the axle before cleaning the machined surface to prevent
contamination.
CAUTION: Install the differential housing cover within 15 minutes of applying the
silicone material.
CAUTION: Allow the sealant to cure for one hour before filling the axle with
lubricant.
Apply a continuous bead of sealant, of the specified thickness, to the differential housing cover
mounting surface.
zUse Clear Silicone Rubber F7AZ- 19554-CA or equivalent meeting Ford specification
ESB- M4G92- A.
59. Install the differential housing cover.
60. CAUTION: First fill the rear axle (4001) with 118 ml (4 oz) of Additive Friction
Modifier C8AZ- 19B546-A or equivalent meeting Ford specification EST- M2C118-A.
Install the rear axle assembly in the vehicle. Fill the axle with the specified lubricant. For
additional information, refer to Axle Housing in this section. Klj . 34 ba
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Klj . 35 ba
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SPECIFICATIONS
SECTION 205-
05: Rear Drive Halfshafts 2003 Mustang Workshop Manual General Specifications
Item Specification
Halfshaft assembled length 817.6 mm (32.19 in)
Torque Specifications Description Nm lb-
ft Tie-
rod end to knuckle 47 35
Shock absorber to suspension lower arm 133 98
Suspension upper arm and bushing to knuckle 90 66
Rear brake anti-
lock sensor bolt 7 5
Rear axle wheel hub retainer 325 240 Klj . 1 ba
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