2003 FORD MUSTANG differential

7. Install the right side bearing cap and tighten the left side and right side bolts to specification.
8. Rotate the differential assembly several times to verify that the differential bearings have seated
correctly.
Measuring backlash 9. Using the special tools, measure the ring gear backlash. zIf backlash is within the specification, refer to Backlash within specification in this
procedure. The specification shown is the full allowable range. For the preferred range,
refer to Specifications in this section.
z If a zero backlash condition occurs, refer to Zero backlash in this procedure.
z If backlash is not within the specification, refer to Backlash not within specification 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 Klj . 8 ba
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12. Rotate the differential assembly several times to verify that the differential bearings seated
correctly.
13. Measure the backlash. Refer to Measuring backlash in this procedure.
Backlash not within specification 14. To increase or decrease the backlash, remove the bearing caps and install a thicker shim and thinner shim accordingly.
zIf backlash is not within the specification, increase the thickness of one differential
bearing shim and decrease the thickness of the other differential bearing shim by the
same amount.
15. Install the bearing caps and the bolts. Klj . 10 ba
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16. Rotate the differential several times to verify that the differential bearings have seated correctly.
17. Using the special tools, recheck the backlash.
zIf backlash is within the specification, refer to Backlash within specification in this
procedure. If backlash is not within the specification, repeat Backlash not within
specification in this procedure.
z The specification shown is the full allowable range. For the preferred range, refer to
Specifications in this section.
Backlash within specification 18. Remove the bolts and bearing caps.
19. Set the differential bearing preload. 1. To establish differential bearing preload, increase both left and right differential bearing shim sizes by the specification shown.
2. Using the special tool, fully seat the differential bearing shims. Make sure the assembly rotates freely. Klj . 11 ba
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20. Install the bearing caps and bolts.
21. Using the special tools, recheck the backlash.
zThe specification shown is the full allowable range. For the preferred range, refer to
Specifications in this section.
22. Install the axle shafts. For additional information, refer to Axle Shaft in this section.
23. Install the differential housing cover and refill the rear axle with specified lubricant. For additional information, refer to Differential Housing Cover in this section. Klj . 12 ba
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REMOVAL AND INSTALLATION
Axle Assembly
Removal and Installation
1. CAUTION: The vehicle must be on level ground and at curb height.
Mark the rear shock absorbers relative to their protective sleeve. zDuring installation, raise the suspension to this reference mark before tightening the
suspension fasteners.
2. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
3. Remove the rear wheel and tire assemblies. For additional information, refer to Section 204 - 04 .
4. CAUTION: Index- mark the driveshaft flange and pinion flange (4851) to maintain
initial balance during installation.
CAUTION: The driveshaft centering socket yoke fits tightly on the pinion flange
pilot. Never hammer on the driveshaft or any of its components to disconnect the yoke
from the flange. Pry only in the area shown, with a suitable tool, to disconnect the yoke
from the flange.
Disconnect and position the driveshaft out of the way. For additional information, refer to
Section 205 - 01 .
SECTION 205-
02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring
Gear 2003 Mustang Workshop
Manual Klj . 1 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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8. Remove and discard the nuts and bolts retaining the shock absorbers to the axle.
9. Remove and discard the nuts and bolts retaining the upper suspension arm and bushings to the
differential housing.
10. Lower the axle slightly, and remove the springs.
11. Remove and discard the nuts and bolts retaining the lower suspension arm and bushings to the axle. Klj . 3 ba
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DISASSEMBLY AND ASSEMBLY
Differential Case and Ring Gear
Disassembly
1. Remove the differential assembly from the differential housing. For additional information, refer to Differential Case in this section.
2. Remove the bolts.
3. CAUTION: Do not damage the threads in the bolt holes.
Insert a punch in the bolt holes and drive off the ring gear.
SECTION 205-
02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring
Gear 2003 Mustang Workshop
Manual Special Tool(s)
2-
Jaw Puller
205- D072 (D97L-4221- A) or
equivalent Installer, Differential Side
Bearing
205-
009 (T57L-4221- A1) Step Plate
205-
D016 (D80L-630- 5) or
equivalent Klj . 1 ba
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