2003 FORD MUSTANG torque

1. Adjust the special tool to zero.
2. Tighten the screw until the differential housing is spread to the specification.
3. Remove the special tools.
8. CAUTION: Mark the position and location of the differential bearing caps as the
arrows may not be visible. Always install the differential bearing caps in their identical
location and position.
Remove the differential bearing caps. 1. Remove the bolts.
2. Remove the differential bearing caps.
9. CAUTION: Use wood blocks to avoid damaging the differential housing.
Remove the differential assembly. 1. Position wood blocks at the top and bottom of the differential case (4204).
2. Pry the differential assembly and the differential bearing shims (4067) out of the
differential housing.
3. Remove the special tool.
10. CAUTION: Record the torque necessary to maintain rotation of the drive pinion gear Klj . 6 ba
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housing.
15. NOTE: Disregard the index marks if installing a new rear axle pinion flange.
Position the rear axle pinion flange. 1. Lubricate the rear axle pinion flange splines.
„Use SAE 75W- 140 High Performance Rear Axle Lubricant F1TZ-19580- B or
equivalent meeting Ford specification WSL-M2C192- A.
2. Position the rear axle pinion flange.
16. Using the special tool, install the rear axle pinion flange.
17. CAUTION: Do not under any circumstance loosen the nut to reduce preload. If it is
necessary to reduce preload, install a new differential drive pinion collapsible spacer and
nut.
Tighten the nut to set the preload.
zRotate the pinion occasionally to make sure the pinion bearings seat correctly. Take
frequent pinion bearing torque preload readings by rotating the drive pinion gear with a
Nm (inch/pound) torque wrench.
z For new pinion bearings, tighten the nut to specification. Refer to torque specifications for Klj . 19 ba
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new pinion bearings in the Specifications portion of this section.
z For used pinion bearings, if the preload recorded prior to disassembly is lower than the
specification for used bearings, then tighten the nut to specification. Refer to torque
specifications for used pinion bearings in the Specifications portion of this section.
z For used pinion bearings, 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.
18. CAUTION: 118 ml (4 oz) of Additive Friction Modifier C8AZ- 19B546-A or equivalent
meeting Ford specification EST- M2C118-A must be used in the axle.
Lubricate each steel clutch plate and soak all friction plates for no less than 15 minutes. zUse Additive Friction Modifier C8AZ- 19B546-A or equivalent meeting Ford specification
EST- M2C118- A.
19. CAUTION: Do not mix the clutch plates, clutch discs or shim from one side with the
other.
Assemble the differential clutch packs (without the shims) on their respective differential side gear. Klj . 20 ba
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31.
NOTE: If a new bolt is unavailable, coat the original bolt threads with Threadlock and Sealer
EOAZ- 19554- AA or equivalent meeting Ford specification WSK-M2G351- A5 prior to final
installation.
Install the differential pinion shaft and install a new bolt finger- tight.
32. Mount the differential case and the special tool in a vise. Using the special tool, check the torque necessary to rotate one differential side gear.
zIf reusing the original clutch plates, the initial minimum break- away torque must be no
less than the specification. The minimum rotating torque necessary to keep the
differential side gear turning with new clutch plates may vary.
33. CAUTION: The Master bearings are marked LH and RH. Install them as shown.
Install the special tools on the differential case. Klj . 24 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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DESCRIPTION AND OPERATION
Rear Drive Halfshafts
The rear wheel drive halfshaft system consists of and operates as follows:
zHalfshafts (4K138) transmit engine torque from the rear axle housing to the rear wheels.
z Halfshafts rotate at approximately one- third the speed of a driveshaft and do not contribute to
rotational vibration disturbances.
z A constant velocity (CV) joint is a mechanism for transmitting uniform torque and rotary motion
while operating through a range of angles.
z CV joints at both inboard (differential) and outboard (wheel) ends provide operating
smoothness.
z The inboard CV joints are plunge- type joints that provide the axial movement necessary to
affect shaft length changes.
z The outboard CV joints have a higher angle capability than the inboard CV joints to
accommodate suspension travel.
z Inboard and outboard CV joints connect to a splined shaft.
z A driveshaft bearing retainer circlip retains the splined inboard CV joint to the differential side
gear. Install a new circlip every time you remove the halfshaft from the vehicle.
z A rear axle wheel hub retainer secures the interconnecting shaft and outboard CV joint to the
rear hub.
z The lubed-for- life CV joints use special CV joint grease. They require no periodic lubrication.
z To separate the halfshaft from the rear hub, press the outboard CV joint from the rear hub.
z To separate the halfshaft from the differential, apply a load to the back face of the inboard CV
joint assembly to overcome the circlip.
z The halfshaft assemblies are not repairable. Install a new assembly if worn/damaged.
SECTION 205-
05: Rear Drive Halfshafts 2003 Mustang Workshop Manual Klj . 1 ba
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SPECIFICATIONS
SECTION 206-
00: Brake System — General Information 2003 Mustang Workshop Manual Torque Specifications
Description Nm lb-
ft lb-
in Front disc brake caliper bleeder screw 12-
18 9-13 —
Front master cylinder brake tube 22-
28 17-
20 —
Rear bleeder screw 20 15 —
Rear master cylinder brake tube 15-
20 11-
14 —
Master cylinder bleeder screws 9 — 80 Klj . 1 ba
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GENERAL PROCEDURES
Runout Check —
Brake Disc and Hub
CAUTION: The brake disc (1126) runout specification must be met to ensure correct brake
performance without roughness complaints.
CAUTION: Do not install brake discs that are less than the minimum thickness specified.
Do not machine a brake disc below the minimum thickness specification.
NOTE: When installing brake discs, always align the painted match marks on the brake discs with
those on the front hub or rear axle.
NOTE: When installing brake discs, always apply anti- seize lubricant to the brake disc-to-front hub or
to the brake disc- to-rear axle mating surfaces.
1. Do not remove the tire and wheel assembly. Tighten the wheel nuts to specification with a torque stick or torque wrench.
2. Raise and support the vehicle.
3. Assemble the Brake Measurement Kit, using the spherical tip extension.
4. Locate an opening on the inboard side of the dust shield that will allow the dial indicator tip to be positioned at least 5 mm (0.2 inch) from the outer edge of the brake disc.
5. NOTE: Do not clamp the gauge set to a vehicle component separated from the brake disc by a
flexible joint, such as a ball joint or body mount.
Clamp the Brake Measurement Kit on the vehicle, making sure the flexible indicator arm and
probe tip do not touch the dust shield or tire while rotating.
6. NOTE: For rear wheel measurement only, have an assistant push in on the wheel cover or axle
shaft center while rotating the wheel.
Rotate the wheel for six revolutions, and record the total indicated runout.
SECTION 206-
00: Brake System — General Information 2003 Mustang Workshop Manual Special Tool(s)
Brake Measurement Kit
134-R0199 or equivalent
Material Item Specification
High Temperature Nickel Anti-
Seize Lubricant
F6AZ-
9L494- AA ESE-
M12A4-
A Klj . 1 ba
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