Ford Mustang (1999-2004) Service Manual: Installation

1. Inspect the rear axle pinion flange seal journal for rust, nicks, and scratches prior to installing the flange. Polish the seal journal with fine crocus cloth, if necessary.

2. 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.

3. NOTE: Disregard the index marks if installing a new rear axle pinion flange.

Position the rear axle pinion flange.

Drive Pinion Flange

4. Using the special tools, install the rear axle pinion flange.

Drive Pinion Flange

5. 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 (4662) and nut.

Tighten the nut to set the preload.

  • Rotate the pinion occasionally to make sure the pinion bearings (4630) (4621) seat correctly. Take frequent pinion bearing torque preload readings by rotating the drive pinion gear with a Nm (inch/pound) torque wrench.
  • If the preload recorded prior to disassembly is lower than the specification for used bearings, then tighten the nut to specification. 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.
  • Refer to the torque specification for used pinion bearings in the Specifications portion of this section.

Drive Pinion Flange

6. CAUTION: Align the index-marks.

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 WSKM2G351- A5 to the threads of the original bolts.

CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. To make sure that the yoke seats squarely on the flange, tighten the bolts evenly in a cross pattern as shown.

Connect the driveshaft.

Drive Pinion Flange

7. Install the rear brake calipers.

8. Install the rear wheel and tire assemblies.

9. Lower the vehicle.

    Removal
    1. Raise and support the vehicle. 2. Remove the rear wheel and tire assemblies. 3. CAUTION: Remove the rear brake calipers to prevent drag during the drive pinion bearing preload adjustment. CAU ...

    Pinion Seal
    Special Tool(s) Installer, Drive Pinion Oil Seal 205-133 (T79P-4676-A) Removal 1. Remove the pinion flange (4851). For additional information, refer to Drive Pinion Flange in this sec ...

    Other materials:

    Installation
    1. NOTE: The LH side is shown, and the RH is similar. Install the supply manifold and tighten the four bolts. 2. Connect the EGR vacuum line. 3. Install the EGR to exhaust manifold tube. For additional information, refer to Section. 4. NOTE: The eng ...

    Daytime running lamps
    WARNING: Always remember to turn on your headlamps at dusk or during inclement weather. The Daytime Running Lamp (DRL) system does not activate the tail lamps and generally may not provide adequate lighting during these conditions. Failure to activate your hea ...

    Rear Window Glass
    Special Tool(s) Rotunda Pneumatic Knife with Offset Blade 107-R1511 or equivalent The Pumper 164-R2459 or equivalent Rotunda Interior Auto Glass Cut-Out Knife Kit 164-R2450 or equivalent ...