Ford Mustang (1999-2004) Service Manual: Assembly

1. Lubricate the differential side gear thrust washers and the differential side gear journals, and assemble the washers to the gears.

  • Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.

Differential Case and Ring Gear - Conventional

2. Lubricate the differential pinion thrust washers and the differential pinion gears, and assemble the washers to the gears.

  • Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.

Differential Case and Ring Gear - Conventional

3. Position the differential side gear and thrust washer assemblies in the differential case.

Differential Case and Ring Gear - Conventional

4. Engage the differential pinion gears with the differential side gears and rotate the pinion gears to align with the differential pinion shaft bore.

Differential Case and Ring Gear - Conventional

5. Insert the differential pinion shaft.

  • Align the hole in the differential pinion shaft with the hole in the differential case.

Differential Case and Ring Gear - Conventional

6. Install a new bolt finger-tight.

Differential Case and Ring Gear - Conventional

7. Using the special tool, install the new differential bearings, if removed.

Differential Case and Ring Gear - Conventional

8. Position the ring gear and the differential case. Align the bolt holes by starting two bolts through the holes in the differential case and the ring gear. Press the ring gear on the differential case.

Differential Case and Ring Gear - Conventional

9. Install the bolts.

  • Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the bolt threads.

Differential Case and Ring Gear - Conventional

10. Install the differential assembly. For additional information, refer to Differential Case in this section.

    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 thread ...

    Differential Case and Ring Gear - Traction-Lok
    Special Tool(s) 2-Jaw Puller 205-D072 (D97L-4221-A) or equivalent Gauge, Differential Clutch 205-022 (T66L-4204-A) Gauge, Differential Clutch 205-135 (T80P-4946-A) ...

    Other materials:

    Wheel And Tire
    Removal 1. CAUTION: Do not use heat to loosen a seized wheel nut (1012). Heat can damage the wheel and wheel bearings. NOTE: To avoid damage or scratching to the center cap, place facing up when removed. Loosen the wheel nuts. 1. NOTE: To avoid wheel damag ...

    Inspection and Verification
    1. The keyless entry system is a generic electronic module (GEM). 2. Verify the customer concern by using the remote transmitters to operate the keyless entry system. 3. Visually inspect for the following obvious signs of mechanical and electrica ...

    Disassembly
    1. NOTE: The index mark on the output shaft must be aligned with the index mark on the output shaft ring gear during the assembly procedure. Remove the ring gear snap ring. 2. Separate the ring gear and output shaft. 3. Remove the three output shaft seal ...