Ford Mustang (1999-2004) Service Manual: Final disassembly

32. If not done previously, remove the bolts.

Excessive differential ring gear backface runout

33. CAUTION: Do not damage the bolt hole threads.

If not done previously, insert a punch in the bolt holes and drive off the differential ring gear.

Excessive differential ring gear backface runout

34. Using the special tools, remove the differential bearing.

  • Repeat for the other side.

Excessive differential ring gear backface runout

35. Remove the bolt and remove the differential pinion shaft (4211).

Excessive differential ring gear backface runout

36. WARNING: The differential clutch spring (4214) is under tension. Remove the spring carefully. Failure to follow these instructions may result in personal injury.

Remove the differential clutch spring.

Excessive differential ring gear backface runout

37. Remove the differential gears.

1. Remove the two differential pinion gears (4215) and pinion thrust washers (4230).

2. Remove the two differential side gears (4236) with the clutch packs (4947) and the shims and tag them "left" and "right."

Excessive differential ring gear backface runout

38. CAUTION: Keep the differential clutch packs in order. Do not mix them. Always reassemble them in the same sequence.

Remove the differential clutch packs and shims from the differential side gears.

  • Clean and inspect the remaining differential components for wear and damage. Install new parts as necessary.

Excessive differential ring gear backface runout

39. CAUTION: Do not use acids or solvents when cleaning the differential clutch packs.

Wipe the components only with a clean, lint-free cloth.

Clean and inspect the differential clutch packs for wear and damage. Install new parts as necessary.

    Disassembly
    Initial disassembly 1. Remove the differential housing cover (4033) and drain the lubricant into a suitable container. 2. Wipe the lubricant from the internal working parts and inspect the parts for ...

    Assembly
    Initial assembly 1. Coat the new differential drive pinion bearing cup(s) with lubricant. Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specificatio ...

    Other materials:

    Inspection and Verification
    NOTE: A new instrument cluster must be reconfigured. NOTE: The instrument panel dimmer switch is a part of the headlamp switch. 1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical damage. Visual Inspection Chart Electric ...

    Hinge Adjustment
    NOTE: The door should be adjusted for even and parallel fit with the body opening and surrounding panels as well as making sure that the anti-chuck pin is not binding on convertible models. 1. Remove the A-pillar lower trim panel. 2. Position the ...

    Installation
    Using special tool 205-054 NOTE: This is the preferred method for installing the pinion bearing cups. If necessary, proceed to Using special tools 205-153, 205-054, and 205-D055 in this procedure for an alternate method. 1. Position the special tools and th ...