Ford Mustang (1999-2004) Service Manual: Installation

1. Inspect the 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 pinion flange splines.

  • Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.

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

Position the pinion flange.

Drive Pinion Flange and Drive Pinion Seal

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

Drive Pinion Flange and Drive Pinion Seal

5. CAUTION: Do not under any circumstance loosen the nut to reduce preload. If it is necessary to reduce preload, install a new collapsible spacer (4662) and nut.

CAUTION: Remove the special tool while taking preload readings with the Nm (inch/pound) torque wrench.

Tighten the nut to set the preload.

  • Rotate the drive pinion occasionally to make sure the differential pinion bearings (4630) (4621) seat correctly. Take frequent differential pinion bearing torque preload readings by rotating the drive pinion 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 differential pinion bearings in the Specifications portion of this section.

Drive Pinion Flange and Drive Pinion Seal

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 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 and Drive Pinion Seal

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 ...

    Differential Housing Cover
    Removal 1. Raise and support the vehicle. 2. NOTE: Empty the lubricant into a clean container for reuse. Remove the differential housing cover (4033). 1. Remove the 10 bolts and drain the lubrica ...

    Other materials:

    Wheel Studs
    Special Tool(s) C-Frame and Clamp Assembly 211-023 (T74P-3044-A1) Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A ...

    Flexplate
    Removal and Installation 1. Remove the transmission. For additional information, refer to Section. 2. Remove the six bolts retaining the flexplate to crankshaft, and remove the flexplate. 3. To install, reverse the removal procedure. Tighten the bolts in ...

    Torque Converter Cleaning And Inspection
    Material Item Specification MERCON V Automatic Transmission Fluid XT-5-QM, XT-5-DM MERCON V 1. If a new torque converter is being installed, continue with Substep 2 of Step 2. 2. If a new torque converter is not being installed, the fol ...