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.
4. Using the special tools, install the rear axle 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.
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.
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:
Suction Accumulator
NOTE: Installation of a new suction accumulator is not required when
repairing the air conditioning
system except when there is physical evidence of contamination from a failed A/C
compressor or
damage to the suction accumulator.
In addition to th ...
Component Tests
Grid Wire Test
1. Using a bright lamp inside the vehicle, inspect the wire grid from
the exterior. A broken grid wire
will appear as a brown spot.
2. Run the engine at idle. Set the rear window defrost switch to ON. The
indicator light should
co ...
Inspection and Verification
CAUTION: Do not hold the steering wheel (3600) at the stops for an
extended amount of
time. Damage to the power steering pump (3A674) will result.
NOTE: Make the following preliminary checks before repairing the
steering system:
1. Verify the customer conce ...
