Ford Mustang (1999-2004) Service Manual: Assembly

1. NOTE: Universal joint kits are to be installed as complete assemblies only. Do not mix components from other U-joint kits.

Install the spider.

1. Start a new bearing cup into the driveshaft yoke.

  • Check the needle bearings for correct positioning.

2. Position the new spider in the driveshaft yoke.

3. Position the driveshaft in the U-joint tool.

4. Press the bearing cup to just below the snap ring groove.

  • Repeat for the other bearing cup.

Universal Joint - Single Cardan, Flange Yoke

2. Inspect the driveshaft flange yoke. Install new if necessary.

3. Install the driveshaft flange yoke.

1. Start a new bearing cup into the driveshaft flange yoke.

  • Check the needle bearings for correct positioning.

2. Position the driveshaft flange yoke.

3. Position the driveshaft in the U-joint tool.

4. Press the bearing cup to just below the snap ring groove.

  • Repeat for the other bearing cup.

Universal Joint - Single Cardan, Flange Yoke

4. NOTE: Use the yellow snap rings supplied in the kit to assemble the universal joint (U-joint). If difficulty is encountered with the yellow snap rings, install the black snap rings, as required.

Remove the driveshaft from the U-joint tool, and install the four snap rings.

Universal Joint - Single Cardan, Flange Yoke

5. NOTE: Do not strike the bearings.

Check the U-joints for freedom of movement.

  • If binding, strike the yoke with a brass or plastic hammer.

Universal Joint - Single Cardan, Flange Yoke

6. Install the driveshaft. For additional information, refer to Driveshaft in this section.

 

    Disassembly
    1. Remove the driveshaft (4602). For additional information, refer to Driveshaft in this section. 2. CAUTION: Under no circumstances is the driveshaft assembly to be clamped in the jaws of a vise o ...

    Rear Drive Axle/Differential - Ford 7.5-Inch Ring Gear
    General Specifications a: In-vehicle repair refill capacities are determined by filling the rear axle with the specified lubricant to 6.4-14.3-mm (1/4-9/16-in) below the bottom of the fill hole. To ...

    Other materials:

    Trim Panel - Door
    Removal All vehicles 1. CAUTION: Use a shop towel or similar material between the tool and the front door trim panel or damage to the front door trim panel may occur. Position the window regulator switch plate (14527) aside. 1. Pull at the ser ...

    Camshaft Journal - Clearance, Plastigage Method
    Special Tool(s) Plastigage 303-D031 (D81L-6002-B) or equivalent NOTE: The camshaft journals must meet specifications before checking camshaft journal clearance. 1. Remove the camshaft bearing cap and lay Plastigage across the surface. Refer ...

    Accelerator Cable Bracket - 3.8L
    Removal and Installation 1. Disconnect the speed control cable from the throttle body and the bracket. For additional information, refer to Section. 2. Disconnect the accelerator cable from the throttle body by rotating the throttle body full open and align ...