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:

    Shock Absorber
    Removal WARNING: All vehicles are equipped with gas pressurized shock absorbers which will extend unassisted. Do not apply heat or flame to the shock absorbers during removal or component servicing. Failure to follow these instructions can result in personal ...

    Engine (Removal)
    Special Tool(s) Lifting Bracket, Engine 303-D087 (D93P-6001-A1) Lifting Bracket, Engine 303-D088 (D93P-6001-A2) Spreader Bar 303-D089 (D93P-6001-A3) Removal All vehicles 1. Disconnect the battery ground cable. Fo ...

    Inspection and Verification
    1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical and electrical damage. Visual Inspection Chart Mechanical Electrical Fuel tank Engine coolant level Accessory drive belt Engine oil level Par ...