Ford Mustang (1999-2004) Service Manual: Installation

1. Install the bushings, if removed.

2. Using the transmission jack, raise the rear axle assembly into position.

3. Install the bolts and nuts.

4. Install the bolts.

5. CAUTION: Align the index-marks.

Connect the driveshaft and install the bolts.

6. Install the pinion nose crossmember.

7. NOTE: The following halfshaft and knuckle assembly installation steps apply to both sides of the vehicle.

Remove the special tool.

8. CAUTION: Differential seal damage will occur if installing the halfshaft without the special tool.

Install the special tool.

9. Position the halfshaft for installation.

10. Seat the CV joint stub shaft in the differential side gear.

1. Slide the stub shaft into the differential housing until the shaft splines are past the differential seal.

2. Remove the special tool.

3. Align the stub shaft splines and the side gear splines, and slide the stub shaft into the gear until it seats.

• When seated, the axle circlip will lock the stub shaft in the differential side gear.

  Check the circlip engagement by attempting to pull the inboard CV joint out of the differential side gear. If the circlip has not seated, push the CV joint inward until the circlip is fully engaged in the differential side gear.

11. CAUTION: Do not tighten the fastener at this time.

Connect the knuckle to the upper suspension arm and bushing.

1. Position the knuckle.

2. Install the new cam bolt and nut.

12. CAUTION: Do not tighten the fastener at this time.

Connect the knuckle to the lower suspension arm and bushing.

1. Position the knuckle.

2. Install the new bolt and nut.

13. Connect the toe link to the knuckle.

1. Position the toe link.

2. Install the new nut.

3. Install the new cotter pin.

14. CAUTION: Install the hardened washer between the lower suspension arm and bushing and the shock absorber. Failure to do so can result in damage and failure of the lower suspension arm and bushing.

Position the shock absorber, and install the bolt and the new nut.

15. Install the other halfshaft and knuckle assembly, toe link, and shock absorber as described in the previous steps.

16. Raise the suspension until the shock absorbers compress to the previously established alignment mark (curb height).

17. Tighten the nut.

18. Align the marks on the cam bolt and the upper suspension arm and bushing, and tighten the nut.

19. Repeat the two previous steps for the other knuckle.

20. Lower the suspension and remove the jack stands.

21. Apply Anti-Seize Lubricant to the rear brake anti-lock sensors where they contact the axle housing and install the anti-lock sensors.

• Use High Temperature Nickel Anti-Seize Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A.

22. Install the brake disc, and the rear disc brake caliper and support bracket assembly.

23. Position the parking brake cable and conduit.

24. Connect the parking brake cable and conduit to the caliper and parking brake lever.

25. Repeat the three previous steps for the brake components on the other side of the vehicle.

26. Install the exhaust system.

27. Install the wheels and tires.

28. CAUTION: If refilling the rear axle (4001), first add 118 ml (4 oz) of Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A.

Check the lubricant level.

• If necessary, fill the rear axle housing to the level shown with SAE 75W- 140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. The refill capacity is 1.23-1.37 liters (2.6-2.9 pints).

29. Lower the vehicle.

30. Check, and adjust the wheel alignment as necessary.