Question about 2004 Ford Mustang

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Rear differential on a 2004 Mustang gt leaking fluid

How hard is it to put a new pinion seal int he rear of this car? Also, could I possibly need the crush sleeve replaced? The car shifts okay.....Thanks

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  • Ford Master
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This is for 2003 7.5 inch ring gear axle. SECTION 205-02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring Gear 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Drive Pinion Flange and Drive Pinion Seal Special Tool(s) Rear differential on a 2004 Mustang gt leaking flu - s3b%7eus%7een%7efile=st2026a.gif%7egen%7eref.gif2-Jaw Puller 205-D072 (D97L-4221-A) or equivalent Holding Fixture, Drive Pinion Flange 205-126 (T78P-4Rear differential on a 2004 Mustang gt leaking flu - s3b%7eus%7een%7efile=st1862a.gif%7egen%7eref.gifes/s3b%7eus%7een%7efile=st1862a.gif%7egen%7eref.gif" alt="s3b%7eus%7een%7efile=st1862a.gif%7egen%7eref.gif" class="h_mi" />Installer, Drive Pinion Flange 205-002 (TOOL-4858-E) or equivalent Removal

  1. Raise and support the vehicle.
  1. Remove the rear wheelRear differential on a 2004 Mustang gt leaking flu - s3b%7eus%7een%7efile=ani_caut.gif%7egen%7eref.gif"h_mi">s3b%7eus%7een%7efile=ani_caut.gif%7egen%7eref.gif CAUTIRear differential on a 2004 Mustang gt leaking flu - s3b%7eus%7een%7efile=ani_caut.gif%7egen%7eref.gifg during the drive pinion bearing preload adjustment. s3b%7eus%7een%7efile=ani_caut.gif%7egen%7eref.gif CAUTION: Do not allow the calipers to hang from the brake hoses. Remove thRear differential on a 2004 Mustang gt leaking flu - s3b%7eus%7een%7efile=ani_caut.gif%7egen%7eref.gif knuckle as an assembly. Wire the caliper and support bracket assembly out of the way.
  2. CAUTION: Index-mark the driveshaft flange and pinion flange (4851) to maintain initial balance during installation. s3b%7eus%7een%7efile=ani_caut.gif%7egen%7eref.gif CAUTION: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the yoke from the flange. Pry only in the area shown, with a suitable tool, to disconnect the yoke from the flange. Disconnect and pRear differential on a 2004 Mustang gt leaking flu - s3b%7eus%7een%7efile=ani_caut.gif%7egen%7eref.gif
    1. Install an Nm (inch/pound) torque wrench on the nut and record the torque necessary to maintain rotation of the drive pinion gear through several revolutions.
    1. s3b%7eus%7een%7efile=ani_caut.gif%7egen%7eref.gif CAUTION: After removing the nut, discard it. Use a new nut for installation. Use the special tool to hold the pinion flange while removing the nut.
    1. Index-mark the pinion flange and drive pinion gear stem to maintain initial balance during installation.
    1. Using the special tool, remove the pinion flange.
    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.
    1. Lubricate the pinion flange splines.
      • Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or eqRear differential on a 2004 Mustang gt leaking flu - s3b%7eus%7een%7efile=ani_caut.gif%7egen%7eref.gif
    1. NOTE: Disregard the index marks if installing a new pinion flange. Position the pinion flange.
    1. Using the special tools, install the pinion flangRear differential on a 2004 Mustang gt leaking flu - s3b%7eus%7een%7efile=ani_caut.gif%7egen%7eref.gif="http://i.fixya.net/uploads/images/s3b%7eus%7een%7efile=ani_caut.gif%7egen%7eref.gif" alt="s3b%7eus%7een%7efile=ani_caut.gif%7egen%7eref.gif" class="h_mi" /> 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. s3b%7eus%7een%7efile=ani_caut.gif%7egen%7eref.gif 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 specificatioRear differential on a 2004 Mustang gt leaking flu - s3b%7eus%7een%7efile=ani_caut.gif%7egen%7eref.gifification. If the preload recorded prior to disassembly is higher than the specification for used bearingsRear differential on a 2004 Mustang gt leaking flu - s3b%7eus%7een%7efile=ani_caut.gif%7egen%7eref.gif recorded.
      • Refer to the torque specification for used differential pinion bearings in the Specifications portion of this section.
    1. CAUTION: Align the index marks. s3b%7eus%7een%7efile=ani_caut.gif%7egen%7eref.gif 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 WSK-M2G351-A5 to the threads of the original bolts. s3b%7eus%7een%7efile=ani_caut.gif%7egen%7eref.gif 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. .
    1. Install the rear brake calipers.
    1. Install the rear wheel and tire assemblies.
    1. Lower the vehicle.

Posted on May 26, 2009

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Posted on Jan 02, 2017

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SOURCE: what are the torque specs for the pinion nut and

Most pinion nuts don't have a published torque spec. they are to be tightened until the pinion requires a specified torque to spin with the wheels and brake drums removed. Often times, when a rebuild is not performed, it should be torqued to the same preload as before the work. autozone.com has alot of good repair info and diagrams.

Posted on Nov 17, 2009

  • 3 Answers

SOURCE: Rear differential oil leak

You can buy the step-by-step repair manuals for this truck from your local dealer, it makes things a lot easier.

Posted on Sep 28, 2008

  • 188 Answers

SOURCE: 94' toyota 4runner rear differential seal

1st, check to see ifthe vent is plugged on the Differental????? This will make the oil to come out when the oil heats up amd makes gases & pressure. The gases & pressure has to go somewhere!!!! Did the person put a new Crush sleeve, to take the slack out of the pinion, which will makes to pinion move from side to side. Replacing it is no problem. Just time! Gear oil, Seal, Gasket, & Crush sleeve. Place everything on the ground in the order that you take it off. Also check upper & lower bearing & races to see if they need to be replaced. This will also make slack, which will mess up your seal, and star leaking again. Good luck,and take your time.

Posted on Feb 08, 2009

  • 95 Answers

SOURCE: refill gear oil in rear differential on 2003 ford mustang gt

The differential will have a plug in the driver's side of the housing that is removed with a 3/8" drive ratchet or square drive. Be sure you know what type of fluid is recommended for your vehicle. It will depend on whether it is a locking differential or standard.

Posted on Sep 21, 2009

  • 538 Answers

SOURCE: torque specs on rear differential

Put it together without the seal in place, you may have to take it apart again. You want to have about 8-10 inch pounds of preload on new bearings, less on used probably just a light drag. I recommend using a 3/4 in drive socket and ratchet and you have to hold the yoke somehow, a pipe wrench works but it's kind of crude. Put a little oil on the bearings and on the threads, if you have a new nut, save it for your final assembly. It's best to have helper because you really have to pull on the wrench to get the crush started. Once the sleave starts crush it gets easier, tighten the nut until the the end play is gone, check it frequently and spin it occasionaly as you tighten the nut. Once the free play is gone and the pinion still spins freely carefully continue to tighten the nut until you feel drag on the shaft. You need a dial type inch pound torque wrench to check the preload not a click type. If you don't have a torque wrench you can do it by feel it should take a little effort to turn the shaft you should be able to turn it by hand. Once you confident you have the right preload you may want to put the ring gear in and check the backlash and wear patern. If you are just replacing the bearings you shouldn't have any trouble. If you are changing the gears you could run into all kinds of problems and may need to seek a pro to help. If the gears are not set up right they will make noise and the gears won't last. Once you sure you have everthing right remove the pinion nut and yoke and put in the new seal. Clean the oil from the threads with brake parts cleaner and put some blue lock tight on the thread. Install the yoke and the new nut using care not to crush the sleave anymore but, at the same time make sure it's tight. I hope this helps, good luck.

Posted on Dec 05, 2009

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1 Answer

2000 Ford F150 rear differential fluid VANISHING


This is different. In a perfect world, you would run the truck on a dynamometer, get it up to 55 MPH and look under the truck. The fluid is going somewhere.
There is a vent tube on most axles. Follow the tube to find its' end and see if the fluid is traveling away from where you had expected a leak. Check your axle shafts under the rear rotors to see if the Emergency brake drum is oil coated.
Another way to think about this is the original failure. The pinion seal. The seal contacts the rotating flange. If you have a wobble in the driveshaft, (balance issues, U-joints) then the rotating flange can wobble. If you have a bad pinion bearing or carrier bearing, it can work to make the spline gear wobble.
So I am suggesting that the leaking Pinion seal was caused by something and the seal was a casualty of an undetermined cause.
You should be able to add an Ultra-violet dye to the axle fluid to find your leak. Even if it is running from the same place, the current leak will be showing the UV dye.
Please rate my info.

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Rear differential seal


There are two places it can leak from. The rear differential cover or the pinion seal at the front of the differential. Both are easy to replace. The pinion seal will require a little more labor than the differential cover plate. You will have to remove the drive line and then break the pinion nut loose. Use a good impact wrench for this and a six point socket for that step. Then you will need to remove the yoke from the pinion gear. Should be able to tap it off. If not use a puller. Remove the old pinion seal with a flat tip screw driver by driving it through the lip of the old seal and push the screwdriver to the side and it will pop out. Clean the hole for the new seal. install the new seal and the yoke. Tighten the pinion nut. You will need to get access to a manual to check the bearing preload on the pinion nut. Then use a torque wrench to check for correct bearing preload. Re-install the drive line.

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I went to have my rear u joints done and the guy bent the pinion ...I couldn't get him to fix the problem and he refused to finish repairing the truck...I need a quick fix for leaking rear...


wow sorry about that. well there is no grease or quick fix for that, the pinion seal will have to be replaced. with the drive shaft removed you can remove the nut holding the yoke to the pinion gear (rear end) ,pop out the old seal and drive in the new seal, then reinstall the yoke and torque down the nut and reinstall the drive shaft. fluid loss while replacing the seal should be minimal but if you do lose fluid you may need to refill.

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2003 Jeep Liberty is leaking yellowish fluid. Could it be fluid from the 4 wheel drive? I had it serviced last year.


If the yellow fluid is bright yellow, and has a foul smell when you smell it up close (put a little on your finger and see), then it is most likely gear oil in the differential.

The only yellow fluid at the center rear of the Jeep is the gear oil in the differential. It is probably due to a leaking seal at the pinion seal, (at the front of the differential where the drive shaft connects) which would then run down the differential housing and drip off the bottom. I described the smell before because gear oil is quite foul smelling so if you wet your fingers on the fluid and smell it you might get more idea that it is gear oil.

If it is the pinion seal the drip should be in the middle of your rear tyres.

Have a look at the pictures in this link that illustrate where I think the Leak is coming from...

http://www.agcoauto.com/content/news/p2_articleid/88

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When do you change the fluid in the rear differencial. I was told by a mechanic that the rear differencial fluid was low and had metal shavings in it, and that the fluid needed to be changed and that it...


I'd say yes. The differential fluid is often overlooked by oil change technicians, even though it's something that should be topped off periodically.

It probably would cost more than that to repair it once it wears out.
Axle Housing Assembly Removal & Installation To Remove:
  1. Lift the vehicle.
  2. Drain the lubricant from the rear axle housing.
  3. Remove the rear axle assembly from the vehicle.
  4. Remove the brake caliper brackets from the rear hubs.
  5. Remove the rear cover and gasket from the rear axle housing.
  6. Remove the rear axle shafts from the vehicle.
  7. Remove the rear differential assembly from the vehicle.
  8. Remove the brake backing plates from the rear hubs.
  9. Remove the rear drive pinion shaft yoke and seal from the drive pinion.
  10. Remove the drive pinion from the rear axle housing.
To Install:
  1. Install the drive pinion into the rear axle housing.
  2. Install the rear drive pinion shaft yoke and seal onto the drive pinion.
  3. Install the rear differential assembly into the vehicle.
  4. Adjust the differential side bearing preload and the backlash.
  5. Perform a gear tooth contact pattern check.
  6. Install the brake backing plates onto the rear hubs.
  7. Install the rear axle shafts into the vehicle.
  8. Install the rear cover and gasket onto the rear axle housing.
  9. Install the brake caliper brackets onto the rear hubs.
  10. Install the rear axle assembly into the vehicle.
  11. Refill the lubricant in the rear axle housing.
  12. Lower the vehicle.
prev.gif next.gif ---
I think that changing the fluid would take about an hour, and depending on the garage, and the labor rate, that they might elect to take the rear cover off of the differential, and drain it that way and replace the fluid once it was put back on. He could inspect the gears while the cover was off and tell you how bad it was.'

Do you hear any clunking or gear mesh noises from the rear when putting it in gear or running the vehicle?


Some mechanics would simply top off the fluid and wait until it wears out, which could be several thousand miles in the future.

Use gear oil for it of the recommended viscosity in the service manual.

Generally thicker than motor oil.

So, adding fluid would cost only the amount of the fluid plus some labor.
A bottle of fluid might cost $9.99 or so depending on where you get it.

You might be able to do this yourself if you crawl under there, remove the fill plug at the top, and just add gear oil. If there isn't enough room you might drive it up on some ramps and then crawl under there.

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SECTION 205-02B: Rear Drive Axle/Differential — Ford 8.8-Inch Ring Gear 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Axle Shaft Removal
  1. Raise and support the vehicle. For additional information, refer to Section 100-02 .
  1. Remove the wheel and tire assembly. For additional information, refer to Section 204-04 .
  1. Remove the rear brake disc (2C026). For additional information, refer to Section 206-04 .
  1. Remove the differential housing cover (4033) and drain the lubricant. For additional information, refer to Differential Housing Cover in this section.
  1. Remove the differential pinion shaft (4211).
    1. Remove the differential pinion shaft lock bolt (4241).
    1. Remove the differential pinion shaft.
  1. s3b~us~en~file=ani_caut.gif~gen~ref.gif CAUTION: Do not damage the rubber O-ring in the axle shaft groove.
    Remove the U-washer (4N237).
    1. Push the axle shafts (4234) inboard.
    1. Remove the U-washer.
  1. s3b~us~en~file=ani_caut.gif~gen~ref.gif CAUTION: Damage to the rear brake anti-lock sensor (2C190) may occur if it is not removed before the axle shaft.
    Carefully remove the rear brake anti-lock sensor. For additional information, refer to Section 206-09A .
  1. s3b~us~en~file=ani_caut.gif~gen~ref.gif CAUTION: Do not damage the wheel bearing oil seal.
    Remove the axle shaft.
--------------------------------------------------------------------------------------
Rear Wheel Bearing and Axle Shaft Oil Seal Removal
  1. Remove the axle shaft (4234). For additional information, refer to Axle Shaft in this section.
  1. NOTE: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged.
    Using the special tools, remove the rear wheel bearing and wheel bearing oil seal.
Installation
  1. Lubricate the new rear wheel bearing with the specified lubricant.
  1. Using the special tools, install the new rear wheel bearing.
  1. Lubricate the lip of the new wheel bearing oil seal.
    • Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
  1. Using the special tools, install the new wheel bearing oil seal.
  1. Install the axle shaft. For additional information, refer to Axle Shaft in this section.

-------------------------------------------------------------------
Installation
  1. Lubricate the lip of the wheel bearing oil seal
    • Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
  1. s3b~us~en~file=ani_caut.gif~gen~ref.gif CAUTION: Do not damage the wheel bearing oil seal.
    Install the two axle shafts.
  1. s3b~us~en~file=ani_caut.gif~gen~ref.gif CAUTION: Do not damage the rubber O-ring in the axle shaft groove.
    Install the U-washer.
    1. Position the two U-washers on the button end of the axle shaft.
    1. Pull the axle shaft outward.
  1. NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5 prior to installation.
    Install the differential pinion shaft.
    1. Align the hole in the differential pinion shaft with the case lock bolt hole.
    1. Install a new differential pinion shaft lock bolt.
  1. Install the differential housing cover and fill the rear axle with the specified lubrication. For additional information, refer to Differential Housing Cover in this section.
  1. Install the rear brake anti-lock sensor. For additional information, refer to Section 206-09A .
  1. Install the rear brakes. For additional information, refer to Section 206-04 .
  1. Install the tire and wheel assembly. For additional information, refer to Section 204-04 .
  1. Lower the vehicle.

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1 Answer

Replace left rear axle seal 1999 ford explorer


Axle Shaft Removal
  1. Raise and support the vehicle. For additional information, refer to Section 100-02 .
  1. Remove the wheel and tire assembly. For additional information, refer to Section 204-04 .
  1. Remove the differential housing cover (4033).
    1. Loosen the bolts and drain the lubricant from the rear axle housing (4010).
    1. Remove the bolts.
    1. Remove the differential housing cover.
Remove the rear brake disc (2C026). For additional information, refer to Section 206-04 .
  1. sxn~us~en~file=ani_caut.gif~gen~ref.gif CAUTION: Turning the differential case (4204) or an axle shaft (4234) with the differential pinion shaft (4211) removed will cause the differential pinion gears (4215) to fall out of the assembly and damage the components.
    Remove the differential pinion shaft.
    1. Remove the differential pinion shaft lock bolt.
    1. Remove the differential pinion shaft.
  2. sxn~us~en~file=ani_caut.gif~gen~ref.gif CAUTION: Do not damage the rubber O-ring in the U-washer groove.
  3. Remove the U-washer (4N237).
  4. Push the axle shaft inboard.
  5. Remove the U-washer.
Reinstall the differential pinion shaft.
  1. Install the differential pinion shaft.
  2. Install the differential pinion shaft lock bolt finger-tight.
  3. sxn~us~en~file=ani_caut.gif~gen~ref.gif CAUTION: Do not damage the wheel bearing oil seal (1177).
    Remove the axle shaft.
-----------------------------------------------------------------------------------------------------------------
Seal Removal
  1. Remove the axle shaft (4334). For additional information, refer to Axle Shaft in this section.
  1. sxn~us~en~file=ani_caut.gif~gen~ref.gif CAUTION: Never remove the wheel bearing oil seal (1177) by itself. Always remove the rear wheel bearing (1225) and the inner wheel bearing oil seal at the same time.
    NOTE: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material.
    Using the special tools, remove the rear wheel bearing and wheel bearing oil seal together.
6c7eb46.gif Installation
  1. Lubricate the new rear wheel bearing.
    • For 4.0L SOHC and 4.0L EI with limited slip rear axles and 5.0L vehicles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
    • For 4.0L SOHC and 4.0L EI with conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.
  1. Using the special tools, install the rear wheel bearing.

ece7d89.gif
  1. Lubricate the lip of the new wheel bearing oil seal.
    • Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
  1. Using the special tools, install the wheel bearing oil seal.
c21e27d.gif
  1. Install the axle shaft. For additional information, refer to Axle Shaft in this section.

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