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IN-
VEHICLE REPAIR
Differential Housing Cover
Removal 1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. NOTE: Empty the lubricant into a clean container for reuse.
Remove the differential housing cover (4033). 1. Remove the 10 bolts and drain the lubricant from the differential housing (4010).
2. Remove the differential housing cover.
Installation 1. CAUTION: Make sure the machined surfaces on both the differential housing and
the differential housing cover are clean and free of oil before applying the new silicone
sealant. To prevent contamination, cover the inside of the rear axle (4001) prior to
cleaning the machined surface.
Clean the differential housing and the differential housing cover gasket mating surfaces.
2. CAUTION: Install the differential housing cover within 15 minutes of applying the
silicone, or it will be necessary to remove and reapply new sealant.
Apply a continuous bead of sealant of the specified thickness to the differential housing cover.
zUse Clear Silicone Rubber D6AZ- 19562-AA or equivalent meeting Ford specifications
ESB- M4G92- A.
SECTION 205-
02B: Rear Drive Axle/Differential — Ford 8.8-Inch Ring
Gear 2003 Mustang Workshop
Manual Klj . 1 ba
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3.
NOTE: If possible, allow one hour before filling the axle with lubricant to make sure the silicone
sealant has cured.
Install the differential housing cover. 1. Install the differential housing cover.
2. Install the 10 bolts.
4. NOTE: If it is necessary to refill a Traction- Lok® axle with new lubricant, add 118 ml (4 oz) of
Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-
M2C118- A before filling the axle with the new lubricant.
NOTE: 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.
Fill the rear axle to the level shown, approximately 1.66-1.77- liters (3.5-3.75-pints) of lubricant,
and install the filler plug.
zUse SAE 75W- 140 High Performance Rear Axle Lubricant F1TZ-19580- B or equivalent
meeting Ford specification WSL- M2C192-A.
5. Lower the vehicle. Klj . 2 ba
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Klj . 3 ba
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IN-
VEHICLE REPAIR
Axle Housing Bushing
Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure can result in major service expense. A new part with
the same part number must be installed if installation becomes necessary. If substitution is
necessary, the part must be of the same finish and property class. Torque values must be used
as specified during reassembly to make sure of correct retention of these parts.
1. Remove the upper arm and bushing (5500). For additional information, refer to Section 204 - 02 .
2. Using the special tools, remove the bushing.
Installation 1. Using the special tools, install the bushing.
SECTION 205-
02B: Rear Drive Axle/Differential — Ford 8.8-Inch Ring
Gear 2003 Mustang Workshop
Manual Special Tool(s)
Axle Suspension Bushing Set
204-
S030 (T78P-5638- A) Klj . 1 ba
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2. Using a suitable calibrated micrometer, measure the bushing as shown. If not within
specifications, adjust as necessary.
3. Install the upper arm and bushing. For additional information, refer to Section 204 - 02 . Klj . 2 ba
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IN-
VEHICLE REPAIR
Drive Pinion SECTION 205-
02B: Rear Drive Axle/Differential — Ford 8.8-Inch Ring
Gear 2003 Mustang Workshop
Manual Special Tool(s)
Adapter for 205-
S127
205- 105 (T76P-4020- A3) Adapter for 205-
S127
205- 109 (T76P-4020- A9) Adapter for 205-
S127
205- 110 (T76P-4020- A10) Adapter for 205-
S127
205- 111 (T76P-4020- A11) Adapter for 205-
S127
205- 129 (T79P-4020- A18) Adapter for 205-
S127
205- 130 (T79P-4020- A19) or
equivalent Adapter for 303-
224 (Short
Handle)
205- 153 (T80T-4000- W) Handle
205-
D055 (D81L-4000- A) or Klj . 1 ba
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equivalent
Holding Fixture, Drive Pinion
Flange
205-
126 (T78P-4851- A) Installer, Drive Pinion Bearing
Cone
205-
005 (T53T-4621- C) Installer, Drive Pinion Bearing
Cup
205-
024 (T67P-4616- A) Installer, Drive Pinion Bearing
(Outer)
205-
231 (T85T-4616- AH) Installer, Drive Pinion Flange
205-
002 (TOOL- 4858-E) or
equivalent Installer, Drive Pinion Oil Seal
205-
133 (T79P-4676- A) Plate, Bearing/Oil Seal
205-
090 (T75L-1165- B) Protector, Drive Pinion Thread
205-
460 Klj . 2 ba
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Removal
1. Remove the differential assembly from the differential housing. For additional information, refer to Differential Case in this section.
2. CAUTION: Record the torque necessary to maintain rotation of the drive pinion gear
through several revolutions prior to removing the pinion flange (4851).
Remove the pinion flange. For additional information, refer to Drive Pinion Flange and Drive Pinion Seal in this section.
3. Force the rear axle drive pinion seal metal flange up. Install gripping pliers and strike with a hammer to remove the seal.
4. Remove the rear axle drive pinion shaft oil slinger (4670).
5. Using the special tool and a soft-faced hammer, drive the pinion assembly out of the outer differential pinion bearing (4621) and remove the drive pinion through the rear of the differential
housing (4010). Puller, Bearing
205-
D064 (D84L-1123- A) or
equivalent Klj . 3 ba
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