2003 FORD MUSTANG oil

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
132003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

Setting pinion depth
7. NOTE: Apply only a light oil film on the differential pinion bearings before assembling the tools.
Assemble and position the following in the differential housing.
8. NOTE: This step duplicates final differential pinion bearing preload. Item Part
Number Description
1 205-109 Adapter for 205-
S127 (T76P-4020- A9) 2 205-105 Adapter for 205-
S127 (T76P-4020- A3) (1.612 inch
O.D.) 3 4630 Rear (inner) pinion bearing
4 205-129 Adapter for 205-
S127 (T79P-4020- A18) (1.1884
inch thick) 5 205-110 Adapter for 205-
S127 (T76P-4020- A10) (1.7 inch
thick) 6 4621 Front (outer) pinion bearing
7 205-111 Adapter for 205-
S127 (T76P-4020- A11) Klj . 7 ba
132003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

12. Position the correct thickness drive pinion bearing adjustment shim and the differential pinion
bearing on the drive pinion gear. Using a suitable press and the special tools, press the
differential pinion bearing until it seats firmly against the drive pinion gear.
13. Place a new collapsible spacer on the pinion shaft against the pinion stem shoulder.
14. Install the outer differential pinion bearing.
15. Install the rear axle drive pinion shaft oil slinger. Klj . 9 ba
132003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

z
The differential housing (4010) consists of a cast aluminum housing and a cast aluminum
differential housing cover (4033). The differential housing cover uses silicone sealant as a
gasket.
z The hypoid- design gearset consists of a 8.8- inch differential ring gear and a drive pinion gear.
Two opposed pinion bearings (4621) (4630) support the drive pinion gear in the differential
housing.
z A differential drive pinion collapsible spacer (4662), located on the drive pinion gear shaft,
maintains pinion bearing preload. The pinion nut adjusts the preload.
z Differential bearing shims (4067), located between the differential bearing cups (4222) and the
differential housing, adjust the differential ring gear backlash and the differential bearing
preload.
z The differential case (4204) is a one- piece design with two openings to allow for assembly of
the internal components and lubricant flow. Two opposed differential bearings (4221) support
the differential case in the differential housing. Removable differential bearing caps retain the
differential assembly in the differential housing.
z Inside the differential case, the differential pinion shaft (4211) supports two differential pinion
gears (4215). The pinion gears engage the differential side gears (4236), to which the halfshafts 10 4033 Differential housing cover
11 4B416 Inboard CV joint stub shaft pilot bearing housing
seal
12 4B413 Inboard CV joint stub shaft pilot bearing
13 4010 Differential housing
14 4662 Differential drive pinion collapsible spacer
15 4670 Rear axle drive pinion shaft oil slinger
16 4851 Rear axle pinion flange
17 389546-
S100 Pinion nut
18 4859 Drive pinion oil seal deflector
19 4676 Rear axle drive pinion seal
20 4621 Pinion bearing
21 4616 Differential drive pinion bearing cup
22 56187-
S Bolt
23 — Drive pinion gear (part of 4209)
24 — Differential bearing cap
(part of 4010)
25 4628 Rear axle pinion bearing cup
26 4630 Pinion bearing
27 4663 Drive pinion bearing adjustment shim
28 4A321 Rear axle differential clutch shim
29 — Clutch plate (part of 4947)
30 — Clutch disc (part of 4947)
31 4236 Differential side gear
32 4214 Differential clutch spring
33 4215 Differential pinion gear
34 4947 Differential clutch pack Klj . 2 ba
32003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

IN-
VEHICLE REPAIR
Stub Shaft Pilot Bearing and Seal
Removal 1. Remove the halfshaft assembly. zThe knuckle and halfshaft are removable as an assembly. For additional information,
refer to Axle Housing in this section. If it is necessary to remove the halfshaft from the
knuckle, refer to Section 205 - 05 .
2. NOTE: If only removing the inboard CV joint stub shaft pilot bearing housing seal (4B416),
SECTION 205-
02C: Rear Drive Axle/Differential — Ford 8.8-Inch IRS 2003 Mustang Workshop Manual Special Tool(s)
Remover, Bearing Cup
308-
047 (T77F-1102- A) Protector, Differential Seal
(Pair)
205-
461 Installer, Differential Oil Seal
205-
293 (T89P-4850- A) Adapter for 303-
224 (Handle)
205- 153 (T80T-4000- W) Slide Hammer
100-
001 (T50T-100- A) Installer, Needle Bearing
205-
288 (T89P-1244- A) Klj . 1 ba
42003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

IN-
VEHICLE REPAIR
Pinion Seal
Removal 1. Remove the pinion flange (4851). For additional information, refer to Drive Pinion Flange in this
section.
2. Force up the metal flange of the rear axle drive pinion seal (4676). zInstall gripping pliers and strike with a hammer to remove the seal.
Installation 1. Lubricate the new rear axle drive pinion seal. zUse Premium Long- Life Grease XG-1-C or equivalent meeting Ford specification ESA-
M1C75- B.
2. CAUTION: Installation without the proper tool can result in early seal failure. SECTION 205-
02C: Rear Drive Axle/Differential — Ford 8.8-Inch IRS 2003 Mustang Workshop Manual Special Tool(s)
Installer, Drive Pinion Oil Seal
205-
133 (T79P-4676- A) Klj . 1 ba
22003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

DISASSEMBLY AND ASSEMBLY
Axle
SECTION 205-
02C: Rear Drive Axle/Differential — Ford 8.8-Inch IRS 2003 Mustang Workshop Manual Special Tool(s)
2-
Jaw Puller
205- D072 (D97L-4221- A) or
equivalent Adapter for 205-
S127
205- 105 (T76P-4020- A3) Bearing Preload Tool
205-
395 (T93P-4220- A) Plate, Bearing/Oil Seal
205-
090 (T75L-1165- B) Gauge, Clutch Housing
308-
021 (T75L-4201- A) Holding Fixture, Drive Pinion
Flange
205-
126 (T78P-4851- A) Installer, Drive Pinion Flange
205-
002 (TOOL- 4858-E) or
equivalent Dial Indicator Gauge
100-
D005 (D78P-4201- G) or
equivalent Klj . 1 ba
352003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

Gauge, Differential Bearing
205-
338 (T93P-4222- A) Installer, Drive Pinion Bearing
Cone
205-
005 (T53T-4621- C) Installer, Drive Pinion Bearing
Cup
205-
024 (T67P-4616- A) Protector, Drive Pinion Thread
205-
460 Installer, Drive Pinion Oil Seal
205-
133 (T79P-4676- A) Gauge, Differential Bearing
205-
339 (T93P-4222- B) Adapter for 205-
S127
205- 109 (T76P-4020- A9) Step Plate
205-
D061 (D83T-4205- C2) or
equivalent Klj . 3 ba
352003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...