SECTION 205-02: Rear Drive Axle/Differential — Ford 8.8-Inch Ring Gear
2014 Mustang Workshop Manual
IN-VEHICLE REPAIR
Procedure revision date: 01/07/2013

Differential Bearings


Special Tool(s)
2 Jaw Puller
205-D072 (D79L-4221-A1) or equivalent
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)
Installer, Differential Side Bearing
205-010 (T57L-4221-A2)
Installer, Drive Pinion Bearing Cup
205-024 (T67P-4616-A)
Installer, Shaft Bearing Cone
308-169 (T88T-7025-B)
Plate, Bearing/Oil Seal
205-090 (T75L-1165-B)
Protector, Drive Pinion Thread
205-460 or equivalent
Puller, Bearing
205-D064 (D84L-1123-A) or equivalent
Step Plate
205-D016 (D80L-630-5) or equivalent


Item Part Number Description
1 — Differential bearing cap bolt (part of 4010)
2 — Differential bearing cap (part of 4010)
3 4067 Differential bearing shims (2 required)
4 4222 Differential bearing cups (2 required)
5 4221 Differential bearings (2 required)
6 4204 Differential assembly
7 4209 Drive pinion
8 4663 Pinion bearing adjustment shim
9 4630 Inner pinion bearing
10 4628 Inner pinion bearing cup
11 4662 Collapsible spacer
12 4616 Outer pinion bearing cup
13 4621 Outer pinion bearing
14 4670 Pinion oil slinger
15 4320 Pinion nut

Removal

  1. Remove the drive pinion seal. For additional information, refer to Drive Pinion Flange and Drive Pinion Seal in this section.
  1. Remove the differential carrier. For additional information, refer to Differential Carrier in this section.
  1. Remove the axle drive pinion shaft oil slinger.
  1. Using the Drive Pinion Thread Protector and a soft-faced hammer, drive the pinion assembly out of the outer pinion bearing and remove it through the rear of the differential housing.
  1. Remove the outer pinion bearing.
  1. Remove the drive pinion collapsible spacer and discard it.
  1. Using the Bearing Puller and a suitable press, remove the inner pinion bearing.
  1. Using a brass drift, remove the pinion bearing cups by tapping alternately on opposite sides of the bearing cups.
  1. Using the 2 Jaw Puller and Step Plate, remove the 2 differential bearings.

Installation

  1. Position the Drive Pinion Bearing Cup Installer and the new inner and outer drive pinion bearing cups in their respective bores.
    1. After placing the inner and outer drive pinion bearing cups in their bores, place the Drive Pinion Bearing Cup Installer (inner) on the inner drive pinion bearing cup.
    1. Place the Drive Pinion Bearing Cup Installer (outer) on the outer drive pinion bearing cup.
    1. Install the Drive Pinion Bearing Cup Installer threaded rod.
  1. Tighten the Drive Pinion Bearing Cup Installer to seat the drive pinion bearing cups into their bores.

  1. NOTE: If a feeler gauge can be inserted between a drive pinion bearing cup and the bottom of its bore at any point around the drive pinion bearing cup, the drive pinion bearing cup is not correctly seated.

    Make sure the drive pinion bearing cups are correctly seated in their bores.

  1. NOTE: Install new drive pinion bearings without any additional lubricant since the anti-rust oil provides adequate lubricant without upsetting the drive pinion bearing preload settings.

    Assemble and position the Adapters for 205-S127.


    Item Part Number Description
    1 205-105 Adapter for 205-S127 (1.612 inch OD) (T76P-4020-A3)
    2 205-111 Adapter for 205-S127 (T76P-4020-A11)
    3 4621 Drive pinion bearing (outer)
    4 205-109 Adapter for 205-S127 (T76P-4020-A9)
    5 4630 Drive pinion bearing (inner)
    6 205-129 Adapter for 205-S127 (1.1884 inch thick) (T79P-4020-A18)
    7 205-110 Adapter for 205-S127 (1.7 inch thick) (T76P-4020-A10)

  1. NOTE: This step duplicates final drive pinion bearing preload.

    Tighten the Adapter.

  1. NOTE: The Adapter must be offset to obtain an accurate reading.

    Rotate the Adapter several half-turns to make sure of correct seating of the drive pinion bearings.
  1. Install the Adapter.
    1. Position the Adapter.
    1. Install the 2 differential bearing caps.
    1. Install the 4 differential bearing cap bolts.
      • Tighten to 122 Nm (90 lb-ft).

  1. NOTE: Drive pinion bearing adjustment shims must be flat and clean.

    NOTE: A slight drag should be felt for correct drive pinion bearing adjustment shim selection. Do not attempt to force the drive pinion bearing adjustment shim between the gauge block and the Adapter. This will minimize selection of a drive pinion bearing adjustment shim thicker than required, which results in a deep tooth contact in final assembly of integral axle assemblies.

    Use a drive pinion bearing adjustment shim as a gauge for drive pinion bearing adjustment shim selection.
  1. Using the Shaft Bearing Cone Installer and Bearing/Oil Seal Plate, press the inner drive pinion bearing and drive pinion bearing adjustment shim until it is firmly seated on the pinion shaft.
  1. Install a new drive pinion collapsible spacer on the pinion shaft against the pinion shaft shoulder.
  1. Position the drive pinion assembly into the axle housing.
  1. Install the outer drive pinion bearing and the drive pinion shaft oil slinger.
  1. Install the drive pinion seal and flange. For additional information, refer to Drive Pinion Flange and Drive Pinion Seal in this section.
  1. Using the Differential Side Bearing Installer, install the 2 new differential bearings.
  1. Install the differential carrier. For additional information, refer to Differential Carrier in this section.