205-02B-1 Rear Drive Axle/Differential — Ford 8.

8-Inch Ring Gear 205-02B-1

IN-VEHICLE REPAIR
Differential Bearings Special Tool(s)
Adapter For 205-S127
Special Tool(s) 205-109 (T76P-4020-A9)

2-Jaw Puller
205-D072 (D79L-4221-A1) or
equivalent

Adapter For 205-S127

205-129 (T79P-4020-A18)

Step Plate
205-D061 (D83T-4205-C2) or
equivalent

Adapter For 205-S127

205-110 (T76P-4020-A10)

Installer, Differential Side

Bearing
205-010 (T57L-4221-A2)

Adapter For 205-S127

205-130 (T79P-4020-A19)

Adapter For 205-S127

205-105 (T76P-4020-A3)

Dial Indicator With Holding

Fixture
100-002 (TOOL-4201-C) or
Adapter For 205-S127 equivalent
205-111 (T76P-4020-A11)

Gauge, Clutch Housing

308-021 (T57L-4201-A)

Remover, Differential Bearing

205-116 (T77F-4220-B1)

Shim Driver
205-220 (T85L-4067-AH)

(Continued)

(Continued)

Copyright  2006, Ford Motor Company

Last updated: 6/19/2006 2007 Mustang, Mustang GT 8/2006
205-02B-2 Rear Drive Axle/Differential — Ford 8.8-Inch Ring Gear 205-02B-2
IN-VEHICLE REPAIR (Continued)
Special Tool(s) Special Tool(s)
Holding Fixture, Drive Pinion Protector, Drive Pinion Thread
Flange 205-460 or equivalent
205-126 (T78P-4851-A)

Installer, Drive Pinion Bearing Puller, Bearing

Cone 205-D064 (D84L-1123-A) or
205-005 (T53T-4621-C) equivalent

Installer, Drive Pinion Bearing

Cup
205-024 (T67P-4616-A)

Installer, Drive Pinion Flange

205-002 (TOOL-4858-E) or
equivalent

Installer, Drive Pinion Oil Seal

205-208 (T83T-4676-A)

Plate, Bearing Oil Seal

205-090 (T75L-1165-B)

Item Part Number Description

(Continued)
1 4670 Oil slinger
2 4621 Outer pinion bearing
3 4616 Outer pinion bearing cup
4 4662 Collapsible spacer
5 — Inner pinion bearing cup shim
(5.4L only)
(Continued)

2007 Mustang, Mustang GT 8/2006

205-02B-3 Rear Drive Axle/Differential — Ford 8.8-Inch Ring Gear 205-02B-3
IN-VEHICLE REPAIR (Continued)
Item Part Number Description 4. CAUTION: The driveshaft centering
6 4628 Inner pinion bearing cup socket yoke fits tightly on the pinion flange
7 4630 Inner pinion bearing pilot. Never hammer on the driveshaft or
8 4663 Pinion bearing adjustment any of its components to disconnect the
shim driveshaft centering socket yoke from the
9 4209 Drive pinion pinion flange. Pry only in the area shown
with a suitable tool to disconnect the
10 4209 Ring gear
driveshaft centering socket yoke from the
11 4221 Differential bearing pinion flange.
12 4222 Differential bearing cup
Using a suitable tool as shown, disconnect the
13 4067 Differential bearing shim driveshaft centering socket yoke from the
pinion flange.
Removal
• Using mechanic’s wire, position the
driveshaft aside.
1. Remove the differential carrier assembly. For
additional information, refer to Differential
Carrier in this section.

2. Index-mark the driveshaft flange and pinion

flange for correct alignment during installation.

5. CAUTION: Discard the nut after

removal. Use a new nut during installation.
Use the special tool to hold the pinion flange
while removing the drive pinion nut.

3. Remove the 4 driveshaft flange bolts.

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205-02B-4 Rear Drive Axle/Differential — Ford 8.8-Inch Ring Gear 205-02B-4
IN-VEHICLE REPAIR (Continued)
6. Index-mark the pinion flange and the drive
pinion stem for correct alignment during
installation.

10. Remove the axle drive pinion shaft oil slinger.

11. Using the special tool and a soft-faced hammer,

drive the pinion assembly out of the outer
7. Using the special tool, remove the pinion pinion bearing and remove it through the rear
flange. of the differential housing.

8. Using a screwdriver, force up the rear axle 12. Remove the outer pinion bearing.
drive pinion seal metal flange.
13. Remove the drive pinion collapsible spacer and
discard it.

9. Using gripping pliers and a hammer, remove

the axle drive pinion seal.

2007 Mustang, Mustang GT 8/2006

205-02B-5 Rear Drive Axle/Differential — Ford 8.8-Inch Ring Gear 205-02B-5
IN-VEHICLE REPAIR (Continued)
14. Using the special tool and a suitable press,
remove the inner pinion bearing.

15. NOTE: On 5.4L applications, remove the inner

pinion cup shim from the housing.
Using a brass drift, remove the pinion bearing
cups by tapping alternately on opposite sides of
the bearing cups.

Installation

1. Press the left and right differential bearing on

the differential assembly.
1 Position the differential bearings.
2 Using the special tool, press the differential
bearings on the differential assembly.

16. Using the special tools, remove the differential

bearings.

2007 Mustang, Mustang GT 8/2006

205-02B-6 Rear Drive Axle/Differential — Ford 8.8-Inch Ring Gear 205-02B-6
IN-VEHICLE REPAIR (Continued)
2. NOTE: On 5.4L applications, install the inner 4. NOTE: If a feeler gauge of the specification
pinion bearing cup shim in the housing before shown can be inserted between a cup and the
installing the bearing cups. bottom of its bore at any point around the cup,
Position the special tool and the inner and outer the cup is not correctly seated.
bearing cups in their respective bores. Make sure the differential pinion bearing cups
1 After placing the inner and outer bearing are correctly seated.
cups in their respective bores, place the
special tool of the inner bearing cup.
2 Place the special tool on the outer bearing
cup.
3 Install the special tool.

3. Tighten the special tool to seat the pinion

bearing cups in their bores.

2007 Mustang, Mustang GT 8/2006

205-02B-7 Rear Drive Axle/Differential — Ford 8.8-Inch Ring Gear 205-02B-7
IN-VEHICLE REPAIR (Continued)
5. NOTE: Install new drive pinion bearings 6. NOTE: The gauge block must be offset to
without any additional lubricant since the obtain an accurate reading.
anti-rust oil provides adequate lubricant without Rotate the gauge block several half turns to
upsetting the drive pinion bearing preload make sure of correct seating of the drive pinion
settings. bearings and position the gauge block.
Assemble and position the drive pinion depth
gauge set.
1 Position the screw.
2 Position the aligning adapter.
3 Position the gauge disc.
4 Position the gauge block.
5 Position the inner drive pinion bearing.
6 Position the outer drive pinion bearing.
7 Thread on the handle and tighten.
X Tighten to 2.2 Nm (20 lb-in).

7. Install the special tool.

1 Position the gauge tube and the paper
shipping tabs.
2 Install the differential bearing caps.
3 Install the differential bearing cap bolts.
X Tighten to 112 Nm (83 lb-ft).

2007 Mustang, Mustang GT 8/2006

205-02B-8 Rear Drive Axle/Differential — Ford 8.8-Inch Ring Gear 205-02B-8
IN-VEHICLE REPAIR (Continued)
8. 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 gauge block and
gauge tube. 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 11. Install the drive pinion assembly into the axle
selection. housing.
• After the correct drive pinion bearing
adjustment shim thickness has been
determined, remove all of the special tools.

12. Install the outer drive pinion bearing and the

drive pinion shaft oil slinger.

9. Using the special tool and a shop press, drive 13. Using the special tool, install the drive pinion
the inner drive pinion bearing and drive pinion seal.
bearing adjustment shim until they are firmly
seated on the pinion shaft.

10. Install a new drive pinion collapsible spacer on

the pinion shaft against the pinion shaft
shoulder.
2007 Mustang, Mustang GT 8/2006
205-02B-9 Rear Drive Axle/Differential — Ford 8.8-Inch Ring Gear 205-02B-9
IN-VEHICLE REPAIR (Continued)
14. Using the special tools, install the drive pinion 16. Place the differential carrier assembly with the
flange. new differential carrier bearing cups in the axle
housing.

15. CAUTION: Do not, under any

circumstance, loosen the drive pinion nut to 17. Install a differential bearing shim on the LH
reduce pinion bearing preload. If it is side.
necessary to reduce the preload, install a new
drive pinion collapsible spacer and drive
pinion nut.
CAUTION: Remove the special tool
while taking rotational pinion bearing
preload checks with the Nm (lb-in) torque
wrench.
Use the special tool to hold the pinion flange
while tightening the pinion nut.
• Rotate the pinion occasionally to make sure
the differential pinion bearings are seating
correctly. Take frequent differential pinion
bearing preload checks by rotating the
18. NOTE: Apply pressure toward the LH side to
differential pinion with a Nm (lb-in) torque
make sure the left differential bearing cup is
wrench. Tighten the pinion nut in small
seated.
increments to avoid excessive pinion bearing
preload. Tighten the pinion nut until the Install the LH differential bearing cap and
drive pinion bearing preload is in loosely install the differential bearing cap bolts.
specification.

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205-02B-10 Rear Drive Axle/Differential — Ford 8.8-Inch Ring Gear 205-02B-10
IN-VEHICLE REPAIR (Continued)
19. Install progressively larger differential bearing 22. Install the special tools and measure the ring
shims on the RH side until the largest gear backlash.
differential bearing shim selected can be • If the backlash is within specification,
inserted by hand. proceed to Step 25.
• If a zero backlash condition occurs, proceed
to Step 23.
• If the backlash is not within specification,
proceed to Step 24.

20. Install the RH side differential bearing cap and

tighten the differential bearing cap bolts.
• Tighten to 112 Nm (83 lb-ft).

23. If a zero backlash condition occurs, add 0.50

mm (0.020 in) to the RH side shim and subtract
0.50 mm (0.020 in) from the LH side shim to
allow a backlash indication. Go back to Step
22.

24. To correct for high or low backlash, increase

the thickness of one differential bearing shim
and decrease the thickness of the other
differential bearing shim by the same amount.
Refer to the following tables when adjusting the
backlash. When the backlash is within
21. Rotate the differential assembly to make sure it specifications, proceed to Step 25.
rotates freely.
Backlash Change Thickness Change
Required Required
mm Inch mm Inch
0.025 0.001 0.050 0.002
0.050 0.002 0.050 0.002
0.076 0.003 0.101 0.004
0.101 0.004 0.152 0.006
0.127 0.005 0.152 0.006
0.152 0.006 0.203 0.008
0.177 0.007 0.254 0.010
0.203 0.008 0.254 0.010
0.228 0.009 0.304 0.012

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205-02B-11 Rear Drive Axle/Differential — Ford 8.8-Inch Ring Gear 205-02B-11
IN-VEHICLE REPAIR (Continued)
Backlash Change Thickness Change Differential Shim Size Chart 4067 (Continued)
Required Required
Stripes and Dimension A
mm Inch mm Inch
Color Code mm Inch
0.254 0.010 0.355 0.014
5 — ORNG 6.4262-6.4389 0.2530-0.2535
0.279 0.011 0.355 0.014
4 — ORNG 6.3754-6.3881 0.2510-0.2515
0.304 0.012 0.406 0.016
3 — ORNG 6.3246-6.3373 0.2490-0.2495
0.330 0.013 0.457 0.018
2 — ORNG 6.2738-6.2865 0.2470-0.2475
0.335 0.014 0.457 0.018
1 — ORNG 6.2223-6.2357 0.2450-0.2455
0.381 0.015 0.508 0.020
2 — RED 6.1722-6.1849 0.2430-0.2435
1 — RED 6.1214-6.1341 0.2410-0.2415
Differential Shim Size Chart 4067

Stripes and Dimension A

25. Rotate the differential assembly several times to
Color Code mm Inch make sure the differential bearings are seated.
2 — C-COAL 7.7978-7.8105 0.3070-0.3075
1 — C-COAL 7.7470-7.7597 0.3050-0.3055
5 — BLU 7.6962-7.7089 0.3030-0.3035
4 — BLU 7.6454-7.6581 0.3010-0.3015
3 — BLU 7.5946-7.6073 0.2990-0.2995
2 — BLU 7.5458-7.5565 0.2970-0.2975
5 — PINK 7.4422-7.4549 0.2930-0.2935
4 — PINK 7.3914-7.4041 0.2910-0.2915
3 — PINK 7.3406-7.3533 0.2890-0.2895
2 — PINK 7.2898-7.3025 0.2870-0.2875
1 — PINK 7.2390-7.2517 0.2850-0.2855
5 — GRN 7.1882-7.2009 0.2830-0.2835 26. Using the special tools, recheck the ring gear
4 — GRN 7.1374-7.1501 0.2810-0.2815 backlash.
3 — GRN 7.0866-7.0993 0.2790-0.2795
2 — GRN 7.0358-7.0485 0.2770-0.2775
1 — GRN 6.9850-7.0485 0.2750-0.2755
5 — WH 6.9342-6.9469 0.2730-0.2735
4 — WH 6.8834-6.8961 0.2710-0.2715
3 — WH 6.8326-6.8453 0.2690-0.2695
2 — WH 6.7818-6.7945 0.2670-0.2675
1 — WH 6.7310-6.7437 0.2650-0.2655
5 — YEL 6.6802-6.6929 0.2630-0.2635
4 — YEL 6.6294-6.6421 0.2610-0.2615
3 — YEL 6.5786-6.5913 0.2590-0.2595
2 — YEL 6.5278-6.5405 0.2570-0.2575 27. Remove the differential bearing cap bolts and
1 — YEL 6.4770-6.4897 0.2550-0.2555 differential bearing caps.

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205-02B-12 Rear Drive Axle/Differential — Ford 8.8-Inch Ring Gear 205-02B-12
IN-VEHICLE REPAIR (Continued)
28. To establish differential bearing preload, 31. Using the special tools, recheck the backlash.
increase both LH and RH differential bearing
shim sizes as shown. 32. Apply marking compound and rotate the
differential assembly 5 complete revolutions.

33. Check and verify an acceptable pattern.

34. Install the axle shafts. For additional

information, refer to Axle Shaft in this section

35. Position the driveshaft and align the index

marks on the pinion flange.

29. Using the special tool, fully seat the differential

bearing shims. Make sure the assembly rotates
freely.

36. CAUTION: The driveshaft centering

socket yoke fits tightly on the pinion flange
pilot. To make sure that the driveshaft
centering socket yoke seats squarely on the
pinion flange, tighten the driveshaft flange
bolts evenly in a cross pattern.
Install the driveshaft flange bolts.
30. Install the differential bearing caps and • Tighten to 112 Nm (83 lb-ft).
differential bearing cap bolts.
• Tighten to 112 Nm (83 lb-ft).

2007 Mustang, Mustang GT 8/2006