Ford Mustang (1999-2004) Service Manual: Axle Housing Casting Porosity (Holes in Casting) Repair
CAUTION: To keep the axle's sound characteristics, do not disassemble the carrier.
NOTE: Casting porosity is a condition where occasionally gas bubbles will form during the casting process leaving small pockets in the metal that will cause the axle housing to leak.
1. To fill small pockets, peen in a small amount of body lead.
2. Seal the pocket.
- Use epoxy sealer meeting Ford specification M-3D35A(E).
3. To fill large pockets, drill and tap a shallow hole for a small setscrew. Install the setscrew and seal it.
- Use epoxy sealer meeting Ford specification M-3D35A(E).
Axle Housing Weld Leaks Repair
1. CAUTION: To keep the axle's sound characteristics, do not disassemble the carrier.
CAUTION: Rear axle housing straightness is too critical for field repair. Install a new axle housing if a weld is broken.
NOTE: Most minor weld leaks are repairable. This includes the puddle and fill welds that join the axle shaft tube to the axle housing on integral axles.
Seal the weld.
- Use Devcon Aluminum Liquid F2 or equivalent meeting Ford specification M-3D35A(E).
Driveline Angle Inspection
Special Tool(s)
Anglemaster II Driveline
Inclinometer
164-R2402 or equivalent
NOTE: An incorrect driveline angle can cause a vibration or shudder.
1. Check the vehicle for evidence o ...
Driveshaft
Torque Specifications
Description
Nm
lb-ft
Pinion flange bolts
112
83
...
Other materials:
Inspection and Verification
NOTE: If any concerns are noted with the speedometer, stoplamps, or
horn, address those concerns
by referring to their associated sections before continuing speed control
diagnosis.
1. Verify the customer concern by operating the speed control system.
2. Vi ...
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. ...
Removal
WARNING: The restraints control module (RCM) orientation is critical
for proper system
operation. If a vehicle equipped with an air bag supplemental restraint system
(SRS) has been
involved in a collision in which the center tunnel area has been damaged,
in ...
