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).