Ford Mustang (1999-2004) Service Manual: Axle Housing Casting Porosity (Holes in Casting) Repair

Ford Mustang (1999-2004) Service Manual / Driveline / Driveline System - General Information / 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.

Axle Housing Casting Porosity (Holes in Casting) Repair

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).

Axle Housing Weld Leaks Repair

 

    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:

    Powertrain Control Module (PCM)
    Removal 1. Disconnect the battery ground cable. For additional information, refer to Section. 2. Remove the RH front door scuff plate. 3. Remove the RH cowl side trim panel. Remove the pin-type retainer. Remove the panel. 4. Disconnect ...

    Degas Bottle - 4.6L(2V) and 4.6L(4V)
    Removal and Installation 1. Drain the engine coolant from the degas bottle only. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section. 2. Disconnect the radiator vent hose. 3. Remove the degas bottle return hos ...

    Hill start assist
    WARNING: The hill start assist feature does not replace the parking brake. When you leave the vehicle, always apply the parking brake and shift the transmission into position P for automatic transmission or position 1 for manual transmissions. WARNING: You mus ...