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.

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:

    Camshaft Lobe Lift
    Special Tool(s) Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent 1. Use a Dial Indicator Gauge with Holding Fixture to measure camshaft intake/exhaust lobe lift. Rotate the camshaft and subtract the lowest ...

    Parking brake
    WARNING: If the parking brake is fully released, but the brake warning lamp remains illuminated, the brakes may not be working properly. See your authorized dealer as soon as possible. WARNING: Always set the parking brake fully and make sure that the transmis ...

    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 ...