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:
Trunk release
The remote trunk release button is
located on the center console. Press
the button to unlatch the trunk.
Interior Trunk Control Lockout (Convertible Vehicles Only)
This feature disables the interior trunk control. It helps prevent
unauthorized access to the t ...
Accelerator Cable - 4.6L (2V)
Removal and Installation
1. Push the accelerator cable nylon bushing out of the accelerator pedal and
shaft arm.
2. Remove the bolts retaining the accelerator cable to the dash panel.
3. Disconnect the accelerator cable from the throttle body by rotating ...
Evaporative Emission Repair Verification Drive Cycle
Special Tool(s)
Worldwide Diagnostic System
(WDS)
418-F224,
New Generation STAR (NGS)
Tester
418-F052, or equivalent scan
tool
Drive Cycle Recommendations
NOTE: The following procedure is designed to execute and
complete the evap ...