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:
Installation
All vehicles
1. Position the engine front cover gasket on the engine front cover.
2. NOTE: If the engine front cover is not secured within four minutes, the
sealant must be removed
and the sealing area cleaned with metal surface cleaner. Allow to dry until ...
Rocker Arm
Removal
CAUTION: If removing more than one rocker arm (6564), mark the
components removed
for correct location.
1. Remove the valve covers. For additional information, refer to
Valve Cover-LH and Valve Cover
RH in this section.
2. Remove the rocker ...
Actuator Cable - Speed Control-Cobra
1. Remove the speed control actuator cable end from the throttle body.
1. Lift the speed control cable from the throttle nailhead.
2. Release the speed control cable from the throttle bracket.
2. Remove the speed control cable from the retaining cli ...
