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:
Door Speaker - Upper
Removal and Installation
1. Remove the front door trim panels (239420). For additional
information, refer to Section
2. Remove the upper speaker access cover.
3. Remove the upper speaker housing.
1. Remove the screw.
2. Remove the upper spea ...
Stub Shaft Pilot Bearing and Seal
Special Tool(s)
Remover, Bearing Cup
308-047 (T77F-1102-A)
Protector, Differential Seal
(Pair)
205-461
Installer, Differential Oil Seal
205-293 (T89P-4850-A)
Adapter for 303-224 (Handle)
205-153 (T80T-4000-W)
...
Child seat positioning
WARNING: Airbags can kill or injure a child in a child seat.
Never place a rear-facing child seat in front of an active airbag.
If you must use a forward-facing child seat in the front seat, move the
vehicle seat upon which the child seat is installed all th ...