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:

    Manual climate control
    A. Defrost: Distributes air through the windshield defroster vents and demister vents. You can use this setting to defog and clear the windshield of a thin covering of ice. B. Rear defrost: Turns the heated windows and mirrors off and on. See Heated windows ...

    Inspection and Verification
    Certain axle noise or vibration symptoms are also common to the engine, transmission, wheel bearings, tires, and other parts of the vehicle. For this reason, be sure that the cause of the trouble is in the axle before disassembling, adjusting or repairing th ...

    Striker Adjustment
    NOTE: After adjusting the door latch striker plate, verify that the door can be closed easily and fits tightly. 1. Loosen the door latch striker plate bolts. 2. Reposition the door latch striker plate from side to side or up and down as necessary. ...