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:
Relay Switch
1. Disconnect the battery ground cable. For additional information, refer
to Section.
2. Remove the power distribution box cover.
3. Remove the starter relay from the power distribution box.
Installation
1. To install, reverse the removal procedure. ...
Key Programming - Additional Key With One Programmed
Key
Special Tool(s)
Worldwide Diagnostic System
(WDS)
418-F224,
New Generation STAR (NGS)
Tester
418-F052, or equivalent
diagnostic tool
NOTE: This procedure is used when a customer needs to have an additional key
programmed into the
veh ...
Locking and unlocking
You can use the power door lock control or the remote control to lock
and unlock your vehicle.
Power Door Locks
The power door lock control is located on the driver and front passenger
door panels.
A. Unlock
B. Lock
Remote Control
You can use the remote cont ...