Axle Housing Casting Porosity (Holes in Casting) Repair

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Do not disassemble the carrier. Make repairs on the outside of the axle.

NOTE: Casting porosity is a condition where occasionally gas bubbles will form during the casting process leaving small pockets in the metal that may cause the axle housing to show signs of dampness.

To fill small pockets, peen in a small amount of body lead.

Fig 1: Filling Small Pockets
Courtesy of FORD MOTOR CO.
Seal the pocket.
- Use Devcon Aluminum Liquid F2 or equivalent meeting Ford specification M-3D35A(E).
To fill large pockets, drill and tap a shallow hole for a small setscrew. Install the setscrew and seal it.
- Use Devcon Aluminum Liquid F2 or equivalent meeting Ford specification M-3D35A(E).