Axle Housing Casting Porosity (Holes in Casting) Repair

WARNING: This page is about a different car, the 2003 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.

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.

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

Fig 1: Peening In A Small Amount Of Body Lead
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).