Axle Housing Weld Leaks Repair

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. 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.

CAUTION: 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 epoxy sealer meeting Ford specification M-3D35A(E).
  
  Fig 1: Installing New Axle Housing Weld Broken
  Courtesy of FORD MOTOR CO.