Ford F150 Pickup. Manual — part 652

Fig. 47: Checking Pinion Angle
Courtesy of FORD MOTOR CO.

8. To check the engine angle, rotate the driveshaft so that the slip yoke ear is parallel to the floor. Remove

the U-joint snap ring, then install the special tool. Check and record the engine angle reading.

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If the angle is not within specifications, repair or adjust to obtain the correct angles. Inspect the
powertrain/drivetrain mounts or frame rails for wear or damage.

2003 Ford Pickup F150

2003 GENERAL INFORMATION Driveline System - General Information - F150 Pickup

Fig. 48: Checking And Record Engine Angle Reading
Courtesy of FORD MOTOR CO.

AXLE HOUSING CASTING POROSITY (HOLES IN CASTING) REPAIR

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

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.

2003 Ford Pickup F150

2003 GENERAL INFORMATION Driveline System - General Information - F150 Pickup

Fig. 49: Identifying Axle Housing Casting Porosity (Holes In Casting) Repair
Courtesy of FORD MOTOR CO.

2. Seal the pocket.

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Use Devcon Aluminum Liquid F2 or equivalent 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.

z

Use Devcon Aluminum Liquid F2 or equivalent meeting Ford specification M-3D35A(E).

AXLE HOUSING WELD LEAKS REPAIR

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.

2003 Ford Pickup F150

2003 GENERAL INFORMATION Driveline System - General Information - F150 Pickup

1. Seal the weld.

z

Use Devcon Aluminum Liquid F2 or equivalent meeting Ford specification M-3D35A(E).

Fig. 50: Identifying Axle Housing Weld Leaks Repair
Courtesy of FORD MOTOR CO.

2003 Ford Pickup F150

2003 GENERAL INFORMATION Driveline System - General Information - F150 Pickup