Aerostar 2WD V6-182 3.0L (1995)
Differential Axle Housing: Service and Repair
External Structural Repair
Inspect visually for damage. Ensure differential bearing bores are smooth and that threads are not damaged. Remove any nicks or burrs from mounting
surfaces of housing. Only repairs to cast axle housing and the "puddle-welded" area of the housing are approved. They should be made as follows:
1. Clean surfaces to be repaired by grinding or rotary filing to a clean bright metal finish. Clean repair area thoroughly. Metallic plastic will not stick
to a dirty or oily surface. Chamfer or undercut the hole or porosity to a greater depth than the rest of the cleaned surface. Solid metal must
surround the hole. Openings larger than 1/4 inch should not be repaired with metallic plastic. They can be drilled, tapped and plugged using
common tools.
2. Mix metallic plastic base and hardener according to manufacturer's instructions. Stir thoroughly until uniform.
3. Apply repair mixture with suitable clean tool, forcing epoxy into hole or porosity.
4. Allow repair mixture to harden. Heat cure with a 250 watt lamp placed 10 inches from repaired surface, or air dry for 10 to 12 hours at
temperatures above 50°F.
5. Sand or grind repaired area to blend with general contour of surrounding surface.
6. Paint the surface to match the rest of the axle housing.
