Porosity/Sand Hole Repairing

Porosity or sand holes, which will cause oil seepage or leakage, can occur with modern casting processes. Make a complete inspection of engine and transmission. If the leak is attributed to the porous condition of the cylinder blocks or sand holes, service with an epoxy sealer meeting Ford specificatioNm3D35-A (E). Do not service cracks with this material. Service with this metallic plastic must be confined to those cast-iron engine component surfaces where the inner wall surface is not exposed to engine coolant pressure or oil pressure. For example:
^ cylinder block surfaces extending along the length of the cylinder blocks, upward from the oil pan rail to the cylinder water jacket but not including machined areas.
^ lower rear face of the cylinder blocks.

^ CAUTION: Service is not recommended to the intake manifold exhaust crossover section, since temperatures can exceed the recommended temperature limit of 260° C (500° F).
^ intake manifold (9424)
^ cylinder head along the valve cover gasket surface





The following procedure should be used to service Porous areas or sand holes in cast iron:
1. Clean surface to be serviced by grinding or rotary-filing to a clean, bright metal surface. Chamfer or undercut hole or porosity to a greater depth than rest of cleaned surface. Solid metal must surround hole. Openings larger than 6.35 mm (0.25 inch) should not be serviced using an epoxy sealer meeting Ford specification M3D35-A (E). Openings in excess of 6.35 mm (0.25 inch) can be drilled, tapped and plugged using common tools. Clean service area thoroughly. An epoxy sealer meeting Ford specification M3D35-A (E) will not stick to a dirty or oily surface.
2. Mix an epoxy sealer base meeting Ford specification M3D35-A(E) and hardener as directed on container. Stir thoroughly until uniform.
3. Apply an epoxy sealer meeting Ford specification M3D35-A(E) with a suitable clean tool (such as putty knife or wood spoon), forcing epoxy into hole or porosity.
4. Allow service mixture to harden. Two methods can be used. Heat-cure with a 250-watt lamp (as per direction on container) placed 254 mm (10 inches) from serviced surface, or air-dry for 10-12 hours at temperatures above 10° C (50° F).
5. Sand or grind serviced area to blend with general contour of surrounding surface.
6. Paint the surface to match the rest of the cylinder blocks.