Ford Mustang (1999-2004) Service Manual: Chuckle
Chuckle that occurs on the coast driving phase is usually caused by excessive clearance between the differential gear hub and the differential case bore.
Damage to a gear tooth on the coast side can cause a noise identical to a chuckle. A very small tooth nick or ridge on the edge of a tooth can cause the noise.
Clean the gear tooth nick or ridge with a small grinding wheel. If the damaged area is larger than 3.2 mm (1/8 inch), install a new gearset.
To check the ring gear and pinion, remove as much lubricant as possible from the gears with clean solvent. Wipe the gears dry or blow them dry with compressed air. Look for scored or damaged teeth.
Also look for cracks or other damage.
If either gear is scored or damaged badly, install a new ring gear and pinion.

If metal has broken loose, the axle housing must be cleaned to remove particles that will cause damage. At this time, any other new parts in the axle housing must also be installed, if necessary.
Bearing Whine
Bearing whine is a high-pitched sound similar to a whistle. It is usually
caused by worn/damaged
pinion bearings, which are operating at driveshaft speed. Bearing noise occurs
at all driving speeds. ...
Knock
Knock, which can occur on all driving phases, has several causes including
damaged teeth or gearset.
In most cases, one of the following conditions will occur:
1. A gear tooth damaged on the drive s ...
Other materials:
Output Shaft
Special Tool(s)
Pinion Bearing Cone Remove
205-D002 (D79L-4621-A) or
Equivalent
Spiral Snap Ring Replacer
308-096 (T85P-7025-A)
Disassembly
1. Using the special tool and a press, remove the third/fourth gear
synchronizer asse ...
Apply Components
There are eight apply components used to drive or hold the planetary
gearset components.
Band-Overdrive
1. The overdrive band holds the reverse clutch drum stationary in fourth gear
and manual
2. This action
causes the reverse sun gear to be h ...
Front Seat Cushion
Disassembly and Assembly
All vehicles
1. Remove the seat track. For additional information, refer to Seat Track
in this section.
2. Remove the seat backrest. For additional information, refer to Front Seat
Backrest in this
section.
Vehicles with powe ...
