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.

Chuckle

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:

    Gearshift Rail and Fork
    Disassembly and Assembly 1. Using a 5/32-inch drift and a hammer, remove and discard the split pin. Slide the shift fork from the shift rail. 2. Remove the gearshift fork inserts. 3. CAUTION: Support the shift rail to prevent damage to the parts. Positio ...

    Installation
    1. Install the bearing. 1. Position the knuckle on the press. 2. Using the appropriate step plate adapter, press the bearing into the knuckle until the bearing clears the snap ring groove and bottoms out in the bore. 2. Install the snap ring. 3. CA ...

    Release Cable - Clutch
    Removal CAUTION: Whenever the clutch release lever cable (7K553) is disconnected for any reason, such as transmission removal, clutch pedal components or clutch release lever cable replacement, it is imperative the correct method for installing the clut ...