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:

    Fuel quality
    Note: Use of any fuel other than those recommended may cause powertrain damage and a loss of vehicle performance; repairs may not be covered under warranty. Choosing the Right Fuel Use only unleaded fuel or unleaded fuel blended with a maximum of 15% ethanol. ...

    AM/FM/CD/Sirius satellite radio
    WARNING: Driving while distracted can result in loss of vehicle control, crash and injury. We strongly recommend that you use extreme caution when using any device that may take your focus off the road. Your primary responsibility is the safe operation of you ...

    Removal
    1. Disconnect the battery negative cable. 2. Drain the engine cooling system. 3. Remove the RH exhaust manifold. For additional information, refer to Exhaust Manifold RH in this section. 4. Remove the lower intake manifold. For additional information, re ...