4.0L WITH MANUAL TRANSMISSION - 4TH GEAR RATTLE/KNOCK NOISE ON ACCELERATION - 1800-2200 RPM APPROXIMATELY 45 MPH (72 KM/H)
Publication Date: April 4, 2008
Some 2005-2007 Mustang vehicles, equipped with a 4.0L engine and manual transmission, may exhibit a rattle or knocking noise on light acceleration between 1800-2200 RPM around 45 MPH (72 Km/h). It is most evident in 4th gear after the engine/transmission has reached operating temperatures. It has been described as a helicopter noise, similar to when you put a playing card in bicycle spokes. This noise has no affect on vehicle performance or durability.
Follow the Service Procedure steps to correct the condition.
THIS NOISE IS DUE TO A SYSTEM RESONANCE, COMMON TO SOME 4.0L/MANUAL TRANSMISSION EQUIPPED VEHICLES, AND HAS NO AFFECT ON CLUTCH/TRANSMISSION LIFE/DURABILITY. PERFORMING THIS PROCEDURE WILL GREATLY REDUCE THE NOISE LEVEL.
Follow TSB 08-3-4 to eliminate any noise/vibration related to exhaust system alignment. If rattle noise still persists, then proceed to Step 2.
THIS PROCEDURE WILL NOT FIX THE CONCERN IF THE CUSTOMER COMPLAINT IS:
ABOVE 55 MPH
ON COAST DOWN
IN 1ST OR 5TH GEAR
AFFECTED BY PRESSURE ON THE SHIFTER
A GRINDING NOISE
The noise specific to this procedure is most evident after the engine/transmission has reached operating temperatures. It is due to a resonance. The transfer path for the noise is through the gear shift lever area and transmission mount. If the noise can be replicated in 4th gear on light acceleration between 1800-2200 RPM, around 45 MPH (72 Km/h), then replace the flywheel with the revised flywheel listed in the Parts List. To be compatible, the clutch may need to be replaced depending on build date. See Steps 3 and 4.
THIS PROCEDURE HAS NO AFFECT ON CLUTCH/TRANSMISSION LIFE/DURABILITY.
If the vehicle was built on or after 12/4/2006, then replace the flywheel per Workshop Manual (WSM), Section 303-01A. If not, then go to Step 4.
If the vehicle was built before 12/4/2006, then replace the flywheel, clutch disc, and clutch pressure plate per WSM, Sections 303-01A and 308-01.
Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
2007 Mustang 4.0L Manual Transmission Built On Or After 12/4/6: Replace Flywheel, Includes Time To Remove And Install Transmission (Do Not Use With 7003A, 7003A3, 7003A6)
2005-2007 Mustang 4.0L Manual Transmission Built Before 12/4/6: Replace Flywheel, Clutch Disc, Clutch Pressure Plate And Pedal Assembly, Includes Time To Remove And Install Transmission (Do Not Use With 7003A, 7003A3, 7003A6, 2455B)