M/T - 4th Gear Knock/Rattle on Light Acceleration
TSB 08-8-504/28/08
4.0L WITH MANUAL TRANSMISSION - 4TH GEAR
RATTLE/KNOCK NOISE ON ACCELERATION -
1800-2200 RPM APPROXIMATELY 45 MPH (72 KM/H)
FORD:
2005-2007 Mustang
ISSUE
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.
ACTION
Follow the Service Procedure steps to correct the condition.
NOTE
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.
SERVICE PROCEDURE
1. 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.
NOTE
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
2. 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.
NOTE
THIS PROCEDURE HAS NO AFFECT ON CLUTCH/TRANSMISSION LIFE/DURABILITY.
3. 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.
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.
OTHER APPLICABLE ARTICLES: 08-3-4
WARRANTY STATUS: 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.
OPERATION DESCRIPTION TIME
080805A 2007 Mustang 4.0L Manual 2.7 Hrs.
Transmission Built On Or
After 12/4/6: Replace
Flywheel, Includes Time
To Remove And Install
Transmission (Do Not Use
With 7003A, 7003A3, 7003A6)
080805B 2005-2007 Mustang 4.0L 3.2 Hrs.
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)
DEALER CODING
CONDITION
BASIC PART NO. CODE
6375 07
Disclaimer