[Carlos Kavetsky]

ALCON,

I have a problem with my 2005 Ford Mustang and it only has 21,854 miles. A year ago or more (Nov 06) I took the vehicle in for service and repair because it started to exhibit the following symptoms (and it had less mileage then):

1) Rattling Noise coming out of undercarriage, gear shift area.
2) Rattling noise took place when the vehicle was cold and running at 3000-4000 Rpm and shifting to 2 and 3 gears.
3) Rattling noise reoccurs every time you shift from 2-3 gear between 3000-4000 for 2-4 minutes until the vehicle warms up then it stops.
4) If you warm up the vehicle before you take off it will not exhibit the symptoms. During winter time the rattling gets even worse and happens all the time if you do not warm up the vehicle for at least 5-10 minutes.

The service shop provided the following repair information for my vehicle:
1) Tightened the exhaust clams.
2) The rear seal retainer cast was incorrectly mounted they verified concern, lifted vehicle and inspected. They ran the vehicle on hoist and found engine block plate vibrating against the rear main seal retainer. The retainer had a nipple coming out of it where the block plate is contacting. They called the Ford tech line and ordered a new rear seal retainer. The new retainer did not have any protrusion. The rear seal retainer was removed and replaced. The rear main seal was replaced. They restored the vehicle and test drove it, the results were ok, no noise was heard at the time.

Like around Jul-Aug 07 the same symptoms reoccurred, I was mad. I took it back for the next scheduled service in Sep 07 and the shop could not find the problem. They told me to bring it back another time, well like I said before the rattling noise got worse as the winter got close. I love this vehicle and I want to get it repaired once and for all before the warranty expires at 35,000 (is there warranty for this type of work?). I have an appointment Monday for service and repair, but I am taking the vehicle in Sunday night and will test drive the vehicle cold with the tech on Monday so they can hear for themselves and understand what I am saying. I am taking the TSB with me. Anybody has suggestions or can point me in the right direction? I believe the TSB describes my vehicle symptoms very well. Hope this helps all that read the forum. Thanks

Best Regards,

Los

[rjyoung]

Carlos,

I had almost the exact same symptoms on my 06 GT. I bought it in Sept 05 and in Dec 05 I encountered the problem. My rattle started at 2500 and only when cold. In the winter time, it sounded like a loose bolt rattling against thin sheet metal, or wicked evil pinging!

The dealer tried a 'loose trans mount bolts TSB' but that didn't fix it. After letting their tech drive it home over night, they finally heard it. After working with Ford engineers, they determined that the plate between the block and trans bell housing that holds the starter was hitting the flywheel. Ford recommended they cut a piece out of that plate.

I don't know the details of where or how much they cut, but it did fix the problem.

The dealer was Sansone Ford near Eatontown, NJ. Hope this helps!

-R

[05GT Mustang]

Thanks "R" - I have had the exact same problem since I bought my 05GT in early 07 and have taken it to multiple dealers and spent about $1100 (after the warranty expired) trying to fix it. I love the car but I am embarrassed to drive it. I think I'll try your idea and then officially give up if it doesnt work.

Thanks!
Doug

Originally Posted by rjyoung

Carlos,

I had almost the exact same symptoms on my 06 GT. I bought it in Sept 05 and in Dec 05 I encountered the problem. My rattle started at 2500 and only when cold. In the winter time, it sounded like a loose bolt rattling against thin sheet metal, or wicked evil pinging!

The dealer tried a 'loose trans mount bolts TSB' but that didn't fix it. After letting their tech drive it home over night, they finally heard it. After working with Ford engineers, they determined that the plate between the block and trans bell housing that holds the starter was hitting the flywheel. Ford recommended they cut a piece out of that plate.

I don't know the details of where or how much they cut, but it did fix the problem.

The dealer was Sansone Ford near Eatontown, NJ. Hope this helps!

-R