New Ford Mustang with Low RPM Load Noise

Maurice Business Development Manager Geebung, Australia Posted   Latest   Edited  
Question
Drivetrain
Under Load In Low Rpm In 1St Or Second And A Little In 3Rd We Get A Noise That Sounds Like A Gear Noise

Vehicle details 2018 FORD MUSTANG COUPE Vin 1FA6P8V02K…,030 km (New car) Sold in Australia as a Right hand drive car.

The dealer told my customer that this problem is ok and the noise is normal and nothing to worry about. My customers friend as the exact same model and his car is quite.

This car has a E4 order of vibration and before I go delving into this problem I want to know if anyone has any insight into this issue as there could be a known problem with these cars and there may be a TSB on this issue. Here in Australia we are still denied access to dealer TSBs, we normally find what we want though but this being such a late model car means I can not access any info here in Australia.

I also realise as this car is RH drive so this problem may be only an issue with the export models

When driving the car you only hear the noise when the car is under load at light rpms and in the lower gears. Usually going up a hill but not every time. The customer said it is worse when cold. When in the workshop and holding the rpms up you can hear a noise that seems to represent the noise we hear on the road but not as pronounced. the Pico NVH shown in this thread is captured with the accelerometer sensor directly on the engine and it is obvious that I am picking up a E4 order of vibration. On the road with the accelerometer sensor on the seat rail it is not as obvious but still the E4 is the most noticeable but is not going that much over 10mg.

If any of you Ford guys have any knowledge please could you let me know.

When I first heard this noise it reminded me of a gear mesh noise we can get some times if the tail shaft is out of alignment or the gear is not mesh is not meshing properly. But the fact that the noise changes under hot an cold conditions and that the noise is not noticed every time we go up the same hill at the same rpm makes me rule this out as the reason.

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Daryll Diagnostician
Seymour, Tennessee
Daryll
 

Does this on have the 5.0 or 5.2 V8? Either way, an E4 vibration is perfectly normal due to every crankshaft revolution there are 4 pulses of the crankshaft, which give you a 4th order Engine speed related vibration. Does this one have any ducting running from the air cleaner housing toward to firewall/passenger compartment area near the driver? Ford added a "resonator" that would funnel the

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Maurice Business Development Manager
Geebung, Australia
Maurice
 

Thanks Daryll This is very interesting to consider that this car may have a ducting to funnel the intake pulse sounds into the driver compartment. I will check this out, I did notice there was a air filter pod on this car. I am pretty sure we only get the 5.0 lt V8's here. I have not used the the DVH Microphone yet but when the car comes back I will do this and upload the recording.

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Daryll Diagnostician
Seymour, Tennessee
Daryll
 

This is from a 2016 model. Notice the tubing from the air duct toward the firewall?

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Maurice Business Development Manager
Geebung, Australia
Maurice
 

Ok I will check with my customers car, he had an open air box with a pod filter, being a new car I suspect it came form the dealer like his.

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Maurice Business Development Manager
Geebung, Australia
Maurice
 

Daryll I had my customer send me some pictures of his under bonnet and can not see any Air ducking to the firewall but I can not help wonder if his noise is generated by his pod filter.

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Chris Technical Support Specialist
Commack, New York
Chris
 

Does the customer have the original air box still ??

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Maurice Business Development Manager
Geebung, Australia
Maurice
 

Chris this was dealer delivered this car new this way and my customer claims his friends car which is the same model also has the same pod filter, maybe this is the way the manufacture sets it up for Australia? I am not sure and I will look into this.

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Daryll Diagnostician
Seymour, Tennessee
Daryll
 

I don’t see any of the ducting that i had referenced. Willing to say that the sound is being caused by something else. Curious to know if all of the grommets are seated correctly in the firewall/trans tunnel area

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Maurice Business Development Manager
Geebung, Australia
Maurice
 

I will keep you posted, the customer has gone over seas so it could be a few weeks before I get back to you

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Brendan Owner/Technician
Browns Plains, Australia
Brendan
 

Maurice, The intake box looks identical to this Shelby one, albeit with an original looking flex intake hose, how well does that MAF housing seal into the performance box? - quirkford​.​com/2019-ford-must… It would be very interesting to hear this 'friends car with the same intake' - perhaps they are shipping the V8 Mustangs here to Australia with a few of these performance

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Maurice Business Development Manager
Geebung, Australia
Maurice
   

Hi Brendan Apparently according to my customer his friends car is the exact same model with the same intake system and yes this car did come form the factory like this and now that you have brought Mustang Shelby GT350 to my attention I suspect this is the case with my customers car. I have spoken to Byrne Ford and they are doing to take the car for a road test to get a second opinion before I

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