Steering/Suspension Noise
 

I just bought a 2003 mustang GT 5 speed back in November. The car is running good and going well except for this odd crunching sound when braking to a stop. Its sounds like it is coming from the steering rack.

I myself am a automotive technician, and have access to motoralldata and shopkey, and still this has been scratching my head. I pulled up a TSB that fit the description of the problem I was having. It stated that mustangs from 2002-2004 may expierence a creak or squeak sound when turning or braking. Which is exactly what it does.

Im guessing the brackets get worn out and when the body flexes(under braking), then tubes are getting tension on them casuing them to creak. Since these tubes are mounted to both the frame and steering rack.

For the solution, it stated that I should replace both steering gear tube brackets.

I did. It got rid of the noise while turning, however when coming to a stop I still hear the sound.

Anyone else have this same problem and found a cure yet for it? The sound is highly annoying.

Anybody know? I still havent figured it out.

The TSB you pulled up is probably the known problem of balljoints or tierods causing a squeek. The crunch may be binding somewhere in the balljoints. Did you take the wheel off and try pulling your balljoint to find if thats the cause of the problem. The tierods shouldnt be causing your crunching bind sound but they are known to go bad.

Tie rod ends are brand new. Tested inner tie rod and lower control arm balljoints, their all good. I have never heard a sound such as this before though.

Hmm, do brakes apear to be in decent condition? Are your pads seated correctly? Mine did that before my brakes needed replacing, then it went away after they were just bad all around.

However mine didnt do it in strait line braking, only on slight turn braking like coming around a curve to stop sign, or backing into a parking spot with the wheel turned.

Brakes are fresh, just installed them about a month ago. It did it before the new brakes/rotors were installed also. Im startign to wonder if its not the caliper making the noise. But I doubt it, it only does it when the car is at very low speeds. When the car starts coming to a stop you hear it a bit, even when my foot is off the brake. And I also hear it when I turn the wheel at VERY low speeds. However, if im sitting still, and turn the wheel, theres nothing, even with the car on or off. Also, if i shake/rock the car, i hear nothing at all either. Which is leading me to believe that it has nothing to do with the power steering rack. Id imagine if it was the rack mounts, it would make noise when the wheel turns in any direction, even when the car isnt moving, since all that pressure in the chambers of the rack pushing around.

So im at a loss. Its really giving me a headache. Anything else it could be?

I bought new rack bushings, the polyurethane ones from here, there on there way, and hopefully it fixes the problem, if not, oh well. Its coming to the point to where Im just throwing new parts on there and hoping that something happens.

flaming river manual rack and shaft, manual master cylinder, Stainless steel brake lines :)