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Just wondering if someone could tell me why some trucks exhibit the "cackle" and others don't? Does it have anything to do with chips and programmers for performance?
Man, that is another can of worms. What it seems to have been finally narrowed down too after Ford came up with the #8 long lead injector and a variety of I-dunno's is because the Superduties have a frame mounted electric fuel pump and fuel is drawn under vacuum from the tank on "some" tanks the internal plumbing can leak causing air to be introduced into the fuel system. The "fix" is sold in kit forms on one of the diesel sites. Mine doesn't cackle to extreme so to date, I haven't bothered with it but it is on the list.
Fords fuel system can get air into it a couple of ways. The fuel lines from the tank to the fuel pump use quick connect fittings. Since they are not under presure, they can suck air in. The return line from the fuel filter dumps back in the tank near the pickup. On ford-trucks.com most refer to the mod as the hutch mod, named after poster hutchinagusta. If you go to http://communitywebshots.com/album/32303501JuYKPH he has photos showing the air and his fix for it. Some of the sponsors of the diesel stop sell kits to do this mod. I've done these mods and I can definitely hear the difference in the injector noise.