For 1990-2009 cars

### Diagnostic Aids

All manual transmissions have gear play that might cause a clunk. If the transmission is suspected of causing the clunk, compare it with a similar vehicle. An internal clunk in the transmission is usually caused by wear between 2 components, or from improper assembly, which would also cause other symptoms.

### Test Description

The number below refers to the step number on the diagnostic table.

1. This step inspects for the transfer case causing the clunk. Shift the transfer case into another mode. If the transmission is causing the clunk, there will not be a change in the clunk.

Step | Action | Yes | No
--- | --- | --- | ---
DEFINITION: A clunk is heard and/or felt on acceleration or deceleration.
1 | Did you review the Symptoms - Manual Transmission and perform the necessary inspections? | Go to Step 2 | Go to Symptoms - Manual Transmission
2 | Inspect the engine mounts for being loose or damaged. Refer to Engine Mount Inspection or Engine Mount Inspection. Did you find and repair the condition? | Go to Step 10 | Go to Step 3
3 | Inspect the transmission mounts for being loose or damaged. Refer to Transmission Mount Replacement . Did you find and repair the condition? | Go to Step 10 | Go to Step 4
4 | Inspect the transmission to engine fasteners for being loose or missing. Refer to Fastener Tightening Specifications . Did you find and repair the condition? | Go to Step 10 | Go to Step 5
5 | Inspect the driveline for causing the clunk. Refer to Diagnostic Starting Point - Propeller Shaft. Did you find and repair the condition? | Go to Step 10 | Go to Step 6
6 | Is the vehicle equipped with a transfer case? | Go to Step 7 | Go to Step 9
7 | Shift the transfer case into 4HI. Is the clunk still present? | Go to Step 9 | Go to Step 8
8 | Inspect the transfer case for causing the clunk. Refer to Symptoms - Transfer Case. Did you find and repair the condition? | Go to Step 10 | Go to Step 9
9 |

1. Remove the transmission. Refer to Transmission Replacement .
2. Disassemble the transmission. Refer to Transmission Disassemble.
3. Inspect the following transmission components that could be causing the clunk:

• | Worn speed gear teeth

• | Worn countershaft gear teeth

• | Worn synchronizer sleeve to hub

• | Worn thrust washers and thrust surfaces on the speed gears or mainshaft

Did you find and repair the condition?

Go to Step 10

Go to Diagnostic Aids

10 | Operate the system in order to verify the repair. Did you correct the condition? | System OK | Go to Step 1