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 two 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 the driveline components that may be the cause of the clunk noise. The noise may resonate to the transmission.

Step | Action | Yes | No
--- | --- | --- | ---
DEFINITION: A clunk is heard and/or felt on acceleration or deceleration.
1 | Did you review and perform the necessary inspections? Refer to Symptoms - Manual Transmission. | Go to Step 2 | Go to Symptoms - Manual Transmission
2 | Inspect the engine mounts for being loose or damaged. Refer to Engine Mount Inspection in Engine Mechanical 3.6L or Engine Mount Inspection in Engine Mechanical 6.0L Did you find and repair the condition? | Go to Step 7 | Go to Step 3
3 | Inspect the transmission mounts for being loose or damaged. Refer to Transmission Mount Inspection. Did you find and repair the condition? | Go to Step 7 | 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 7 | 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 7 | Go to Step 6
6 |

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

• | Faulty mainshaft bearings.

• | Faulty countershaft bearings.

• | Worn speed gear teeth.

• | Worn countershaft gear teeth.

• | Worn synchroniser 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 7

Go to Diagnostic Aids

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