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.

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 . 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 Propeller Shaft, Differential, and Driveline Support Replacement . 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 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 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