Transmission/driveline clunk question

[markj8977]

New member here. I have a 1985 2WD, but I would imagine that being 2WD wagon wouldn't make much difference vs. the 4WD regarding this question.

I hear and feel a clunk when I release the clutch. This happens taking off in first, a little less going to 2nd, and a little less going to third. Doesn't seem to do it beyond that. It happens at a fairly predictable point in the clutch travel. I've found that I can ease off on the clutch slowly until I feel whatever it is clunking move a little and then all is good and I can gun it with no clunking or other problems. When I shift to second though it will probably clunk when I release the pedal and give it gas. Once it's in that gear it never clunks again until you change gears.

I have found that I can shift without the clunk by using one of two methods:
1) Double clutch from first to third, and then, with the pedal still down, go to second. When I let up there is usually little or no clunk. Double clutching from second to third also eliminates the clunk on that shift.
2) I can also avoid pressing the clutch any more than is absolutely necessary when starting out and shifting. If I press it to the floor I get the clunk. If I only press it until it disengages I get no clunk. This is true starting out or shifting.

I have a pretty new CV axle on one side. The other side feels fine but the bearing (case bearing?) in the side of the case that the axle goes through has a little play. Little or no leakage there though.

Question: What's going on here? What is the source of the mystery clunk?

[dlb]

welcome to the forum, markj. you're right that there are a lot of similarities between 2wd and 4wd tercels. the carb, emissions, engine, front end, front brakes, and a lot of body and trim pieces are all the same.

check #5 in the FAQ for info on mystery clunk. my money is on strut mounts. best thing to do though is check each front end component individually. some are easily tested in place while others need to be removed--like the strut mounts (aka strut bearing plate), unfortunately. it's actually not too hard to remove the front struts though so pull them out and check to see if the mount wiggles from side to side. it shouldn't at all.

here's the FAQ.

https://tercel4wd.com/forums/viewtopic.php?f=2&t=7442

[markj8977]

Thanks DLB. I'll have a look at the FAQ.

As an update, I adjusted the clutch today just after my first post. It now engages with the pedal just a little off of the floor and the clunk is just about gone. Still trying to figure out what this all means, so if anyone else wants to take a stab at it I'd love to hear your educated guesses.

Also, it's weird to me that my clunking sound is the subject of an FAQ. Is this issue really that common? I've had tons of other cars, usually old ones, and ever experienced this.

[Mark]

Almost all of my automatics have had a clunk that sounds like it's coming from the transmission during a torque reversal (going between "drive" and "reverse" ). I've never checked my strut mounts. -Probably just laziness. I'd be interested to check the mounts if I ever need to remove the struts when they go bad.

[ARCHINSTL]

Absolutely evverthang in Goldie's front has been replaced: all bushings, inner and outer tie rods, new CVs, KYB strut inserts and mounts, springs, ball joints, and rack bushings - also new motor and trans mounts. I still have a not-so-loud clunk from the right side, but only when exiting certain parking lots and only at a certain angle.
When she was new to me in '05, I eliminated a loud clunk by properly torquing the two bolts holding the steering knuckle to the strut on the right side. Since they've not loosened since then and I check them a couple of times a year - I don't worry about it.
The only thing left is something internal on the right side of the PS rack, but since it works OK and there is NO wander at speed - I don't worry about it.
Tom M.

[Petros]

Tom,

mine clunks the same way, I have all good suspension parts too, but I noticed a lot of fine cracks around the strut towers. I suspect it is coming from the frame flexing, you might have the same issue. A strut tower brace helps, but I am considering welding some of the seams to stiffen the front frame back up.

[dlb]

Absolutely evverthang in Goldie's front has been replaced: all bushings, inner and outer tie rods, new CVs, KYB strut inserts and mounts, springs, ball joints, and rack bushings - also new motor and trans mounts. I still have a not-so-loud clunk from the right side, but only when exiting certain parking lots and only at a certain angle.
When she was new to me in '05, I eliminated a loud clunk by properly torquing the two bolts holding the steering knuckle to the strut on the right side. Since they've not loosened since then and I check them a couple of times a year - I don't worry about it.
The only thing left is something internal on the right side of the PS rack, but since it works OK and there is NO wander at speed - I don't worry about it.
Tom M.

tom, what about the passenger side door hinges, could there be slop in them? or the exhaust pipe, could it be missing the clamp and nuts that secures it to the trans? i'm trying to think of other things that could knock around when jarred.

[ARCHINSTL]

tom, what about the passenger side door hinges, could there be slop in them? or the exhaust pipe, could it be missing the clamp and nuts that secures it to the trans? i'm trying to think of other things that could knock around when jarred.

Exhaust stuff is all there and new from when I installed the Bosal in 2012. It did it before then and after.
I hadn't thought about the PS hinges, though - I'll check them when it warms up.
Ditto with Petros' comment about the cracks - since she led a sedentary life in Nashville for 19 year and then 9 more in STL, I had not considered that either. Will check it, too.
Tom M.