Clunk in around 15-20 mph(2nd gear) Please please give input!

[Professor]

Hello all. I'm really tired of replacing things on my 05 4.4i. 123k.

I get a clunk....clunk..clunkclunkclunk almost as soon as it shifts into second gear around 15-20mph. It's more noticeable if I'm on a slight incline. It doesn't always do it but more times than not it does. Rpm's and acceleration is normal (I know what a slipping trans feels like and this is not it). It feels like its under my feet and gear/metal related. If I give it light acceleration I can get it to do it almost always. Heavier acceleration I dont notice it.

Could it be the transfer case? Axels/cv joints?

I took it to an Indy shop and they said there were transfer case codes but they couldn't get the car to do the problem. Of course I can make it do it any time I want. Any help or direction is greatly appreciated!!!!


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[Professor]

Any insight would be welcome. I don't know what the transfer case issues feel like or where I would feel them. It does seem like there is an audibly louder noise when it's lower in the rpm right after it shifts into second.

But why the series of clunking only occurs in second gear at lower speeds/ rpm with light to moderate acceleration I have no idea. No engine or rpm miss, it pulls fine with perfect idle, just a rotating clunk shortly after it shifts into 2nd around 15-20 mph


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[TwinTurboGTR]

So when it does the clunking... it still pulls fine or is there some grab missing issues when you continue to pull away? If you're in the middle of a clunk and smash the accelerator... does it go away immediatly or does it continue to do it?

[Professor]

Just took it out. It pulls fine but continues to "clunk" even when I put the hammer down. Hard at first and kind of fades away. However I put it into M and hammered it in second (which it did the same thing) shifted into third and stayed on the throttle and it kept doing the clunking. If I drove normal, it doesn't do it. I really feel it might be transfer case related but it's a guess.


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[Brandon002]

Is the clunk coming from under the car? Front? rear?

I've heard of clunking like this from worn subframe bushings.

[Professor]

Feels like under the frontish area.

This feels like a rotating clunk purely on acceleration not handling.


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[Brandon002]

Have you inspected the CV boots? Flex discs?

[BigBlack48is]

I would suggest inspecting the cv boots CLOSELY ( inner / outter ) and also do a drain and re-fill on the xfer case ( at least that will give you an idea of the condition of it )

Sometimes you can also check the chain tension in your xfer case while re-filling it

Wouldn't hurt to get into all the bushings with a pry bar to check for wear too!

[Professor]

Don't know if this could cause the clunking but here is my driver side outside boot. What do you think? All others are dry.


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[upallnight]

Originally Posted by Professor

Don't know if this could cause the clunking but here is my driver side outside boot. What do you think? All others are dry.


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Even if it is not source of your problem, you should still get it fix.