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Old 03-17-2014, 08:44 AM   #1
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knock when letting out clutch

2000 2.5L TJ. When letting out clutch there is a clank noise. If extremely careful the noise can be avoided. It happens shifting through all gears.

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Old 03-17-2014, 08:58 AM   #2
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A few possibilities. First, it could be that your 4 wheel drive linkage came apart, and is swinging and knocking against the skid plate right below you whenever you let the clutch out. Just slightly pull up on the 4wd shift lever, and if there is no resistance and it is very loose, that is the problem. Many times when that happens, it pops apart because of a bad/torn transmission mount, and even after putting it back together, if the mount isn't replaced it will pop out again.

The second possibility is a bad transmission mount itself. You can check that by using a small pry bar between the back of the transfer case skid and transfer case and trying to raise the transfer case off the skid. If you can, replace the mount.

A third possibility are u-joints, although if a u-joint was bad enough to make a clunk, there should also be some vibrations when driving.

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Old 03-18-2014, 09:20 AM   #3
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I had a similar issue... My t-case linkage was not in the correct position at all. There is a sensor that comes out of the side of your trans. My linkage was up against this sensor and when I accelerated hard it would torque and slap that sensor creating a fast clack clack clack similar to what you're describing. Check your linkage
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Old 03-20-2014, 07:53 PM   #4
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Thanks. The problem turned out to be badly worn control arm bushings.
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Old 03-21-2014, 10:51 AM   #5
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Quote:
Originally Posted by Water Dog View Post
The second possibility is a bad transmission mount itself. You can check that by using a small pry bar between the back of the transfer case skid and transfer case and trying to raise the transfer case off the skid. If you can, replace the mount.
I have the same problem as OP. I pretty much get clunks shifting through all gears unless I am very gentle with the clutch and match the engine RPMs to the tranny's input shaft almost perfectly, especially when downshifting. I also experience clunks when I am idling in 1st and I hit the gas fairly quickly (usually when driving over speed bumps and such) and I am not even touching the clutch pedal.

I doubt it's the u-joints because I just had the rear u-joints replaced last summer, and I don't think it could be the front u-joints if I am in 2H. When you are using the pry bar, how much should the TC move in order for the mount to be considered bad? I went out this morning and it seemed like I could raise the TC a little bit, but it took a lot of work so I wasn't sure if that was just the weight of the TC or if I was "forcing" it to raise by using so much force.

Edit: also how would I know if the control arm bushings are bad like the OP's?
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