Clunk when shifting 1 to 2 and 2 to 3 manual transmission 06 FX4 LVL 2 4.0L

kprue · #1 06-14-2020, 06:28 PM

This seems like its an issue that comes up every once in awhile, I'm noticing some pretty severe clunking when shifting gears. I can sometimes overcome it by being extremely and overly cautious when shifting.

It is not trans mounts, engine mounts, or tie rods. Clutch has no other notable issues. Pinion seal is seeping and will be fixed tomorrow, fluid levels are fine. I will be greasing the slip yoke, cleaning mass airflow, checking master cylinder while I do the pinion seal.

Is there anything else to look for? Has anyone solved this definitively? Is it backlash or failing clutch? There is notable play in drive shaft which has been noted as normal though I couldn't move my father's explorer's drive shaft at all.

2006 Lvl 2 with 120,000KMS 4.0 V6, 8.8 Diff

tomboy · #2 06-15-2020, 04:05 AM

The driveshaft would be a good place to start, U joints can look good but cause a clunk when trans is shifted, especially from forward to rev.

kprue · #3 06-15-2020, 07:10 PM

So far not an issue when forward to reverse or from neutral to 1st. Only moving forward from 1st-2nd 2nd-3rd and then barely notable up from there.

Ordinary Biker · #4 06-16-2020, 04:08 PM

Quote:

Originally Posted by kprue

So far not an issue when forward to reverse or from neutral to 1st. Only moving forward from 1st-2nd 2nd-3rd and then barely notable up from there.

Not a reason to not check them...

kprue · #5 09-23-2020, 12:19 PM

I checked the U joints when replacing the pinion seal. Its not the issue. Any other ideas?

Minun · #6 12-01-2020, 06:00 PM

Is this occuring as you move the shift lever or when releasing the clutch?

kprue · #7 12-07-2020, 04:02 PM

Releasing and in some cases depressing the clutch. No noise when actually shifting between gears and no issues getting into any gears. It seems like it’s a synchronization issue. If I speed up and then depress the clutch it clunks and if I’m not incredibly careful it clunks when I release the clutch, up shifting or down shifting. Higher rpms seem to help but do not cure the issue.

Update: There is play in my drive shaft but not in the u-joints. Most people say this is not an issue but I’ve been crawling under every Ford ranger or otherwise and mines the only one that moves.

wpginterceptor · #8 12-07-2020, 05:37 PM

could be your diff

oceanhilltender · #9 01-22-2021, 05:35 PM

there can be some noise, and I'm not sure it is unnatural....there is a clunk with mine...and I don't think it's a problem, but maybe a throwout bearing issue? I'm just speculating