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'Clunk' in drivetrain when shifting?

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ravi shank car

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Discussion starter · #1 ·
Hey Forum-goers! (first post)

I was wondering if anybody has experienced a 'clunking' sensation when shifting gears. The clunk feels almost like I've ridden over a boulder... it's quite frustrating. It does not seem to occur when the rev's are matched.

I have no clue if its a problem with the clutch, the gears, the transmission mounts, or if something in the drivetrain is out of balance. If anyone has had a similar problem and came across the culprit, I would be much obliged to hear it!

Cheers

-Jon
 
#2 ·
Well, it could be a transmission ring being worn, which likely is two gears beside each other if you have a bump feeling. Brace for a high cost repair then (several hundreds of dollar, because those parts are very expensive and lots of labor goes into this).
It also could be that your transmission fluid is low and the gears are not completely dipped into it, or that this fluid is of very poor quality (with lots of dirt in it, making the transmission it's work a lot harder).
Notice that the transmission is connected to the transfer case. With a 4WD that is (2WD don't have a transfer case). It contains 5 liters (5.3 quarts) of fluid in total (transmission and transfer case). To flush the gunk, dirt and all out you need at least 10 liters of fluid and to drop the pan. I personally recommend going for a cheap fluid there for the flush. Because the best quality transmission fluid you can get for this transmission (Red line 75 W 90 NS) costs a lot per liter. It however will make shifting so much smoother.
Below a picture to help you understand the transmission and where to drain and fill it. It should be filled up to the filler plug. Good quality fluid should be well possible to see through.
Do not dispose of the fluid with normal waste. It is very bad for the environment.
Greetz

Pim

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#4 ·
It could be a drivetrain mount wore or loose. Most mounts are rubber coated and it wear out or becomes loose. They are on trans,rearend and suspension.
In 5 yrs very few times have clunking noise not been the above.
 
#5 ·
Aloha. I have been having the same problem. When I shift, the front end makes a loud noise. I bought some manual gear oil and poured it into the transmission but 1 bottle was not enough. I have to wait to buy another. The place to add fluid is under the air cleaner box. Have to remove that then under that you will see a loose round vent and next to it the bolt. You will know it is the bolt because there is a small dip stick on the end inside. Make sure you don't loose the washer gasket attached to it. Hope this helps. Aloha.
 
#7 ·
Kenneth, you are talking about the breather plug and the shift lock bolt which are on top. I would not recommend using those to pour in the fluid.

The correct filler plug is at the side (see picture).
If you fill the transmission too full that will not be good for the working of it. So please use the filler plug to fill the transmission and not the breather or shift lock bolt.
Greetz

Pim
 
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Discussion starter · #8 ·
Finally got around to changing the transmission fluid. Didn't flush it because the 75W90 was expensive! I let it drain fully though, and then put in 5 liters. Loosening the drain 24mm drain plug was a royal pain in the ass! It was quite seized.

Pim - when filling, the fluid should be just below the bottom lip of the fill hole, correct? I am asking because I fear I may have put in too much fluid; shifts are still quite stiff and require a bit too much force.

Clunk is still noticeable, especially when engaging the clutch quickly. If I baby the car and shift at just the right RPM's, the clunk (more like a 'thud') is more subtle. This leads me to believe that it is either a problem with the clutch (pressure plate, throw-out bearing(?)) or with transmission mounts being worn down. I am going to ask my more mechanically-inclined friend to help diagnose further... Will keep posted.
 
#9 ·
ravi shank car said:
Hey Forum-goers! (first post)

I was wondering if anybody has experienced a 'clunking' sensation when shifting gears. The clunk feels almost like I've ridden over a boulder... it's quite frustrating. It does not seem to occur when the rev's are matched.

I have no clue if its a problem with the clutch, the gears, the transmission mounts, or if something in the drivetrain is out of balance. If anyone has had a similar problem and came across the culprit, I would be much obliged to hear it!

Cheers

-Jon
Click to expand...
Are you sure it's not just coincidence that it happens when shifting ?

Have you tried when driving to basically floor the gas pedal and let off quickly to see if you get the clunking sound?

The only real clunking sound I had with my RAV4 was the rear differential mount, which is pretty loud, and can happen coincidentally when shifting quickly due to the movement, or upon letting off the gas pedal quickly due to the momentum causing the clunking type sound...

The rear differential mount clunking sound is very common and typical due to the rubber tearing or wearing out in the mount... There have been many discussions about that issue...

Just my .02 cents.
 
#10 ·
DJ is right, could be (engine) mounts too. It is quite a force which is sprung into action when shifting. If you would take a look at the engine while driving (and shifting) you would see it move during shifting. Gentle shifting is the advice then.

Just below the lip is indeed the correct height to fill (if your car was standing level).
And yes, you poured in the highest quality oil, pretty expensive but it's well worth it.
Greetz

Pim
 
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#12 ·
Two bottles of gear oil might not be enough. An AWD contains 5.3 quarts or 5 liters of oil. 1 bottle usually is either 1 liter or 1 quart. So it may not be enough. It is enough the fluid level is just under the filler plug opening.
But it's very well possible that it isn't the issue too.
Greetz

Pim
 
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#13 · (Edited)
Hey ravi shank car....I just bought the same model 1997 and I am having the same problem, the solution for you is easy, go to your local Toyota Dealer and buy both differential supports (mounts) for the rear Differential. They are made of rubber and steel, the rubber bits on top of the mounts get crushed and break up over time, then the rest of the rubber bits get stressed. They look like they are easy to replace, but the bolts should be tensioned to the correct setting when you find out what the setting is.
For me on the other hand, the same solution is not that easy, I know what the problem is, I know how to fix it, but because I live in Timor Leste (East Timor), my local Toyota Dealer is less than useless. I need to find my own part numbers for these items, and when I do maybe....just maybe the spare parts manager may order them in from Singapore and take over a month to get here. So when you get the right bits, could you do me a big favour and post the part numbers on this site so I can somehow see if I can order the parts myself from Australia?

Rob.
 
#15 ·
Rob C,
You may want to look at www.amayama.com they are a Japanese company selling ONLY genuine manufacturer parts, they have every part for our Rav's listed, right down to the nuts and bolts, even the balance weights for the propshafts!!! (read drive shaft in the USA)
I thought I was going to need both rear diff mounts and the propshaft mount/bearing support, they quoted me a much much cheaper price than any Toyota dealer could and they ship all over the world!
good luck!
 
#16 ·
Guys, ineresting post for a RAV4 newbie. I've got the same clunk. Garage took a look and pointed out what seems to be the problem, although rather worryingly didn't know what it was called! It looks like the driveshaft centre support bearing, but it's ( looking from the rear of the car ) just behind the exhaust box. Is it just misnamed or am I looking at the wrong thing!

thanks
 
#17 ·
Ken Allistone said:
Rob C,
You may want to look at www.amayama.com they are a Japanese company selling ONLY genuine manufacturer parts, they have every part for our RAVs... even balance weights for the propshafts!!! (read drive shaft in the USA)
Click to expand...

A 'Thank You' to you Ken, for that website link.

I've just ordered the two rubber door stops I need (driver's door handle-height 90541-09006) and rear door top (90541-09043) since it is a very direct "view it, buy it site" whereas the other one I looked at for these rubbers (www.japarts.co.uk) you have to ask politely and wait for them to wake up and think about it - which they haven't done in a week.

What does the US fraternity call a drive-shaft then? ;)
I thought prop-shaft balancing was a skill best left to a specialist workshop.

Paul
 
#18 ·
@angryspaniel
Please provide pictures (multiple angles will help identify) where you encircle the exact component you are talking about.
It's pretty hard to know if you are talking about the differential, axles or something else.
Greetz

Pim
 
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#20 ·
That indeed is the differential support there.
It's costing you around 100 euro OEM to replace that. I also found it for 45 pounds in the US by Rockauto (but not including shipping, you get a discount code at this forum too).
Expensive part, really strong. However will eventually give way like this one clearly did.
Your exhaust may need replacement too, looking at the rust.
Greetz

Pim
 
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