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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 939 (Manual Transmission -- ZF S6-650) >> Diagnostic Information and Procedures >> Transmission Clunk on Acceleration or Deceleration >> Test Description

Test Description

WARNING: This page is about a different car, the 2004 GMC Sierra and 2004 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.

The numbers below refer to the step numbers on the diagnostic table.

  1. 8:  This step inspects for the transfer case causing the clunk. Shift the transfer case into another mode. If the transmission is causing the clunk, there is not be a change.
  2. 11:  This step inspects for the dual mass flywheel causing the clunk. A clunk from the dual mass flywheel would also be present in neutral.
Transmission Clunk on Acceleration or Deceleration

Step Action Yes No
DEFINITION: A clunk is heard and/or felt on acceleration or deceleration.
1 Did you review the Symptoms - Manual Transmission and perform the necessary inspections? Go to Step 2  Go toSymptoms - Manual Transmission 
2 Inspect the engine mounts for being loose or damaged. Refer to Engine Mount Inspection in Engine Mechanical - 6.6L or Engine Mount Inspection in Engine Mechanical - 8.1L.
Did you find and repair the condition?
Go to Step 13  Go to Step 3 
3 Inspect the transmission mounts for being loose or damaged. Refer to Transmission Mount Replacement .
Did you find and repair the condition?
Go to Step 13  Go to Step 4 
4 Inspect the transmission to engine fasteners for being loose or missing. Refer to Fastener Tightening Specifications .
Did you find and repair the condition?
Go to Step 13  Go to Step 5 
5 Inspect the exhaust hanger mounting bracket on the transmission for being loose or for missing fasteners. Refer to Exhaust Hanger Mounting Bracket Replacement (6.0L, 6.6L, and 8.1L Engines) in Engine Exhaust.
Did you find and repair the condition?
Go to Step 13  Go to Step 6 
6 Inspect the driveline for causing the clunk. Refer to Diagnostic Starting Point - Propeller Shaft in Propeller Shaft.
Did you find and repair the condition?
Go to Step 13  Go to Step 7 
7 Is the vehicle equipped with a transfer case? Go to Step 8  Go to Step 10 
Shift the transfer case into 4HI.
Is the clunk still present?
Go to Step 10  Go to Step 9 
9 Inspect the transfer case for causing the clunk. Refer to Diagnostic Starting Point - Transfer Case in Transfer Case - NVG 246-NP8 or Diagnostic Starting Point - Transfer Case in Transfer Case - NVG 261-NP2.
Did you find and repair the condition?
Go to Step 13  Go to Step 10 
10 Is the vehicle equipped with the 6.6L diesel engine? Go to Step 11  Go to Step 12 
11  Inspect the dual mass flywheel. Refer to Engine Flywheel Replacement - Manual Transmission in Engine Mechanical - 6.6L.
Did you find and repair the condition?
Go to Step 13  Go to Step 12 
12
  1. Remove the transmission. Refer to Transmission Replacement .
  2. Disassemble the transmission. Refer to Transmission Disassemble in Manual Transmission - ZF S6-650 Unit Repair.
  3. Inspect the following transmission components that could be causing the clunk:
    • The mainshaft bearing preload
    • The countershaft bearing preload
    • Worn speed gear teeth
    • Worn countershaft gear teeth
    • Worn synchronizer sleeve to hub
    • Worn thrust washers and thrust surfaces on the speed gears or mainshaft
Did you find and repair the condition?
Go to Step 13  Go to Diagnostic Aids
13 Operate the system in order to verify the repair.
Did you correct the condition?
System OK Go to Step 1