I have a 2004 TJ 4.0 5spd. Today leaving work I noticed when I release the clutch into first there is a clunk until I am fully engaged. It only happens in first gear from a dead stop and i can feel it right below my feet. This was accompanied by a funky smell on the way home like something is burning but i could honestly not tell you what. Definitely not oil, rubber or coolant..... any ideas or suggestions?
Clunking in 1st Gear
- Thread starter Anthony S
- Start date
Were the RPMs randomly shooting up at any point while driving? Burning is often a slipping clutch. Usually smells like burnt brakes. (Think of the smell from a large truck rolling down the mountain too quickly.)
It could also be something else in the system binding up and releasing, such as the pivot fork or the hydraulic clutch linkage.
Can you replicate the clunk starting from a standstill in 2nd gear?
When was the last time the clutch was replaced? It may be getting close to the end of it's life.
Another possibility is that the engine or transmission mounts are getting old. Inspect those and check for any movement. You would especially hear clunking when going from very low torque to very high torque, like when starting out in 1st gear or starting from any gear in 4low.
It could also be something else in the system binding up and releasing, such as the pivot fork or the hydraulic clutch linkage.
Can you replicate the clunk starting from a standstill in 2nd gear?
When was the last time the clutch was replaced? It may be getting close to the end of it's life.
Another possibility is that the engine or transmission mounts are getting old. Inspect those and check for any movement. You would especially hear clunking when going from very low torque to very high torque, like when starting out in 1st gear or starting from any gear in 4low.
The RPMs remained normal and its engages fine. Clutch was replaced maybe 15k miles ago. 144k on the odometer. I will have to check about starting from second but I it really shouldn't be the clutch.. (Un)fortunately doesn't smell like brakes either.
I will check out the mounts though. Its only from real low rpms and driving around it feels fine. I believe the peak torque is around 3200rpm which is pretty much as high as i ever get up to and no sound....but then that smell.
Possible interference on the shifter? Making contact with the tub could cause the clunking. Have a buddy give you a hand by stepping on, off,on,off the clutch while you are underneath making sure everything is moving as it should. Try and get your nose close to the bellhousing where the clutch fork enters. Sniff to see if that is where the smell is coming from. If that's it then something is wrong with the clutch. Any oil drips coming out the bottom of the bellhousings? Oil leaking onto clutch causing slippage will make for a good strong odor.
Not sure what the resolution of this was, but I have been chasing a clunk in 1st for several months and resolved it over the weekend.
Symptoms
Turns out, it was the rear upper and lower control arms. I had been under there looked around and thought they were fine, but pulled out the torque wrench and nearly all of them were significantly under-torqued. Torqued them all to spec (55lb upper, 130lb lower) and all clunking symptoms are gone.
Hopefully this helps someone, as I was very worried the clunk was coming from my clutch, transmission, transfer case or diffs.
Symptoms
- Rolling in 1st and give gas (clunk)
- Rolling in 1st and depress clutch, e.g. when coming to a stop (clunk)
- Sometimes when braking hard (clunk)
Turns out, it was the rear upper and lower control arms. I had been under there looked around and thought they were fine, but pulled out the torque wrench and nearly all of them were significantly under-torqued. Torqued them all to spec (55lb upper, 130lb lower) and all clunking symptoms are gone.
Hopefully this helps someone, as I was very worried the clunk was coming from my clutch, transmission, transfer case or diffs.
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