XJ-NC

Got a 94 XJ 5 speed. When I release the clutch to shift gears, I hear a clunk. Soulds like it's coming from the read diff. When I turn the drive shaft by hand while stopped, I can hear the clunk as it stops, coming from the rear diff.

Read these rigs weren't meant to be quite, so is this normal?


If not, is it something I need to replace?

jeepride

I have a 98xj auto it clunks some times in the rear end

96rhino

are you sure its coming from the rear diff? Im sure that you are, just checking. Isolate the noise, if its coming from inside the diff, then you should be concerned. Probably worn gears, slack in the gears caused by failure of a component or excessive wear. If you haven't done so already check for condition and level of fluid in the diff.
It may be the rear u joint also, if you can't isolate the noise in the rear, pull the drivbeshaft off to remove the ujoint to help isolate the clunk.
There are some bushings back there also, check those and make sure there not cracked/missing.

XJ-NC

Thanks. I pulled the drive shaft and removed the U joint. Clunk for sure is coming from the rear diff. Replaced the fluid and it still clunks. Think you might be right about worn grears. Thing is, it only has 158K miles and the previous owner never took it off road and took real good care of it. Guess I'll have to replace the gears.

To be honest though, I really thought about driving it till it breaks and just upgrading at that point.

jd4x426

b4 you go replacing the gear checkt the backlash on the gears or have someone check it for you if you dont know how if its out that could cause the clunk because its moving to much b4 it actually contacts the pinion gear

XJ-NC

I do all my work at a hobby shop where there are certified mechanics who can help. But just for my knowledge, what is "backlash"?

I'd take it to a mech, but I like to do everything myself, otherwise I'd never learn. Thanks.

jd4x426

its the amount of play in your pinion before it turns the ring gear every trucks is different but im sure someone on here would no what the specs are for the backlash