Clunk when changing gear

3962 Views 35 Replies 7 Participants Last post by thiagaraj87, 6 mo ago

flightrisk

Discussion Starter · Jun 30, 2020

My W123 has a manual 5 speed. When pulling away in 1st, if I don't release the clutch gently I get a slight clunk.
This also happens when changing to 2nd and to a lesser extent 3rd.
There's obviously some play somewhere but I'd like advice where to look first.
If I grab the prop shaft, should there be any rotational play at the diff end? What about the gearbox end?
I read somewhere it could be engine mounts, but these have been changed recently along with gearbox mount and diff mount.
Could this be a sign the clutch needs changing?

21 - 36 of 36 Posts

flightrisk

Discussion Starter · #21 · Aug 13, 2020

It's a manual, so not that.

flightrisk

Discussion Starter · #22 · Aug 18, 2020

I changed the front flex disc and the noise has pretty much gone.

Can't believe how well the car drives now!

I used to get a large clunk going over bumps as if a ball joint had worn....that's gone too.

It didn't take much to undo the bolts on the gearbox support plate. I reckon there was some movement there sometimes.

Probably some issues with axles/diff, but happy for now.

flightrisk

Discussion Starter · #23 · Sep 22, 2020

OK, so the clunk returned after a few weeks.
I checked the bolts for the gearbox support and they are tight.
Going to change the drive shafts next.
Is SKF a good brand? Can't get mine refurbed in the UK.

flightrisk

Discussion Starter · #24 · Oct 22, 2020

Drive shafts ordered. Not sure if that's going to fix it to be honest. Can someone confirm whether the play at the diff is excessive?

mrmauren

· #25 · Apr 10, 2021

Did you solve this eventually? I kind of got the same problem..

flightrisk

Discussion Starter · #26 · Apr 10, 2021

I changed the axle shafts and it has improved some more, but not gone completely I think there has been excessive play in each bit of the drive train. I have removed the flex disc and axle shafts from the suspect list by changing them. Both were past their best. The U joint appears fine. The only other areas are the diff and the gearbox.

mrmauren

· #27 · Apr 10, 2021

Alright, i guess due to wear, both the differential and the gearbox could have some excessive play that´s hard to get rid of, as you said. I will change engine mounts, gearbox mount, differentialmount and both flexdiscs to begin with and then I guess the most of the play is gone.

wcktan

· #28 · 6 mo ago

flightrisk said:
My W123 has a manual 5 speed. When pulling away in 1st, if I don't release the clutch gently I get a slight clunk. This also happens when changing to 2nd and to a lesser extent 3rd. There's obviously some play somewhere but I'd like advice where to look first. If I grab the prop shaft, should there be any rotational play at the diff end? What about the gearbox end? I read somewhere it could be engine mounts, but these have been changed recently along with gearbox mount and diff mount. Could this be a sign the clutch needs changing?

I have a W123 1982 230E 5 speed manual which has exactly the same problem. I have had practically everything associated with it inspected and replaced. My mechanic now says it is my rear differential gear pinion gears which are worn. I have difficulty finding a new differential gear or find a used one which is ‘tight’ and no free play. How did you solve your problem and do I have other options?

flightrisk

Discussion Starter · #29 · 6 mo ago

What is the mileage of your car?
I convince myself that each thing I did made the clunk go, but I think I was kidding myself

I currently have all the rear suspension and subframe off and I'll reassess when back together with new bushes.
From what I've read, I think it's rare to get differential wear unless it's lost oil or has been used for loads of towing.

wcktan

· #30 · 6 mo ago

flightrisk said:
What is the mileage of your car?
I convince myself that each thing I did made the clunk go, but I think I was kidding myself I currently have all the rear suspension and subframe off and I'll reassess when back together with new bushes.
From what I've read, I think it's rare to get differential wear unless it's lost oil or has been used for loads of towing.

The odometer reading is I believe a genuine 210,000 miles. This is because I know the 2 previous owners.

I have had the car given a thorough going over when I bought it 3 years ago and changed/repaired almost all mechanical parts, in particular drive shafts, prop shafts, suspension and all bushes/bearings etc.

If not the rear differential, I am suspecting the clutch plate as well as there is also excessive vibration when the car is accidently driven in too high a gear.

Anyway, thanks for the response. Will keep you posted.

flightrisk

Discussion Starter · #31 · 6 mo ago

Hmm. Mine has a little clutch judder when cold. My car has about 120000 miles which is why I don't think it's the diff.

wcktan

· #32 · 6 mo ago

I am in Malaysia and cannot find a replacement rear differential. I wonder if you can recommend me a reliable supplier of the part in the UK.
You may take this conversation out of the forum through my email [email protected], if you like.

flightrisk said:
Hmm. Mine has a little clutch judder when cold. My car has about 120000 miles which is why I don't think it's the diff.

tsharkey

· #33 · 6 mo ago

Hi - PM me if you want a diff centre as I have a few and have come to the conclusion I wont be using them anytime soon. Do you know what ratio the 230E 5 Speed Uses ? Not sure how much to freight from AU to MY tho as they are heavy (probably 15Kgs).

wcktan

· #34 · 6 mo ago

The ratio on the 5 speed is 3.58.
Could you use my email to give me your suppliers please?

wcktan

· #35 · 6 mo ago

tsharkey said:
Hi - PM me if you want a diff centre as I have a few and have come to the conclusion I wont be using them anytime soon. Do you know what ratio the 230E 5 Speed Uses ? Not sure how much to freight from AU to MY tho as they are heavy (probably 15Kgs).

I would like some diff centres if you have them. The part is certainly around 15kg but I am in no hurry, so can find a cheaper way to freight.
My ratio is 3.58 and I add the photo here with the part number.

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thiagaraj87

· #36 · 6 mo ago

Looks like a pressure plate issue.

21 - 36 of 36 Posts