Well, there is and it arises as I said from the natural and required clearances in the drive train hardware.

I seldom hear the noise as I am smooth with the clutch and throttle. I can cause it at will but don't like to as that clunk is the hardware -- gear teeth, bearings/shafts -- hitting against other hardware.

(The clunk has been present in all my larger cars with the bigger heavier duty transmissions/diffs. I can't hear it from my Boxster, and I don't recall it coming from my Golf TDi, but I hear it from my Turbo, and it was present in my GTO, my Camaro Z28. I can't recall it is was present in my Mustang GT. Probably but I can't remember now.)

In the OP's case if he hears frequently, going over speed bumps, etc., that's not due to drive train clearances but something else. Motor, transmission mounts have to be suspect as does a loose/failed suspension bushing or link, which others have already offered up.

 

it's funny you mention your golf and "clunking" as my gti clunks ALWAYS but i have the dsg g'box and it's prone to all kinds of rough herky jerky kinda performance in spite of its well deserved rep as a fantastic semi auto dbl clutch g;box!

..and i'm with you on "anyone can make their 96t "clunk" but if i do it's ALWAYS a "driver error" like the ONE time on PCH after sitting in stop go traffic for an hour i decided to simply drop the clutch a moment after selecting first. man, was that a "sheepish" moment. i think there was a gallardo in the lane to my right. he got a better chuckle out of it than i did!..

but back on point hopefully ( caffeine..)

i never hear ANY clunking while my dual turbo car is operating as it should and does, was my earlier point. your experience seems to differ, and that's cool. you "know" your stuff.

but my SINGLE turbocharged gti? why, it's a virtual clunker!

but again, a dsg 6spd semi auto box is hands down a better g'box ( in my uneducated opinion ) than the tippy is for the 996t. it even has paddle shifters stock, while the poor sods with tips have to endure those godforsaken levers on the steering wheel ( at least they can retrofit paddles onto another or the same wheel!! ) but still..

tips remind me of VW 411's ( or whatever they were called ) with that first iteration semi auto g'box of the early 70's

btw..nice to read/see you over here again,.. rather than the stuffier and more sanctimonious "other" room we also frequent. cheers mac..

 

Probably a torn Guiboi flex joint on your front drive shaft easy to obtain and replace cost approx 80 bucks on ebay either do ur self or have a shop do it 1hr labour max.

Just Make sure u buy the german bilstein made replacement not the chinese rip off

Cheers
Tim

 

I seem to recall Amazon had the guiboi too? Someone found a cheap source of good ones if you search. If it's that easy to clunk maybe put it on jack stands and run it a little with someone outside listening? Might make locating it easier...

 

I replaced my Guiboi flex joint years ago it was badly torn, if I rememver correctly I was experiencing a similar clunk as the OP describes.

Remember these cars are getting on a bit rubber parts are perishable any subjected to load should be replaced when you get the chance Guibui Joints Strut mounts Engine Mounts etc etc

Cheers Men
Tim

 

i feel like an idiot

wtf is a "guibo"!?!

 

Flexible rubber joint between the gearbox and front propulsion shaft. Reduces shock load on the gearbox.

You dont need worry about it Mark yours would of been removed once you went to RWD only.

Id post a link but its too hard in my current state using only my phone. I have surgery again this morning 13th time in two months hopefully the end is getting closer.

Cheers men,
Tim

 

hah! thx tim! one less thing to replace!

GL w the surgery bro.

 

GL w the surgery bro.
[/QUOTE]

Thanks my brother

 

you should hear my e46 m3, sounded like a garbage truck-reminded me of my 240sx when i had upgraded bushings with open diff

 

So after inspecting the front diff by rotating the front axle i have confirmed that the noise is coming from inside the front diff. There is a great deal of play inside the diff and i suspect its going to need a new ring and pinion as well as bearings.

Anyone got a recommendation for who can rebuild a front diff in California?

 

given where you are in CA i'd give roger a call at CA motorsports which in AZ of all places. if you end up having to remove the thing and ship for a rebuild? this is a place that knows their stuff.

there are of course a hundred places in CA that can also competently do the job and its easier to have one place r&r the diff AND repair it but this all depends upon the level of competency and depth of the shops knowledge of the more inner working of the car. i.e.

my "shop" can remove the trans AND repair then simply re-install. many can not. but they are in SoCal. you need a NorCal referral like a
"S Car Go" or a
"Sharkwerks"

i'd begin ( once you're "done here if the right referral isn't made as a result of your query..) and then begin by calling the best local NorCal shops such as the two i mentioned.

if you end up needing a SoCal place, let me know via pm, i can steer you. good luck. I disconnected mine lol

 

996 TURBO and C4 driveshaft coupling FEBI # 34744

 

Is this a part that can be faulty and cause this clunk?

 

It is a possibility. You need to check if yours is not damaged or worn.


I figure you would be better off $$$ wise to get a used diff.