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Posted By Discussion Topic: Strange Clunk Sound -- page: 1 2     doning 06-19-2012 @ 4:17 PM reply profile send p.m. New Member Posts: 158 Joined: Nov 2009 Hello all! Once in awhile, not every time, I here and sometimes even feel up through my clutch pedal pad a soft clunk sound. If I put it in reverse, add a little gas and slowly let the clutch out I here a soft clunk. Then sometimes as I am coming to a stop I depress the clutch to put the car in neutral and I hear it. It's a '37 Ford car. Everything is new! And I mean new. Pressure plate, disc, all bushings, clevis's, pins, springs, throw-out bearing, pilot bearing, etc. I have 1 inch pedal travel. The "only" thing I did not replace was the u-joints. They looked and felt okay. I have been hearing it when I started driving the car last year. Any ideas? Thanks, Don ford38v8 06-19-2012 @ 7:40 PM reply profile send p.m. Senior Posts: 2798 Joined: Oct 2009 Doning, we areall amatuers here, most of us anyway, and we make mistakes. I don't remember how many times I assembled my transmission only to have to disassemble it again to finally get it right. Any restorer that tells you they got everything right the first time is just plain not telling the truth. All this explanation just to suggest that you will see the problem if you take off the floorboard one more time. As you did say you "sometimes" feel the thump in the pedal, I'd say it's not directly related to the clutch, but more indirectly, like one of the transmission mounts being loose. It's real easy to forget to tighten one mount, or have the rubber cocked, thinking it's tight when it's not. That's just my guess, as of course I've never had to do a job over again. Alan supereal 06-19-2012 @ 8:18 PM reply profile send p.m. Senior Posts: 6819 Joined: Oct 2009 Did you remember to reinstall the spacer the goes under the bolt that holds the u-joint to the transmission shaft? It is a special thick washer. Without it, the u-joint can move back and forth on the splines. It is easy to forget, as I learned years ago, and will produce that kind of noise. doning 06-20-2012 @ 2:42 AM reply profile send p.m. New Member Posts: 158 Joined: Nov 2009 Oh wow Super! Man, I don't remember that but it doesn't mean I didn't do it. Oh, well. I'm not ripping it apart for that. For as much as I drive the car it's going to stay there. This weekend I am going to go under it and tighten everything that I can. Thanks. doning 06-20-2012 @ 2:48 AM reply profile send p.m. New Member Posts: 158 Joined: Nov 2009 Thanks for your help ford38V8! I'll check to make sure everything is tight. This message was edited by doning on 6-20-12 @ 2:48 AM TomO 06-20-2012 @ 7:43 AM reply profile send p.m. Senior Posts: 7278 Joined: Oct 2009 Doning, if you don't eliminate the problem by checking everything else, I would remove the rear end to check the washer that Supereal mentioned. If the washer is missing, the universal yoke can slide back and forth on the transmission output shaft until it leaves you stranded some day. Tom doning 06-20-2012 @ 8:59 AM reply profile send p.m. New Member Posts: 158 Joined: Nov 2009 Does anyone have a photo or a drawing what this washer looks like? I did the restoration on this 5 or 6 years ago so I don't remember it. It's not like I put it all together and left parts out. Thanks. supereal 06-20-2012 @ 9:49 AM reply profile send p.m. Senior Posts: 6819 Joined: Oct 2009 Here is a drawing of the spacer. It is part # B-7095. It was used from '28-'48. It has a 13/32" hole, an outside diameter of 1 5/32", and a thickness of 11/64". It is important, not only to secure the u-joint, but to position the output shaft of the transmission. If omitted, it can cause the noise you hear, and/or prevent smooth gear shifting. If you can't find yours, C&G has them for a couple of bucks. doning 06-20-2012 @ 10:51 AM reply profile send p.m. New Member Posts: 158 Joined: Nov 2009 I think I'm in the clear. I never took the U-joint apart so the washer should still be inside. I kind of remember seeing it now. Is it held together with a bolt and washer I see? It's hard to tell. It's been so long ago. Also, the transmission shifts very nicely. doning 06-20-2012 @ 1:43 PM reply profile send p.m. New Member Posts: 158 Joined: Nov 2009 Supereal: The washer is in there. After studying your drawing I remember it now. This weekend I'll get underneath the car and just make sure everything is tight. Thanks again.

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