I think I've narrowed down the rattle/clunk in the front end, there seems to be excessive play (up and down, side to side) where the right side CV axle goes into the transmission, the left side has zero movement. I've replaced the axle with a new one, not rebuilt, and have the same amount of play so I'm wondering if the bushing or bearing on the output side of the transmission is the problem, this is a 5 speed manual. Bear with me, this is what I've already replaced trying to find the noise: rack and pinion, tie rods and ends, struts, ball joints, motor and transmission mounts, links, control arm bushings, and sway bar bushings. Has anyone experienced this problem and if so, can it be repaired without pulling the engine and transmission? Thank you for any input.

 

I see you have a 2007 model year that helps indicate which transmission you have
and there is a Speedi-sleeve just for this issue

You simply tap the sleeve in with the tool on the left of the photo

 

There is supposed to be in/out play, without it you could not drive over bumps. Up/down is from bad CV. The inner end is a tri-pot, slip joint; the outer end is a CV joint.

 

Oldblue,
Thank you for your reply. I am unable to open the link you provided in your email. Any help appreciated.

Sailor2

 

It’s a photo not a link, here is the link

https://www.rockauto.com/en/catalog/...r+sleeve,14015

 

Oldblue, thank you, I appreciate your help. Can you confirm that part #99138 and #99139 are the same. I don't want to order the wrong one and the "info" on both numbers are the same. Also, can this sleeve actually be installed on the transmission output without removing the seal? I have been unable to find any videos on the process. If you have a video link, I'd gratful if you would send it to me. Again, this is on a 2007 LT manual transmission.

 

The numbers for dimensions in the description are the same, But upon further investigation the sleeve is for the seal not the bearing.
you will need to replace the bearing

 

Following the advice I got on the forum, I ordered a Speedi Shim that Rock Auto listed for my 2007 LT with a 5 Speed manual. I'm a little confused, my understanding was the shim would help with the horizontal and vertical play on the passenger side CV axle (not in and out which is normal) but the shim is sized to go on the large diameter machined part of the axle that rides in the oil seal, it doesn't seem like that will solve my problem. Am I missing something here?

 

Sorry about the confusion and thank you for confirming the shim is for the seal and not the bearing.

 

To your knowledge do they make a shim for the bearing that can be installed without dropping the transmission, if so what does that do in terms of lubrication where the small slots are machined on the axle stub?