Originally Posted by ka5ysy
Hmm... Is the clunk you are hearing occurring when you press the shift lever with the clutch pulled in? I am not clear if the clutch is pulled fully, or if you are shifting while in the friction zone (some loading in the transmission), which would cause a jerk if the engine speed is not fully matched with the transmission. If you are describing the clunk you hear when shifting with the clutch is pulled in, that is not going to stress the U-joints as the drive line is not connected at that point.
Something you might try is to preload the shifter lightly for the downshift, and without pulling the clutch in, roll off the throttle very slowly and see if the transmisson downshifts smoothly. This sounds silly, but you can do a smooth downshift without clutch if necessary, as easily as upshifts. Most convenient with broken clutch cables !
Only use the clutch to stop/start and if i'm not paying attention and stuff up an up/downshift.
Get the odd clunk but generally reasonably smooth for a boxer g/box
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