Both of my inner CV housings(bolted securely to the differential output shafts), have about 1/8"-3/16" of free play up and down or side-to-side. Is this normal? Their entire assemblies can be moved easily by hand- no indication of any leaks around any seals. No indication of radial slop between the two output shafts. No evidence of internal slop in the CV joints themselves. I observed this while looking for evidence of radial slop in the CV's. I've got the click and will be re-torqueing the half-shafts.

Also observed yet another weird noise from the rear end. It's happened four times. the first three, I thought my left rear tire had picked up something about the size and weight of a golf ball and thrown it up into the wheel well with considerable force- preceeded by some metallic clunking noises-all over in about 1/2 second. This last time I'm sure the road was perfectly clean though with a few bumps. Always happens about 40 mph during normal driving. Weird. 30K mi total- 2001. Going in for TSB 00-054 Wednesday.

 

Unfortunatley I have no answers for you But I do have the same problem as you so I would be VERY interested to learn what it is, and solve it
I've tried explaining it to a few people but not one person understands what i'm getting at and youv'e just hit the nail on the head.

 

is there rotational play in the joint

 

If there is it is not obvious. Some movement occurs when rotating the propeller shaft by hand with the wheels locked, but its not much more than you would expect just taking up gear-lash in the diff. I'm very curious to know if the substantial amount of side play in the CV housings is normal. Both sides are the same. if you hold the outer housing of the inner CV in your hand, you can easily move the entire assembly up and down, sideways, or around(describing a cone) about 1/8-3/16" measured at the outboard end of the housing. This could be perfectly normal, I don't know.

As for the loud bang I hear while driving(this has happened four times in the last 5K miles)- It is as though under certain conditions some kind of binding occurs within the drive-train until suddenly all the energy is released at one point. You can feel a shock run through the whole car. I dismissed it the first couple of times as an external object being picked up and thrown by a rear tire, but I've since ruled that out. I've got an appointment with the dealer this AM to meet with a tech. I'll pass on anything I learn.

 

sounds like it could be bearing caps.

do you drag race?

 

I was under my car yesterday and remembered this post so I grab each drive shaft near the center CV joint and wiggled it. Yes, I have the same amount of play as you describe and I have had no odd noises or issues with my car's rear end. Also the free play on the propellor shaft is as you described.

 

Yes- the dealer confirmed that this play is normal. I suspected as much since it was the same on both sides. A bit of a shock when you first discover it , though! They are convinced I need TSB 054 ans new, re-torqued half-shaft nuts- so I'm lookin forward to those fixes. Still no good theory on the occasional bang. It happens so quickly and infrequently that you can never be ready for it. Its always like"what the hell was that?", followed by an effort to re-construct the event in your mind. Oh, well-nothing to lose sleep over.

 

Well, I just had both done myself. Couldn't...be...happier about the TSB-054. My clutch, its engagement, and a lack of [dare I say my car sounded like a diesel decellerating?] noise is fantastic. You'll probably appreciate it as well.

Like I said, I had both things done. I have the popping in the rear too -- although I can't say I have the "energy-sprung" whallup you seem to speak of...at least not yet. But I've been possessed with the initial popping when going forward or reverse from a standing stop. Bleh! Anyway, first my dealer re-torqued the existing nuts -- good for ~ 200 miles. Brought it back recently and had them replace the nuts with new ones -- good once again for ~ 200 miles... I've got to put her in the shop...but I have too many fun mods up and coming that keeps me from letting go of the car for them to give it a good investigation over and above Honda's view of the axle hub nuts being the culprit. Hrumph! Better luck to you I wish...but I'll try to keep this thread posted as I find out new information from my own experience...

- Dave