Rep Power: 0

I have a 2004 Civic EX with an automatic transmission. When put into drive I feel it engage the transmission, but when I first step on the gas, there is a clunk. The transmission works well after the initial clunk. It does have a problem going into reverse and back into drive. It does not clunk again after coming to a stop and going again.
It has 99,000 miles, trans fluid is fresh DW1. All shifts are smooth with no slippage. It gets 40 mpg on highway driving.
I have gone over the entire front end suspension, and all control arm bushings, ball joints, tie rods, drop links are good. No problems with struts, new axles.
The only problem I can think of is old engine and transmission mounts. Would it make sense that the mounts could be the problem? The car has no codes when checked on the scanner.

 
Rep Power: 229

if it was a mount then when you revers, then shift back to D it should clunk again. Maybe test that.

Hopefully it is not the transmission.

 
Rep Power: 0

Found the issue. There is play in the splines between the axles and front hubs. It would shift just a bit as direction changed from forward to reverse.

 
Rep Power: 0

I'd bet someone put anti-seize on those splines. I've heard that's a no-no because with just the tiniest play it lets those splines move increasing the play with every movement.

To keep it from getting worse I'd use some blue thread locker on the splines if I ever wanted to disassemble them again, or JB Weld if I figured they were junk. (both the axles & hubs).
That is AFTER I was absolutely sure it wasn't the CV joint. After all the CV axle is a wear part, the splines are not.

 
Rep Power: 0

The axles were new, not re-manufactured. Nothing was put on the splines when installed. Axle nuts were torqued to specifications. It looks like I will have to replace the hubs and axles to eliminate the problem.

 
Rep Power: 0

Wow! That's a lot of play for a splined shaft. Do you think the axles were manufactured out of tolerance?
I just got a set of front struts. When I installed them the toe in was out a good 15 degrees! I had to crank them out to nearly the limit just to be able to get it out of the garage.
I think they're selling me factory rejects in the "economy" category.