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2G Terrible trans noise VIDEO

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And you are absolutely certain you are not dealing with a CV joint or halfshaft or front/rear mount bushing issue?
 
Well I feel a lot better already. If the clunking is just the diff, I might take you up on the plate rearrangement. Do you think it started making the noise as it was "broken in"? I know these dont have a "break-in" procedure, but surely there is some bedding-in process happening during the first few hundred miles.

If I wanted to throw another fluid with less available friction in there, which would you recommend?

Thank you, sincerely
 
Yes sir, I am fairly sure it is not a cv or halfshaft issue. I replaced one under warranty and purchased the other one so I could replace both and rule them out. Front roll stop mount is solid aluminum, back is solid poly from a freelancer, sides are prothane poly. All their bolts are tight, as well as the bellhousing to block bolts (new oem bolts).

The halfshaft support bracket bearing was new when the trans went on but it had a tiny bit of freeplay when I checked it. I installed a new one when I did the axles last week. I may have damaged the first one when I was putting it together, honestly. But this one went in smoothly and is nice and tight.

I openly admit that I could be missing something simple... I was hoping people might throw out some ideas for things to check that I might be neglecting.
 
You can run the regular redline 75w140 which doesnt have the friction modifier for clutch type differentials, and will have less lockup.

Otherwise you can add a 4oz bottle of redline LSD additive, or try out a cheap simple fluid to rule out, like farm n fleet brand Mystic 85w140 gear oil.
 
Update
I dropped the oil and both plugs had a little bit of metal on them. The oil itself doesnt smell burnt but it does have a dark brown color to it. A clean magnet in the old oil reveals no additional metal.
 

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I am sure that is true, he seems to be a generally busy guy... I did swap fluids before I left for my conference. I used Fleet Farm Mystik 85-140. I drove the car for about 2 hours after refilling. Did a lot of figure 8s and u-turns. It seems like the noise was getting less and less pronounced. I am fairly confident there is no major issue. The metal on the plugs is within the normal break-in expectations. This is an evo 2 transmission that got some new pieces when being rebuilt, and the metal is likely to be evidence of the bed-in process.

I am back in Wisco now so I will try to get some more miles on this thing and report back. If the redline oil is causing that much lock-up and binding, I will likely run the redline oil without friction additive on this street car. I am also considering yanking it out and putting a quaife in there.

Thanks for all the responses. I appreciate the insights/advice.
 
After another warm-up cycle and cruise around town the noise is gone. There is no binding/crunching/clunking anymore. It seems the fluid was causing a very aggressive lockup. I am going to drain this fluid and put Redline back in, without the friction additive.

This winter I will pull the diff and re-stack the plates for 65% or even 35% lockup, and see if I can live with it in that configuration.

Again, thanks to everyone for all the input. I am marking this as resolved...
 
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