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Took it for a short ride and I do not really hear an improvement. This noise is very difficult to describe and I might be convinced I have some improvement, but will take another drive tomorrow if I can. It is definitely quiet in 4th gear. When in neutral I sometimes hear it. Can't really explain the conditions that make it come and go other than driving in 1st, 2nd and 3rd gear.
I'm wondering if the throw-out bearing could be participating in this puzzle.
I am going to try and figure out if I can hear the noise both with clutch engaged and dis-engaged. So far I think I have heard some semblance of it in both positions, but it seems to come and go. Mostly it's present (except 4th gear).
OK, so the plot thickens. Cut me some slack as I have not driven the car much at all due to this concern, and I had driven it even less before I took it all apart almost 3 years ago. I did get it out on the highway tonight for the first time. It drives great. Smooth, comfortable, quiet, and quick!
So I can get the noise with the car in 4th gear. It seems to be affected by the position of the shifter handle. Driving in 4th, no noise, but if I press the clutch and roll to an intersection some forward pressure on the gear shift will bring out the noise. Severity changes significantly through the gears. As I said, no noise driving in 4th, but significant noise in third, and also more in first than 2nd.
I'm still skeptical it is rear end noise due to the way it changes with shifter position. I have a Hurst shifter with the welded handle.
Long time since I posted this. Here's what was found. The trans is in great shape. We had it checked out by the specialist my paint shop uses. He reported the trans is in very good shape showing no signs of abuse or wear (will replace the main bearing as it shows a little slop). The throw-out bearing had been installed incorrectly with the spring tabs of the clutch fork outside of the groove they belong in. The reason for the noise not showing up before the car was taken apart was due to the clutch rod. I noticed the old clutch rod had been lengthened for some reason by the PO. I replaced it with a stock rod. Evidently, this created the noise I was experiencing. Should be good to go once I get the car back from the shop.
I've been doing very little with my project lately. Took forever to restore the convertible top frame. I'm losing steam. So I brought it in for some paint repair and to have the top installed. Now that spring is here I hope to get motivated enough to finish.
Great news, and thanks for the update. Be sure to fill the trans up with ONLY gear oil. NO positraction additive. That stuff is a friction modifier designed to help the clutch plates slip over each other without chatter. It is not what you want on your syncronizer rings....too slippery and may cause gear clashing issues.
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