I'm wondering if the sound I'm hearing could be my TOB whining. I started to notice when I downshift and re-engage the clutch I get a whine sound. It's also there on decel at around 45mph. I also had that same kind of "pulsing" sound that you had mentioned earlier. Whatever it is, I hope it's not a combonations of things. I'd rather it be just the tcase or just the trans, not both!

I'm going to keep my car parked until I can change the fluids and see if that heps at all. If not I'll try doing some more diagnosis on my own along with some knowledgable friends. Though they're knowledgable, they have a "drive it to break it" mentality. They all drive their cars HARD, break them, fix them and do it again. They tell me "Yeah, I kind of hear that sound, but who cares, drive it 'til it breaks"... Haha, I'd rather not

Well, I'm glad to hear you got it fixed, though it'd be nice to know what actually fixed it If it's just the throw-out bearing making the noise I assume it's just noisy, not actually a failed part.

I can deal with noise. The noise doesn't bother me, but I associate bad noises with failing parts.

 

Well new noise usually means its on its way to falure. I cant afford any down time, so replacing this was assurance from possible future falure.

On the magnet of the transmission there was some metal shavings. Also in the fluid drained, it had that discoloration uneveness that might be hints metal particles. Thats why I'm not blaming 100% on the TOB yet, untill shep takes a look at my core.

But I took pictures of the drain plug. I'll post pics up with in an hour.

 

Here are pictures of my transmission drain plug. Oem fluid changed at ~23k miles to Amsoil 75w 90 and now at 28,000 miles. I did have bad 5th gear syncro that grinded.







The transfer case drain plug was almost as clean as a whistle.

 

That looks like it's on the bad side of things, but I work for Honda and I've drain fluids from some transmissions that look equal or worse than that with no problems.

Did you use the GL-4 AMSoil? I have some laying around I was going to use in my '03, but with my new '05, I.m afriad the GL-4 will hurt the front LSD.

 

Yes I believe its the GL-4 75w 90.

The front LSD is inside the transfer case so dont worry about that.

 

I'm so used to thinking of FWD transaxles with the diff actually inside the trans. And since the Evo has a transaxle, is was a stupid assumption

 

i can hear some whining under 35 mph. but after that its noise free. i dont know anyone else experience this

 

^^ As long as its not a loud noise you should be fine. Thats just normal drivetrain noise.

Well I was sort of wrong. During city driving 35-40 mph everything was fine. But today I did some highway driving 55+ and the noise is still present but slightly toned down.

Well since I changed the transmission, clutch and tob, only thing left to blame is the transfer case.

Only difference now is, it was making that noise in lower speeds as well 35 mph but now it wont. So maybe the TOB also contributed to it. Only unfortunate part is, the transfer case was not making any noise when we had it on jack stands. I guess it requires a certain amount of load but not acceleration.

 

I changed my transmission fluid today with AMSoil. My drain plug looked just about how yours did. I also checked the transfer fluid by pulling the fill bolt. I stock my pinky finger in as far down as I could and it's dry...

But on a good note. Driving home from work, I did notice less noise, but noise is still present. Man does this AMSoil fluid shift smooth!

I'm going to change the transfer case and rear diff fluid and see where I'm at. I've relized that I need to have the windows up and radio off to hear anything, chance are, I'm ok. But I'm still paranoid. Why can't Evo's have problems with blowing 3rd brake lights or something simple and easy, haha.