I have 2 new issues/noises that started recently that I have been struggling to find the source that I am hoping you folks could help me with. My apologies for a long message as I am a detailed person and I feel details matter. The only recent change to my 05 Evo is a new clutch a month ago but didn't notice these issues until this week.

Issue 1:
Metal on metal clicking/tapping that is noticed primarily when starting from a stop position and sometimes when applying the brakes at slow speeds to a stop.
- Inconsistent and not always noticeable.
- Random and may tick once and other times it will tick multiple times.
- Not noticeable after I speed up but everything is harder to hear when exhaust noise picks up.
- I sometimes feel the vibration in my clutch or brake pedal but not in a way that impacts the pedal movement and it is subtle.
- I “think” the problem might be a bad rear motor mount but I'm not sure. Attached at bottom is a photo of mine and it looks off center so my theory is that the sides of the motor mount are hitting the metal mounting bracket at random times.

Questions:
1. Does my rear motor mount look correct or broken and does my theory sound likely?
2. Am I damaging anything by not addressing this issue for a while?
3. Could this mount be related to my next more concerning issue?

Issue 2:
I have a bad powertrain related whine that started this week and is increasing in loudness, seemingly daily. I noticed both of these issues this week but I'm not sure if they are related. I have read up on the dreaded Transfer Case of death info but I'm not sure if that is the case with my problem and it seems costly to just rebuild items without knowing/diagnosing the source.
- The whine has no grinding sounds. It sounds like my car is using a sequential rally transmission and the pitch increases in tone with speed.
- I mainly notice it only under acceleration/load and in 3rd-5th. I don't notice it on deceleration but I am now starting to slightly hear it when in neutral and coming to a slow stop. I put my car on 4 jack stands and drove it in place up to 60 and 5th gear and didn't notice any issues/sounds but I couldn't really put the car under load in the air and since it is getting worse every day I may be trying again in a couple days.
- I have been trying everything to narrow down if it is my front TC or the rear diff. My son rode in the back seat and he really thinks it is louder from the back so maybe it is the rear diff but I am finding it veeeery difficult to be sure of the source.
- When I grab the drive shaft and rotate it back and forth rotationally, there is approx 1/2 inch of play. Never looked that this before but just checking if it is normal or not?
- I have gear oil on order and will be draining both next weekend and looking for anything attached to the magnetic drain plugs or in the fluid.
- I don't have any shifting problems nor feel anything "off" with the stick shift so I have been assuming it is not related to the transmission but who knows.

Questions:
4. If you were to guess, which one is most likely the cause and anyone have good ideas of other tests I can run to be sure? I'm tempted to attach an old Iphone to record audio near the TC then compare that audio to another run with the phone by the rear diff.
5. Are there any bearings or wearable parts in relation to the drivetrain that could also be the issue?
6. Am I creating any additional damage to other parts by keeping on driving the car if it is the TC or rear diff?

Having these problems is pretty depressing since there isn't anyone around me that I consider experienced with Evo's to figure this out for me and it is my daily driver.
Thanks for the help folks!



Rear motor mount, below throttle body.

 

It got worse today and I was able to get it on jack stands to try to find the source. The noise resonates very strong/loudly from both the drive shaft that connects to the transfer case but also the drive shaft that connects to the rear diff. Sooooo annoying that I cannot pin this down to which one is the source. Here is a video of the noise at 60mpg on the freeway. https://drive.google.com/file/d/1H1L...ew?usp=sharing

I drained the transfer case oil and it looks like this. I'm guessing this much metal means I'm likely dealing with the dreaded bad transfer case. Will drain the rear diff tomorrow to see how it looks.

Funnel used to drain TC fluid.

Oil has some shine to it.

 

Anyone have experience with their drive shaft bearings causing this much noise? I'm wondering if I can remove the drive shaft completely and drive the car to see if I don't have the noise anymore. If not, maybe I can rule out the TC for now???

I'm such a noob at this type of work so appreciate anyone's feedback.
Thanks

 

Have a read of this

Transfer Case Whine? - Page 2 - EvolutionM - Mitsubishi Lancer and Lancer Evolution Community