Alright, I'm new to the forums so hopefully Imdoingitright.

I'll start off with the problem: ever since I had my clutch replaced with an Exedy Stage 2 HD, I've had a barely noticeable whine, particularly only in 4th and 5th gear when giving acceleration. However, just a week ago I was doing 55 mph and I noticed that when first pressing on the accelerator, I could hear a faint metallic grinding/rattling noise, but if I really pressed the gas, the grinding subsides into the whine that I spoke about earlier. The noise sounds like it's coming from the driver side of the hood, and only happens from 40-60 mph when lightly accelerating, or when letting off the accelerator. If I put it into neutral, or press in the clutch, the noise stops completely.

Let me also say that I was diagnosed with a faulty AYC/ACD pump about 1k miles ago, but the dealership said it would be fine if I didn't replace it, but I wouldn't have AWD controls...I'm not entirely sure what to think of all that, but I'm hoping that's not the problem. Note that the AYC reservoir in the trunk is empty, which worries me..

Lately the noise has gotten louder, sounds like metal against metal grinding, and ONLY happens from 40+ mph, 4th or 5th gear. I've read all over the forums about transfer case horror stories and such...I'm hoping that's not the issue either.

Any help would be appreciated, can provide video if needed.

 

That sound is probably your LSD disks burning up due to jack of lubrication. Did you note anything when the clutch was replaced? You might be able to get them to replace your broken stuff, since probably their fault anyway. Good luck.

 

^The S-AWC pump does not lubricate anything really. It only applies pressure to the disk packs to lock them up. I suppose if the system was completely and totally empty, that could pose a problem. But that is unlikely unless there was some major leak or something that went unattended. It shouldn't "hurt" anything-as in damaging internals in the rear diff and transfer case if it is non functional. Having said that, I would still highly suggest getting your pump replaced or rebuilt. It's crucial to the cars performance and should not be ignored. The second thought I have is who replaced your clutch? Did they bleed the S-AWC pump correctly after doing so? This is necessary after separating the transfer case from the trans. If they didn't bleed it, chances are your pump is fine and it's just not bled so it can't make pressure. How long have you driven it this way? Have you checked your drivetrain fluids?

As far as the noise, that Exedy II is a NOISY clutch. I had one in my IX and it was the worst sounding clutch I've ever heard..sounded exactly like you described. AMS installed mine and after asking them why it sounded like that...they responded that it was completely normal. I'll never buy one again.

 

I figured the empty reservoir was bad, so I did order some ATF SP III to fill it up, it hasn't gotten here yet.

I've driven it with the pump not working since I bought it, which is about 4k miles ago. The car only has 30k miles on it total, but does have a salvage title. The clutch was replaced around 2k miles ago.

I am going to change the fluids in both the transfer case and the rear diff today, actually. I'm wondering if it's worth it to check the transmission fluids too?

I know the people who installed the clutch used a lot of the DiaQueen LSD oil, however I cannot say how they used it..I don't know if they bled it.

 

Good luck getting it sorted it, man.

 

Well, I have an update. Today it looks as if oil or another brownish-black fluid is leaking behind the t-case. I drained the fluids out of the rear diff and the transfer case, they both were brownish-black, but not silver. So I don't think it's a transfer case issue..

I took it out for a spin and the noise was still there, I'm pretty sure it's getting worse. Sounds like plates scraping together or something, and there is a really bad hum in low-rpm 4th gear.

Oddly enough, I got back and put it in park, and there was this really weird noise when in idle. Sounds like a rotating clunking noise, like something is loose. When I rev it up, the clunking goes away, but comes back again when it is idling. Sounds as if it's coming from under the car, behind the t-case, almost where it is leaking from. I'm stumped..

 

Alright, well I have a trip to Philly that I need to make, and I really don't know if I should drive the Evo while it's making this noise. Any ideas at all at what this is, and what I need to do to fix it? I'm not so sure that it's the clutch..but I may be wrong.
Here's a video of the problem, sorry about the rain noise.

http://www.youtube.com/watch?v=igdAx...ature=youtu.be

 

Gets some good fluids up in there.

 

is the severe gear for the rear diff ? ive been searching on here for awhile and cant fiind the answer .

 

yes sir SVG (severegear) is for the rear diff and transfer case

 

thank you apagan01 . you guys are great . and ship really fast .

 

i guess that whine dont really go no matter what you do to fix it !

i guess you have to live with it.