Ok. The last few days I've been busy taking things apart then putting them back together. On the rear end knocking, I found that there were some burrs on the differential that were hitting the pinion gear when it came around. I think that when I had it in fourth for the first time it hit, then made the burr bigger, then started hitting all of the time. Thats why you can't hear it in the video until the end of fourth gear. I took the shim behind the pinion gear out. That is how I found it before changing the ring and pinion. That would give me a little more clearance with the pinion, and the contact with the ring and pinion is still ok. I then ground down the burrs smooth on the differential.
With the clutch noise, I took out the pressure plate and compared it with the old one. The old one was solid and the new one would wiggle a bit. I readjusted the contracting springs to make the pressure plate solid.
I put everything back together and started it up. The clutch noise went away and there is not knocking noise in the rear. I can hear the ring and pinion gear making contact when I get close to it and listen though. But I could hear that kind of noise by moving it by hand before putting the rear end back on. I think it is just the small backlash the book calls for (.004 to .008). I'm guessing when things get broke in a little it will be smoother.
Last edited by davidn; 07/23/2009 1:15 AM.
