So, I'm hearing a metallic "clack" during accell and decell of frist and second gear sounds like something is getting chewed up. The noise gets louder and more frequent as the car goes faster. 1st gear it's noticable second gear its louder, shifting to 3 makes the noise stop, 4 and 5 no problem.
Sometimes I can feel the clicking ever so slightly if I have my hand on the shifter

If I go from 1st to 3rd I only hear the clicking in 1st gear. Shifts are still smooth the clicking doesn't happen when in neutral or coasting.

It sounds a lot like a clicking cv joint with no grease in it and its very loud, I can hear it well over a 3 inch exhaust.

Drivetrain is stock, clutch replaced maybe 5 years ago with an oem one 260k on the car.

Ideas?

Load clicking like that could be a CV, but they are usually a pronounced clicking noise when taking off in 1st and turning sharp. Perhaps you have a loose half shaft for the driver side CV if 2Gens have those

I should add this started about 4 months ago and it's just getting louder. Turning doesn't affect the noise, its pretty constant, all my boots are in good shape.
I'll be out there today pushing and pulling on different parts trying to find the noise.
keep the ideas coming

Maybe not an issue on a 2g but on my 1g I had a tranny mount bolt come loose, so the bolt was clicking against the mount every time I moved or slowed down.

Sooo... I was under there today. LR wheel has a lot of play in it compared to the rest. I can shake it in all directions when it's in the air. The lugs are tight and so is the axle nut.

I'm going to guess wheel bearing. I just want to make sure I'm on the right track before I start ordering parts.

Yup forsure your bearing.. take it apart and make sure there isnt anything else worn.. could be your axle as well.. only 100 bucks to replace! ... if you let of the gas with your clutch still engaged and it makes noise.. and if you push the clutch and it goes away.. ill put bets on your axle being toast!
bearing could of worn due to the axle...
PS chris has 2g AWD being parted out on the board.. if anything got worn out

Alright, replaced the wheel bearing. I had to get it torched off because it was pretty much rust welded to the drive shaft. However the clicking continues.

Now that the wheel bearing isn't making so much noise I can better describe it.

I have a clicking noise in first and second gear only under acceleration. It sounds like its coming from the clutch/tranny area. It's a metallic clicking that increases in sound and frequency the faster I go.

Driving slowly in reverse will "sometimes" produce a a much louder and slower grinding/whining noise, almost like something metal is spinning and being pushed against something that isn't moving. Sometimes I can feel the clicking in 1st and 2nd through gear shifter. Not always.

The clicks go away between shifts and any gear above second is fine.

Clutch still grabs well, shifting gears not a problem. It's not the CV shafts, wheel bearings, or the brakes.

I searched around and I'm leaning towards the TOB, but Im not so sure because pushing the clutch peddle stops the noise. I don't think it's the tranny bearings because it sounds fine in neutral

I need a second opinion...

If it's the TOB I think it should make the noise regardless of gear and the noise might go away with the clutch pedal depressed.

I think something in the transmission is making noise only while there is a load on 1st and 2nd gear.

How about the 1-2 gear needle bearing?

Does the noise happen when you are sitting still? If you push in the clutch, does the noise increase in loudness or decrease?

If it's the TOB you'll hear it sitting in neutral with the clutch out.

This sounds similar to the loud clicking I was hering in my transmission this past week....at first I was only hearing a loud clicking in 3rd gear, all other gears were fine.

Then the noise started in all gears, and got progressively louder, like there was a chunk of something floating through the gears!

Then, it got much much worse! While driving to my friends garage to pull the car in and swap transmissions, the tranny made a fairly loud clunk, then stopped and would not budge an inch after that....I am very interested to see the internals of this transmission when we take it off the car tomorrow, i will update with what I find.

Hopefully yours does not progress down the same path that mine has

Yep. My TOB went on my first car, did not exhibit the symptoms you are. I'm inclined to think something either inside the tranny (1-2 needle bearings, detents, rail, possibly roll pin) or a mount.

The clicks go away as soon as the clutch is pushed in. The clicking increases in loudness and frequency as the car accelerates but goes away immediately on deceleration. The clicking ratio stays the same in 1st and 2nd gear.

I'm a little more convinced it's not the TOB. I would really like to know what you find Mike.

needle bearings huh? I'm going to have to check that out. I'm going to drain the oil and see what I get. hopefully this tranny will make it a little longer.

Yeah Andy, you aren't looking at a TOB in this case. TOB makes a "bearing" noise when it's going, more of a grinding/whirring noise.

You might end up pulling apart your tranny. The 1-2 hub/sleeve/fork assembly may have an issue. Draining the oil MAY reveal something, however there's a high probability you will be pulling your tranny out.

It's probably the intermediate shaft bearing. These things happen from time to time and the only real cure is to rebuild it. A lot of guys have the ability to do it here. I have no issues doing it if need be but not until the spring time.

Haven't heard from you, so whats the outcome?. After reading your last post, I am beginning to think broken clutch disk spring or bent pressure plate fingers, had the broken spring happen once and there was a clicking/chattering sound that turned into a crunching sound, clutch chatter on take off in first gear caused and finished off the spring in my case. Turned the flywheel replaced the clutch with non-spring type clutch disk, it had rubber instead of spings and all was good again.

Just a thought.