When driving in 2nd gear, the tranny makes a noise similar to rod knock or similar to a card in the spokes of a bicycle tire submerged in oil.

The rest of the gears are fine, it is just 2nd.

Engagement into gears is fine as well.

5-spd FWD tranny (rebuilt 1yr old)
Quaife LSD (1yr old)
Fidanza Fly (1.5 yrs old)
2600 w/ Street disk (1.5yrs old)
MT90/MTL mix Redline

I will drain the fluid tomorrow morning and post the results of a visual inspection then.

Any advice or sugestions would be appreciated.

Check for debris in the oil when you drain it. Any shavings?

Hello.

I would think the 2nd Gear Synchro is getting bad.

Were the Synchros replaced when the Tranny was "rebuilded"???

Does it do the same if your shift slowly???

Drive the car for a bit and drain some Tranny Fluid into a clear plastic glass to see if their is any metal particule in suspension.

Ghislain.

The car shifts into and out of the gears great - no crunch, and easy engagement.
While in gear, it seems to work fine with the exception of the evil noise.
When in 2nd gear, the noise is proportional to the amount of load (accelleration) that I put on it. If I drive slowly, the noise is minimal but if I hammer it, the noise is louder.

When I drain the fluid I'll check for shavings (and say a lil prayer)

It almost sounds like a chipped tooth on one of the gears, but if it was that, the noise would be all the time since the gears are meshed all of the time.

Yep, sounds like a busted tooth.

I rebuilded one that had a busted 3rd.

The noise was only noticable when in 3rd.

Ghislain.

Thanks guys, I was afraid of that.

Oh well, I have until race season to replace it at least since it is not so critical - I better get the loose metal out of there though ;-)

That would be a good idea.

The 3rd gear tooth (that I'm refering to in my second reply) actually broke the Casing part of the Tranny when it decided to go between the Case and the Front Diff. Made a nice hole for all of the oil to leak out of the Tranny.

Ghislain.

Sounds like bearings need to be checked out if its proportional to load? Wait till the tranny guy gets back from Afrika he can tell you better.

Pretty much garenteed you need to get out there and take the tranny out. Its not going to fix itself.

-nate

Next time when your in 2nd gear, push the shifter further into 2nd while still in gear. Let me know if the noise disappears.