Project Karl - noisy first drive :-(

[sgroer]

Hey all,
Our 84 911 outlaw hit the road for the first time the other day. It was absolutely incredible for it to leave the driveway.

Everything seems to be working great, except we have a strange, grinding / rattling noise in 1-4 gears and neutral when rolling forward. 5th is totally fine.

The car has an LSD from wavetrac and numeric shifter along with wevo side plate and wevo gate shift. The transmission was rebuilt. In hindsight, he came highly recommended but I don’t know how experienced he was with 915 / diff set up.

When moving forward, the only way I can get the noise to stop is to push the gear lever all the way to the right or to shift into 5th. It does not change pitch at all based on the speed of the car. It is consistent at all speeds and all gears as long as the car is rolling forward. If I am rolling in neutral with the engine running, the sound is the same. If I turn the engine off and continue to roll in neutral, the sound goes away. It does not seem to affect the drivability of the car. I have only driven it a few miles. But the car seems to drive fabulously.

Here is a YouTube vid of the sound. https://youtube.com/shorts/-0695k-QuGA?feature=share

I guess it could be a shifter adjustment or something far more complicated.

We are so close to having this car on the road! Your help is appreciated. Here’s a pic of Karl on public roads for the first time!

[Discseven]

That is one nasty---in a beautiful way---looking Porsche Sean. Looks black but I know photos can be misleading. If it is and the wheels are black... work of art. Something about a flared 911 with no tail...Unordinary. The 5th gear thing, I'd be looking at shifter linkage beginning to end. Sound fits the look---nice growl.

[Otter74]

Can you feel the rattle in the shift lever?

[sgroer]

Originally Posted by Otter74

Can you feel the rattle in the shift lever?

Yes for sure

[Tom_in_NH]

Are you using "Sport", semi-solid, or solid engine/trans mounts ?

[sgroer]

Originally Posted by Discseven

That is one nasty---in a beautiful way---looking Porsche Sean. Looks black but I know photos can be misleading. If it is and the wheels are black... work of art. Something about a flared 911 with no tail...Unordinary. The 5th gear thing, I'd be looking at shifter linkage beginning to end. Sound fits the look---nice growl.

Thank you!!!

It’s Irish green with brushed bronze wheels.

Time to figure out the transmission and let this thing sing!!!

[sgroer]

Originally Posted by Tom_in_NH

Are you using "Sport", semi-solid, or solid engine/trans mounts ?

Wevo semi solid

[john walker's workshop]

Sounds like another thread here recently. I suggested maybe the 5th/reverse shift sleeve was adjusted too close to the reverse idler and was rubbing teeth. It was apart, so...

[sgroer]

Originally Posted by john walker's workshop

Sounds like another thread here recently. I suggested maybe the 5th/reverse shift sleeve was adjusted too close to the reverse idler and was rubbing teeth. It was apart, so...

Yes I read that thread and very similar issues. The difference was that he had the sound with the engine off and mine immediately goes away if I switch off the engine while in motion.

I really don’t want to pull the drivetrain but I think that’s where we are headed with this :-(

Anyone else have insight?

[Funracer]

Sounds to me like something is touching the exhaust tubing or maybe a heat shield somewhere. Sound change in a left or right turn?

I would do a lot more looking before dropping the drivetrain.

[$yncro]

Karl seems to pull pretty good, to me it doesn't sound like
You have to drop the trans. Did you check your clips for the
Throttle rod? Sounds like it's rattling under the tunnel.
Good luck.

[sgroer]

Originally Posted by Funracer

Sounds to me like something is touching the exhaust tubing or maybe a heat shield somewhere. Sound change in a left or right turn?

I would do a lot more looking before dropping the drivetrain.

The problem is that it immediately goes away when I push the shifter all the way to the right and comes back as soon as I release it.

[Funracer]

Do you have a two post lift? Is the sound still there with no weight on the suspension?

Anyway wish you the best.

[sgroer]

Originally Posted by Funracer

Do you have a two post lift? Is the sound still there with no weight on the suspension?

Anyway wish you the best.

I can give that a shot…. Good suggestion !