That could explain the clunking at low speeds, not sure if it is the clunk I hear during gear changes. When I put the car in reverse it clunks so I think that is the Locker since the car is barely moving. I don't think the Calvert setup would make any noise when the car is barely moving, especially in reverse. When driving at low speeds over rough pavement I hear a fair amount of clunking from the rear end and I'm guessing that noise is the Calvert load bar hitting the springs. From inside the car it all kind of sounds the same but I think the noises are caused by different things.
I used to put a piece of heater hose on those load bars. Now I have a piece of 1/4" thick polyurethane glued to the top of the spring. The poly holds up better.
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.It doesn't bang on the 1-2 shift but it bangs hard on the 2-3 shift. Not sure why that is. I did try a 2-3 shift while I was on the throttle and it didn't bang so
At part throttle the shift overlap between second and third will pull the load bar off of the spring and then slam it back down. Not nearly as noticable on a full throttle pass. That overlap is a balance of valve body, clutch pack springs, kd lever ratio, kd lever adjustment, kd spring. Careful here because if it doesn't have some overlap it will flare.
I've put enough miles on the car now to figure out that the hard bang when shifting into third gear only happens when the transmission fluid is cold. After about 10 miles of driving the transmission temp is warm enough that the shift into 3rd isn't too bad. At anything over 10% throttle position the shift into 3rd feels just fine. When the trans is cold and with a closed throttle the shift into 3rd feel like car has been hit with a big hammer. Warm at closed throttle sounds bad but doesn't feel bad. Warm and part throttle the shift feels firm just like you expect from a shift kit. I haven't tried any full throttle shifts yet. I opened it up to about half throttle the other day and the 2-3 shift felt exactly like you would want it. So I'm thinking it is just the case of a race valve body plus Caltracs plus Detroit Locker being a harsh combination when used as a daily driver.
