Problem Solved!! Hooray!!
There is still a little noise but you would expect that...right from starting out in first gear I could tell the TC was a lot quieter, and all through the gears whether it be in direct or OD it was 98% quieter...there is still a small whine at around 40, probably gear mesh noise with the original output shaft gear, which was not changed, but that is just fine!
So once again, I swapped out the intermediate gear. I bought a used gear set from Herm, and though one tooth on the intermediate gear was slightly chipped (#%#&!!) in shipping from banging against the other gears, I dressed it out and it works just fine....
This jeep was used mostly as a power unit for farm implements, so whenever the PTO was in use the intermediate gear would have been spinning....it just wore out the bore I guess.
Pictures here...some are of the replacement gear and it's chip, and some of the old original gear...the pics are labeled.
