Trans noise concerns with T-45

your problem is elsewhere, it's not the fluid, if it was a full synthetic.....maybe, but Mercon V is just semi-synthetic, so I dont sea it as an issue....

I doubt it's the fluid. You could change it back to the original fluid that was in it, because it's quick and easy to do....but if that doesn't do it, then I assume it's the clutch. Not knocking your work, but if there is noise it could be a throw out bearing that is making the noise.

Did you guys have the flywheel turned?

Did you put some grease on the input shaft where the tip goes into the pilot bearing and grease on the bearing retainer where the t/o bearing rides?

Was the bearing retainer in good shape, or did it have a groove in it?

Was the pilot bearing in good shape?