So it only makes it when the engine is powering the drive train.
Or does it make it when you rev it?
I think you said it doesn't.
I'd look at all hubs, both propshafts, including taking them both off as you can't feel it when on the vehicle. This is how i knew i had to replace my front one as the slight play in the cardan joint was only obvious off the car.
Then you are down to the gearbox, clutch etc etc.
BUT it could be something to do with the engine bearers as when the engine is under load, it'll compress one side and stretch the other, which could just make metal to metal contact somewhere
EDIT, just reread the thread and realised you had already done a lot of this!
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Hi ive maybe heard it once or twice in past few months whilst stationary and even then for a second a tick tick and no more. 99.9% of the time nothing.
Very noticeable when driving and from cold
I am starting to thing clutch or gearbox tx box. Would clutch springs be able to tick tick. clutch isn't that old, maybe 2 yrs and 10k miles
I doubt it, but I did once come across someone who had a rivet come loose in her clutch and that resulted in intermittently getting no drive at all as it kept the clutchplate just off the flywheel.
I can't see heat making that go away though.
