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sounds like you're getting a bit disillusioned with your olop!
i've had a reconditioned box before, (and as it happens, that was in my old mk 4 as well....told you it was falling apart!!!!!!!!! )
i can only sympathise. im loving mine (i say this while touching wood and hunting for a rabbits foot!!!) once my gearbox ws done in the mk 4 it was fine. i will ask around at work about your noise and come back to you.