"...The noise is present in 1st, 2nd and 3rd gear at the same RPM so I don't think it is a drivetrain noise...."
I don't know if I would be so quick to draw that conclusion. In 4th gear, the amount of torque applied to the drive shafts is less than in the lower gears. Your getting the noise in gear 1-3 but not in 4th.
Have you grabbed the drive shafts on each side of the center carrier and shook them around to see if you can produce a "banging" noise within the carrier?
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Current rides: 2005 Volvo S80 2.5T, 2003 Volvo V70 2.4NA, 1973 Volvo 1800ES (getting ever closer to road worthiness)
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