Thanks for the information! I'm debating on what to do now. I can replace the control board myself as it looks fairly simple, but the question is do I want to drop $215 into it. What do you think? Were you able to get the control board part for cheaper than that?
Also, do you know what the control board would cause this noise? It really seems like something else. But it's hard to argue with you since you replaced all of the other moving parts. Any thoughts as to why this would cause it?
The board is easy to replace. There is a video here. http://www.appliancepartspros.com/samsung-assy-pcb-main-dc92-01021b-ap5623797.html
I found most of my parts new on Ebay for a lot cheaper. I paid $80 for a new main board(free shipping). The motor was new for $80(free shipping) the clutch motor was used for $10(free shipping) and the new clutch came from an appliance repair site for $120(free shipping). You can also find a used board on Ebay but make sure it is tested and they take returns in case it doesn't work.
If your model washer is identical to mine and you want a new board and can't find one on Ebay then google the board # DC92-01021B
and you will find them cheaper than $215.
In the technical information manual attached to the washer you can do some ohm checks on the board but I don't know how accurate they are. I think some of them are incorrect. I attached this page out of the Technical manual and also attached the Service manual.
I agree. The noise sounds mechanical. I am not a appliance repair technician but I have 25 years electronics and automation experience and never would have thought the noise was related to an electronic failure on the main PCB.
If I had to guess I would say the motor control chip(TE8) model# IKCM15F60GA is bad. Mine only made this noise at low rpm when the clutch was engaged. It didn't make the noise when the clutch was disengaged and the agitator was running. So it would make the noise when I first started a load when the tank was filling and at the start of each spin cycle. It stopped making the noise when the drum reached higher RPMs.
I didn't find out about the recall until I already had a bunch of money sunk into replacement parts. I am not sure how much of a rebate they are giving for these washers under the recall but if I had it to do over again I would have just purchased a new washer(Not Samsung).