Hi again, sorry for the delay, same reasons as before: beautiful baby! I dont think it would make sense to spray the transistors as they are new (i replaced the old ones already)... see below the summary of how things went for brainstorming purposes.
Summary so far:
1) The distortion appeared after recap of the power supply.
2) Power supply has been thoroughly tested and ruled out as the problem (thnx to bktheking!)
3) The tone board had been messed around before I got there. Where I should have found 1uf caps (according to the service manual and according to photos of other tone boards ive seen) i've found 3,3uf caps. Dunno if this has any impact on anything.
4) The 100uf cap on the tone board was original and had failed (leaking from below) so I started replacing that one. The distortion was gone for like 30 secs only after blowing the new cap which I had placed backwards (ups!). (this might be a clue, I will come back to this)
5) I replaced the blown cap and placed it correctly: Distortion is back
6) I recapped the rest of the tone board and replaced all transistors on the board: no improvement.
7) I've just bought an old scope but have no idea on how to use it, Im studying a bit
8) I have this crazy idea while I was sleeping that maybe if I replace the 100uf cap with a slightly higher value still in the range of the allowed +50% as per the service manual I might solve it. Why I think this? Because:
a) the distortion affects both channels
b) that cap is the only part of the tone board that affects both channels all of the other components come in pairs and are mirrored (per channel).
c) when I placed that cap backwards, though only for a second, the distortion dissapeared.
d) we have concluded (as per the headphones test) that the main amp cannot be the source of distortion, so we are left with the tone board.
e) Maybe the capacitance of that cap is, after recap of the power supply, not enough to filter properly.
Maybe my whole logic is flawed, but I dont lose anything by trying. I will throw in a 150uf 50v cap and see how it goes. After that fails (hopefully it wont) I will seriously take on the amp with the scope.
Please feel free to give your opinion or thoughts! Thanks!
Cheers!