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My rope makes a clicking noise when going trough gear at any quick speed (rappelling or taking falls on lead).

I think that this is just the build up and discharge of static electricity in the rope.

I have looked over the entire length of rope and see no serious flaws or damage is noticeable.

Have you ever heard of this before and is it something that i should be worried about.

Thanks for any help you can give me

It's probably individual strands breaking.

Or it could be the clicking of your heels trying to get back to Kansas.

Or they could have left an alan wrench in the core when they stitched up the sheath.

That's just a new audible telling you to slow down your rappel. Just like rumble strips on the road.

slowing down doesnt prevent it from happening it just slows down the frequency

Have you tried to measure the voltage? It is probably pretty high.

Oh, and yes it is the sound of the static discharge. It won't hurt anything (unless you hold onto the metal of you rappel device to charge yourself up, then before you touch the ground, you touch your friend's earlobe zapping the crap out of him, that may hurt a bit. not that I have done that or anything).

I would retire the rope, pm me if you want to know the best place to send the rope