Putting a new playback head into an audio cassette deck.

Hi Steve - try this:
Connect amp Tape Playback to deck Line Out.
Connect amp Tape Rec Out to deck Line In.
Play your favourite cassettes.

Hi there.
First - Turn On The Tape Demagnatiser (should be a switch on it)
Second - Insert into cassette player
Third - Turn On cassette player
Fourth - TURN DOWN VOLUME ON AMPLIFIER TO MINIMUM (This is essential!)
Fifth - Press Play on cassette player
Sixth - After 10 seconds press stop on the cassette player
Seventh - Remove the cassette demagnetizer from the cassette player
Eighth - Turn off the demagnetizer and put back in it's usual storage place

AGAIN, MAKE SURE THE VOLUME IS TURN TO MINIUM WHEN USING THIS AS THE NOISES CAN DAMAGE SPEAKERS.

It sounds to me like a stuck gear causing the clicking sound. Pull off the top and see if you can hear it and see where it is coming from.

A lot of tape chewing problems are caused by the capstan roller being worn. Check for wear or oxide on that first.

Suggest having a good clean and replace belts. If it stops around halfway on a C90 or near the end then there's a load problem on the take up reel, before halfway the supply reel.

a system remote is the only option for you here. The deck does not have its own remote receiver. Sorry to break the bad news to you.

Is sound at the headphone socket?
Does the meter show audio output?
If the answer is yes to these questions check that the connections to the amp are correct and the amp is set up is ok.

Regards
John

CHECK CONNECTIONS AT THE BASE OF THE READ HEADS AS THEY HAVE A TENDENCY TO CRACK OVER A PERIOD OF USE. CAREFULLY STRIP BACK AND RESOLDER, REMEMBER TO LEAVE SOME SLACK AS THE HEADS REVOLVE ON TAPE REVERSAL.

Ahh, Another Dual cassette deck. These are typically not worth a repair charge. I went looking for a service manual but Hi Fi Engine did not have one but they had a Owners Manual. Any unit that has a specification as to wow and flutter starting new at .18% was never made to be a long lasting deck of any quality. I don't like to be negative about people equipment but you might be better off getting a better deck from the start. If you think it is worth the repair, then send it to someone but I don't think you will want to sink $100 into a unit like this.
I am not saying it is unrepairable but that with what you come out in the end you could have made a better choice for a deck to buy.
It is probably a bad solder joint or bad capacitor on the circuit board.
I am in Chicago and would look at it for you if you want.