29,000 BTU compressor (2.5 ton)
What do you mean, "the coil is making excessive noise"? Is it the fan or the evaporator making the noise, and describe it, please.
And for heaven's sake, what did you mean by this comment:
.Could the unit's not be matched or was the line not evacuated proprerly/at all.
Do you not know if you evacuated the system or not when you replaced the coil?
Did you change the liquid line dryer at the condenser, or better yet, add one at the evaporator?
Your condenser is 14 years old and most likely the compressor has bad reed valves, considering that the inside coil was in bad shape and clogged. No doubt the low delta temps you are now getting is a result of an inefficient compressor. Ordinarily a 2,5 ton compressor can handle a 3-ton coil as long as it is properly charged and maintained.
Still, you will only get 2.5 tons of cooling, which will effectively cool about 1500 sq. ft.