I pulled out all my reels today to re-lube them before the season starts. I did all of my baitcasters and they came out smooth as can be. Then I started the spinning reels and after the first one, it started making a rough noise. The reel is a Quantum Energy Pt30i. I just recently bought the Quantum Hot Sauce grease and oil for my reels. I took the spinning reel apart and removed the old grease from the gears. I replaced it with the Hot Sauce grease, put the reel back together(yes, exactly the same way), and spun the handle and it felt rough. Definitely not like my other spinning reels. I thought maybe I didnt put enough grease and the gears were grinding so I took it apart again and added more grease. Same rough feeling. I just cant figure it out. Now I wish I didnt remove the original grease. What do you think it could be? What are my options?

That does happen, could be gears not perfectly meshed.  I gave up taking my reels apart as I have lots of backup.  I always send them back to the manufacturer, it's well worth the money.  They make it right and you have recourse.

The manufacture usually puts very thin copper washers on either side of the main gear in between it and the bearings to align the gears. Adding more grease can actually make the reel preform worse!!

Clean grease off everything.

Check gears for damage.

Re-grease, lightly.

If problem persists, take reel to tackle shop or send it to the Reel Mechanic for repairs.

Tackle shops usually know of local guys who work on reels.

In the Richmond, Virginia area we have Wayne Knobe in Powhatan who does excellent work very inexpensive.

Good luck.

I initially did grease it lightly. I thought if I put more it wont make a rough sound. The original setup had a lot of grease. I thought I'd do the same. The reel still functions but now with a slightly rougher and noisier feel to it. Should I re-grease the gears with a different reel grease? Is there anyone here that cleans and re-lubes reels that would know?

If you can avoid it, its always better to leave the gears as they are because some are run in at the factory and if disassembled, might need it again. I have tried this when nothing else worked. I removed the handle from the reel, chucked a square key that it into where the handle goes and applied some heavy automotive grease to the gears.

Hold the reel tight and run the drill. This will wear in the gears to eachother. Clean off as much grease as you can without removing the gears, re-lube and you should be O.K. I once read in an article that

Toothpaste works well for wearing in gears but haven't tried it yet.

Several pros used to do this.