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I am going a different direction at this point. The guys that have been working on the transfer case pulled the VC and replaced front and rear bearings. Noise is still there. They are charging me $0.00 because they couldn't figure out the problem. I give them a big thanks for being honest and doing the right thing in the end. I am picking it up tomorrow and I will measure drive line angles and see if I come up with anything decisive there. After that I guess I will have to pay someone else to look through the diffs. So far this hasn't cost any extra money, but shipping diffs and having them rebuilt is going to be very expensive. What's the best way to ship a diff housing?
The propeller shafts are now spinning at a faster rpm for any given speed on the road when compared to the stock differential gear ratio. A U-joint's rpm limit generally varies inversely with the angle of its operation, so the combo of lift and higher rpm has found the limit, particularly if the flanges at each end are not parallel to each other....why this problem showed up so drastically when I put the gears in...