Seeking front diff wisdom (3 Viewers)

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Oct 22, 2018
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Denver, CO
Hey, team. I have a '02 with the "clunk" that happens shifting from reverse into drive (and often when downshifting to climb). I've isolated the problem to a bunch of play in the driver side of the front diff. Like if I'm under the truck, I can put my hands on the front drive shaft and the driver CV axle and turn the drive shaft 1/8 (or more?) turn before the CV axle starts to move. The passenger side CV engages almost immediately. The CV axles are both pretty fresh.

My question is this:
Has anyone here ever dealt with something similar? Is there a way to figure out definitively if the problem is the intermediate shaft coming out of the diff or if it's in the diff itself without disassembling the whole thing? Has anybody here ever replaced that intermediate shaft?

What I'm trying to avoid:
If the problem is just that I need to replace the intermediate shaft for a couple hundred bucks, that would be awesome. If I do that and it turns out that I need to replace* the diff itself then I've just cost myself a bunch of time and money unnecessarily.

*I say "replace" because it's relatively cheap compared to a rebuild.
 
The front diff is open so engaging at different times is normal and does not indicate an issue. I did have a slight clunk out of my front diff at 250k because of wear but most of my clunk was front diff bushings and CV/hub flange splines.
 
Right...
The flanges are also new. So are the bushings.

The play is pronounced on the driver side at the tripod end of the CV. Like the CV doesn't move at all on the driver side for a while when turning the drive shaft and is distinctly different from the passenger side. It's way beyond what I've seen as normal slack in a diff. And the clunk is violent. I'll see if I can post a video that captures what I'm seeing...
 

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