Hi,
When you serviced the differential, was the new fluid filled to the bottom of the fill hole? Also, have you checked the transfer case fluid to make sure it isn't low?
How would you best describe the noise? On these vehicles, at the front of the front drive shaft, there is a CV-type joint that connects the driveshaft to the front differential. If it is faulty, it will make a ton of noise. Check that for evidence of leaks and make sure there isn't excessive play in it.
I found a few pics online showing the driveshaft.
Let me know what you find. Also, when you check for play, have it in 2wd to prevent pressure on it.
Take care and let me know if I can help.
Joe
See pics below Pic 1 is from my manual. Pic 2 is a rebuild kit for the joint. I've done several. It's a little time-consuming, but not a difficult job. Pic 3 is the entire shaft.
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Thursday, January 4th, 2024 AT 6:16 PM