I should have access to a garage over the weekend so I'll check all of that and see if it helps. I'm pretty sure the tcase oil is ok, I just put a new tranny in last March and put some fresh sythetic 75w90 in it, but I'll give it a look.
I also noticed something else last night. I had to make a trip on the interstate and I had my hubs locked because of recent snow and I had a terrible vibration above 35mph that isn't there with the hubs unlocked. It was pretty unbearable at 55 and I ended up unlocking the hubs for the trip back home. I've never noticed this before, and I'm not sure if it's related to the noise issue, but I just wanted to put it out there.
As far as restaking the nut, what's the best way to do it? Sorry for all the questions, I've rebuilt just about everything on this truck, but there's always tons to learn! I'm thinking if I have too many more problems I might just buy a welder and torch the front end off and put a solid axle under it
