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lost a tooth off one of the spider gears is my guess. did you rotate the wheel/driveshaft with the covers off? seems it would be in the front end since thats where you are hearing the noise, but the rear would have spun a wheel in 2wd if the front were locked up. the mode range fork could be broken if it is in the case (Hi/Neutral/Low). kinda hard to say without putting my hands on it.
