The noise is back. Dealer is looking into replacing the ‘front half shaft’ mentioned here by another member. I showed them the video as well. Seems like that is the issue. Will let you know when I get a phone call to get the part replaced. Back to driving in AWD again.
Truck is back, new front diff replaced, the noise is certainly better. But it is still there. I’m going to drive it another day or so to double check it’s not just in my head because I’ve been so used to hearing that noise. I will update in few days.
Been dealing with this since 2k, I now have almost 8k. The trucks been to the dealer 6 times and they finally “replicated the noise”. My truck is at the dealer now for a front transfer case change, and maybe differential. I will let you know what they replace, and if it corrected it. There’s a thread here that someone said they greased the rubber boot heavily and the noise went away, not sure that would be a permanent fix.