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you should have no play.i am so glad you posted this a few guys on her have been pushin to get me to do an sfa swap because my d44 is doing the same exact thing on the same exact side.you should probably swap the u joints and the whole enchilada while your in there to prevent further issues thats what im gonna do.the u-joints shouldnt be too hard.if your ball joints are showing any wear whatsoever you may as well swap them while your down there.im doin bearings balljoints tie rods and u joints on mine real soon.let us know if ya need any info
Check the front driveline u joints and CV shaft. The noise could be migrating through the front end, sounding like it is at the wheel ends. Have you replaced the axle u joints on both sides?
Also, what was the condition of the spindle bearings inside the back of the spindle. The axle stub is supported by this bearing and can make noise like this if they are dry or worn out.
The splines all look ok, but I was suprised how easy they slid into the differential. Maybe I missed something on the re-install.
The needle bearings on both side u joints were absolutely shot.
I remembered one thing a few minutes ago. When I installed the driver side axle back in, as I rotated it, I felt a little grinding (this is with the wheels off and the front end lifted), when I spun the axle (by hand) when It was locked. I assumed a lack of lubrication, since it had been sitting that way for 2 days. That's why I double checked the fluid level.
The other thing was that it was snowing like crazy when I went on my test drive. I could of swore I heard a little squeeking noise, but there was so much snow on the ground, plows running, etc, that I don't know if it was in my imagination.