Turned to be something internal. Pretty sure a bearing seized up. Denise had a bad shift fork once that mad simlar noises but it didnt explode. Hence I figured I'd be good for at least the weekend until I could get it to the dealer.
Big 4 is going to split it today and see if they can find what failed. If they do, and its obvious it wasnt driveshaft, or mod related, they will try to go back to dc one more time and see if they can change their minds.
I never did a runout test on the output, but I was vibe free before and after my last wheeling trips. The only use she had seen until the failure was 2 weeks of dd'n back and forth to work.
The rear shaft still has my name written on with one of those paint felts from DSI its so new.
If this doesnt go through Im going to put it down and work towards a custom setup.
Im leaning towards a new NV4500 and Atlas combo. Not cheap, but at least I'll be able to forget about it once its all in there.
Nothing like 1 ton drivetrain in a 4000lb jeep