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You know, if you had an air solenoid bleeding through just a little, that might be enough to keep it from fully disengaging. It would be interesting to disconnect the air from the x-fer case, plug the line so you still have brakes, and drive around to see if you still have the problem.
So it only happens when it's disengaged- not when you're in 6x6?
If so, that's DEFINITELY a case of it not fully disengaging when out of 6x6. If it were the drive flange bolts you'd hear it all the time IMO.
DD