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I see what you are saying. Glad we got it figured out. I didn't find any more metal in there. It's too bad I already refilled it with friction modifier!

Snapped some pics. Everything looks good, I don't see anything alarming. There is just a tiny amount of freeplay between the ring and pinion gear which I believe is normal.

No leaks, and it always seemed to work fine the few times I used it. Slim chance it was an extra washer or something but maybe, just maybe...

Found these stuck to the magnet of the front diff: Everything else in the carrier looks fine. I don't see anything out of place. Any ideas what it could be? I'm not sure if I will have the time to get parts in before we hit the road (we're moving).