So I did a bit of poking around
and there are two things.
Firstly - the U.J.s seem good and solid and quiet and the diffs seem silent, and so does the transfer case.
The front left is making a sort of metal-on-metal squeal when turned, but almost sounds just like a bit of something caught between brake drum and shoe, and is doing it equally in both directions.
The other thing I can see is where the prop-shaft enters the rear diff, where it slides in and out to allow for suspension movement, there is a full 2mm of play around there. I’m assuming there’s a bearing in there? You can rattle it by hand side so it’s quite loose, even though it still slides smoothly in and out.
The input to the rear (or front) differential does not slide in and out. This movement is on a slip joint on the propeller shaft. If there is any sideways play on the input to the rear diff, there is a problem. Disconnect the prop shaft and check the nut on the pinion shaft for tightness - If loose, tightening it may fix the problem, but there is a good chance the bearing has failed. This is a diff out issue, and the whole differential assembly will need to be checked at least. The pinion seal is certain to need replacing as well. The seal and outer pinion bearing could be replaced with the diff in place, but you have no idea what the rest of the differential is like, and the inner bearing is almost certainly in the same condition.
Do you think this is the problem?
Yes. But there may be more than one problem!
If so, is it a job I could do without taking the diff out? What are the costs involved?
Also, is there a PDF workshop manual on here that anyone’s selling?
Thanks

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