I know everyone here has been on the edge of their seat waiting to find out what this noise is. The anticipation is over. It was (
):
The front Tom Woods driveshaft slip yoke.
Yep, that thing was dry. And that's why the noise only occurred when off roading. That's the only time the Disco flexed enough to make the shaft move enough to hear it.
Pro Tip: Using a grease gun on the slip yoke has zero effect, like none, nada. I don't know why Tom Woods put the zerk at the bottom of the yoke where it gets no grease on the splines. The only good way to grease the splines on that slip yoke is to remove the driveshaft and separate it. Brush grease into the splines and put it back together. Also, if you pump a bunch of grease into the yoke zerk, it will eventually blow the dust cap off the yoke and spew grease all over the place. Then you have to beat the cap back in with a punch. Not that I did that or anything
