Pulled my TC output shaft assembly to pieces for a better look and found that the bearings, although they felt smooth to turn, with no play, are definitely showing signs of old age. All taper rollers and both cups are pitted so new bearings and a seal are now on my bench ready for re-assembly. I just hope it is the answer to the vibration and noise. At least if it isn't I have eliminated the transfer case as the cause.

Ian W.