I had some odd clicking, such as might be found with an impending birf blowup - turned out to be a worn MarTack allowing the axle to slip slightly out of position. Had some slight seal splooging happening too, for the same reason. Don't know if you are using MarTacks, but it does sound like an out of position axle. Or worn brass bushings in the spindle.

-Bill
'87 4Runner w/ '96 5VZ-FE, 'Red Chili II'
'97 Taco XtraCab 3RZ-FE, 'BlackBean'
TLCA # 13257, Rising Sun 4x4 Club Land Use Coordinator
"He who stops being better stops being good." -Oliver Cromwell