Got it all out, pinion bearing failed. Before I cracked it open I removed the front drive shaft. I could move the companion flange around quite a bit, the pinion nut was still tight though. I think the carrier is ok, but everything else is trashed. Pinion teeth are curled over a bit at teh top, some nasty marks in the ring gear teeth from hitting the flange behind the pinion. I'll put some more pics up tomorrow. I have a feeling this all goes back to the pos viscous coupling in my 249 going out and putting more stress on eveything. I'm bolting it back together as a 2wd until I fix that. So here's what I guess I have to do, if I miss anything let me know.

New Ring & Pinion
Possibly new carrier.
all new bearings seals in diff.
I need to find a decent 242 transfer case to swap.
New hub for pass. side. (already replaced driver side)
pressure wash or somehow clean all the metal out of my diff.
put it all back together.

that shouldn't cost too much <img src="/forums/images/graemlins/frown.gif" alt="" />

98 Grand Cherokee 5.9 (Using 10% of the nations gas daily)
95 F-250 (The other 90% of the gas)
95 Honda Del Sol V-tec (Corner Carver)