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Highly unlikely that the clicking sound started after your reseal. It had probably been that way for awhile and you just didn’t notice it.
At 135k miles there is bound to be a little wear on things. Just because it’s worn a little doesn’t mean it’s bad.
My opinion only. If it were mine I’d put it back in and run it until it breaks and then replace it with an ARB or Elocker.
Going to 90 weight gear lube may quiet the noise some.
 

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Not to be a negative guy or anything, but that grinding is pretty dang significant.
 

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When I was researching worn spider gears I came across the "BS"Korner guy that talked about his spider gears and knocking out a pin to get them out. I didn't mention it because you seemed to think the Rubicon locker wasn't serviceable. One discussion on the web mentioned difficult parts availability.
 

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I revisited your first posting and we’ve all learned quite a bit about your source of noise. I can hear your frustration in your replies. You did much by providing a bench video. Now you or someone is going to have to narrow it further by looking deeper inside. I personally wouldn’t rebuild my own differential, transmission, or engine. I have a 2004 FSM and couldn’t find anything specific about getting to the spider gears.

I myself would put it back together and take it to a shop. There aren’t very many shops that want to help a DIY get over a hump, although I have met one or two mechanics that did help in that way. At least you know more having put hands on.
 

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I've had a faint spider gear noise in my front diff as long as I can remember. You'll have to think about what your long term plans are for the Jeep. Are you happy with the gear ratio? This could be a good time to replace the OEM locker with a more robust ARB air locker or Eaton E-locker. I'd say you could put it back together and drive it while you budget and gather parts for a permanent fix.

I have an ARB in the rear of my 04 and the OEM in front. If I have any issues with the front I'll get another ARB installed. I haven't been very impressed with the stock lockers on the TJ Rubicons, I guess that's why Jeep went with electric in 07.
 
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