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But I can't overlook that there are metal filings in the grease from the rear differential.

sorry got transfer case stuck in my head and didn't stop to check what I had written before I posted, I am referring to the rear differential, but now that you mention an issue with the transfer case, there is a bit of a rattle that could be coming from there, I had just attributed it to the...

My concern is that there is definitely wear inside the transfer case, metal filings etc. when the service nut is removed. The transfer case became my suspect originally because the noise would only occur noticeably when I was giving gas and thereby actually causing the drive shaft to apply...

I bought my 02 ST in February of this year with about 46000mi, no problems, ran great, clean, and beautiful. Then I deployed to the middle east, by the time I got back in Nov my better half had managed about 10000 miles and the rear gear box sounded like an erector set going through a meat...