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its probably not too common, one side didn't lock up properly or something and ground the teeth a little bit, you would notice taking it off right away though.
take them out and click them open and shut and see if both sides are engaging properly, also check that bearing in the spindle.
Also keep in mind that if you put it in 4x4 with hubs unlocked and its not making the noise, that doesnt rule out all of the parts that are moving. They dont have a load on them which could prevent them from making the noise. If you had your differential in the mud, i would also drain it each and every time you submerge it. Its better to change it often with cheap fluid if your doing that kind of stuff. Also try shooting grease into all of the u joints
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