That's the problem with extended warranties you're completely relying on the dealership or warranty company to fix stuff and pay for it at least with the factory one you know were your standing 90% of the time.
I used the dorman iwe deletes. No issues with 10k hard miles on them so far. Mpg dropped maybe by half a mpg but that doesn't matter when it's 9. Just gotta keep up on diff maintenance.
I think the rotational clearance of the shaft while locked is ok for the required short time fully shifting in and out, but the grinding noise can be a problem still. I have a troubleshooting suggesstion: I assume that there is no clodging in the vacuum system so the vacuum can fully released if you switching to 2 WD mode. If there is so, then I would check the clearance of the outer cv joint housing by hand in the unlocked condition. The housing and its shaft rotates freely inside two needle roller bearings while driving 2 WD, experiences showing that theese bearings or the related surfaces can wear out really fast. Sorry for my bad english, best wishes from Hungary!
Not sure if anyone gives a damn but if you're stoned like me atm then you can watch all the latest movies and series on InstaFlixxer. Been watching with my gf recently :)