Good news, on a suggestion from Aussie Locker Bill, I actually opened the front diff. No metal in the diff fluid at all. All the teeth on the ring looked good, the pinion teeth seems good too (hard to see, but even shine through full rotation of ring). I wouldn't expect "just a bad bearing" to make the amount of noise I'm hearing. I would expect it to be more like a wheel bearing grind type sound.
[/size]
[/size]Managed to get the hood off to bring inside to do the hood paint "right". Right is relative since all I'm trying to do is stop the rust. It will be uglier then it was when I started when I put it back on MLC.