Horrible grinding / popping noise coming from the front axle. Could it be a lunchbox locker issue?

[Oklahomacheapjeep]

So I recently swapped my front and rear axles for a set from a LJ (for the dana 44 and higher gears). I also removed a spartan locker I had in my old dana 30 and reinstalled it into my new axle. Took the jeep out wheeling and anytime going over larger bumps I would get a horrible grinding/popping noise coming from the front. Noise was present in 2wd and 4wd. Locker also seemed to work just as normal. Have some small metal flakes in the diff after pulling the cover but everything visually looks okay. what is the normal amount a metal material for a diff? Any ideas on what could be causing this noise before I start pulling the carrier?
Thanks.

 

[Oklahomacheapjeep]

Update: I pulled apart the carrier/ locker, everything seemed okay. Put it back together and the noise is still present. The noise sounds like something is binding and seems to happen when one side of the front end is compressed, I've checked all the bolts on the front end. My only ideas are that it is something tied to either the oil pan skid or crossover steering kit I installed though I can't see any wear marks. Any ideas would be appreciated thanks.

 

[Lou]

Make sure the fan isn’t hittin the shroud. After I did my bl/mml I didn’t move the shroud enough and while flexing it made a hell of a racket!

 

[Jim Byrne]

First is the locker designed to use in both the model 30 & 44? Check with the manufacture (Spartan).
What is the condition of your axel u-joints/ That will make a lot of ugly noise.
As far as metal flakes---none are acceptable.

 

[basic]

I'm guessing the locker he took was from the old Dana 30 and put it into the 'new' LJ Dana 30 that is standard on the LJ. Unless he swapped from a LJR, but then he would have real lockers front and rear.

I agree- u joints on both axle and driveshaft can make noise.

Any chance you are hitting something underneath?

 

[Oklahomacheapjeep]

Thanks for the replies guys, found out it was the driveshaft boot clamp I used. I went with a standard sized clamp instead of what came on it causing it to contact my exhaust. I suspect I also need to readjust my trackbar.