Has anyone with an AWD front differential/carrier (GM 7.2" IFS used in the Express, Astro/Safari vans, TrailBlazers and other mid-size GM vehicles) had issues? I've been chasing front-end drivetrain noises in my 2005 Express Van AWD and "think" I may have an issue with the front diff. I grab the driver-side CV axle and get about 1/16" of play in all directions from the flange that comes out of the side of the differential. I'm not experienced with these systems but I'm guessing that isn't normal. A mechanic buddy of mine said there should be no play at all so I took a video of me manipulating it and sent it to him to see what he thinks. Here is the video I took (please disregard the intro; Booster is my buddy's nickname):

Van :: MVI_1797.mp4 video by zuren1cs - Photobucket

Is that level of play normal?

I've done a bit of searching online and it seems that AWD GM truck guys on other forums describe exactly what I'm seeing and hearing and it is relatively common. The front differential for AWD is engaged all of the time and they chew up carrier bearings, typically the driver-side, to give you play and bearing noise. The noise sounds like sand in the bearings with the occasional squeek. It could also be the wheel bearing. I drained the fluid, ran a magnet through it and have a magnetic probe I slid into the drain hole - no metal chunks found inside the differential. I can't know for sure but I believe everything is factory with 128k miles on it.

I can go after the wheel bearing but want to eliminate the play at the differential as the problem first. So far I can't get a confirmation and was hoping someone here can help.

Thanks!