Driveline popping Help would be appreciated!

[Robertino]

I have a problem with a popping noise from the drive line on this 95 Safari AWD. The original problem was that the front Diff had a really bad clunk and when I took it out it was shot. The fluid was black as black and it had a really burnt smell. The trans shop where I had it rebuilt said the gears was toast so they rebuilt it with parts from a good one they had in stock.
I installed it and everything work good for a little while until this popping started happening at random. You can feel it in the drive line POP POP POP , the weird thing is if you stop, put it in reverse and then back in drive it will go back to normal as if nothing is wrong. Later on it will come back but not right away. I took off the front drive shaft and so far no noise after 10 miles of driving on the road and on the frwy.
My question is ..has anyone experience this before. Could the banging from the what was happening in the front diff have somehow damaged the Transer-case gears. I took a video of the noise I get when I manually move the drive shaft so you can hear the play/clunk coming from the transfer-case . Should there be this noise when you move it or should it be smooth without noise.
https://vimeo.com/91483552

[chevymaher]

Have you checked the universal joints?

[Robertino]

Check for play ?

[chevymaher]

Yes.

[Robertino]

You know what ..now that you mention it , the front drive shaft is leaking grease from that front u-joint ! thru that little hole in the middle _I'll take a picture of it tomorrow_

[Robertino]

Here is a picture of what Im talking about, is that normal for these ?
I was moving it around and I have to say that there are spots where it's kinda binding a litlle ..not smooth !?
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[Robertino]

So on this 95 is the consensus that it's ok to drive without the front drive shaft. I've read that the folks in the upper east tend to remove them during the summer.