Mil T -
I've read the entire thread and I have a question which, with your disassembly/re-assembly background, you might be able to answer. The sounds are described as either grinding, or clicking, or like cards on bicycle spokes. The noise I hear in my 2018 is grinding as if a brake rotor was rubbing on a piece of stuck gravel. If a partial hub engagement is occurring, why would it sound like grinding? I can understand why it would sound like clicking or cards-on-spokes due to gear teeth partially meshing, but why grinding? Is there an intermediate synchro ring in there somewhere that I don't see?
Thanks, just trying to understand a little more.
Ron