Ok guys, got some time to fool with the differential tonight. [8D]
Got the old one out and I didnt take it apart, but couldnt see any flat spots on the ring or pinion gears. Started moving the ring gear, and apparently it lost the bearing on the ring gear side and is causing a lot of play. The gears still look pretty good though, I must have shimmed them well, so I believe they will be salvageable for another day
On the other hand, I decided to just stick the whole new BP gear set, X diff case, and shock tower in the truck. The only thing I had to modify was the hinge pin brace for the upper arms. Had to dremel it down some to fit in the space. It was a pretty easy fix though and everything else bolted together perfectly. Luckily I got a diff from an X4.6 truck and the drive cups are the same size as the cups on my old differential, so I didnt have to swap anything.
And man these BP gears are beefy! They look sweet
Anyways, ill try and post some pictures tomorrow, just glad to have her fixed and if its not raining tomorrow when i get home id like to try it out, but chances of that are slim...