Its been a while but I thought i would update my latest findings on this issue. I think I may have found the culprit, Diff mounts, apparently they can cause this noise and the do loosen out with age (like all bushings I guess) so it may be that there is some metal on metal vibration going on.
Anyway the fix I am going do is to put in Differential Mounting Void Insert Kit from SuperPro, this should stiffen up the mounts and give sufficient clearance.
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