Did you do a roll-back ??
eg: reverse back, car moving backwards, select first and dump the clutch for a spec'cy launch ??
Shock loads might have chipped a tooth on the ring-gear.
Check for something more than just filings against the oil drain plug.
Alternative is to stick a bore-scope inside the diff and check the teeth faces ....
Sudden change in noise in the diff is rarely good news (but you might create history).
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