Thought I just popped a weld and toasted a bearing or two. Nope. Guess when I welded the assembly together I managed to screw up whatever heat treatment was there. Both the collar and the inner gear exploded. The splines on the intermediate shaft are OK.
The housing is OK, so I'm ordering the AWD sleeve and going to try that.
I'm ordering parts to get the Camaro back on the road as well. I may need a driver.
This is the last money I'm spending on the IFS. If I can't make it live with this setup then it's time to start looking for a D44.