So I get the call: "it's done - everything checks out". I ask about driving another one on the lot, and they're happy to do it.
Upon starting the one on the lot (which has been sitting for weeks), I immediately notice how quiet the trans is. Point it out to the service mgr. We drive off, and it's nice and quiet. Point that out too. Head back, jump in mine, and it's quiet too! Whaa?!?!?
Drop him back off, head home, doing between 50 and 60. Get to a section of the drive where it's 35/40. As I'm cruising along at that speed it starts getting louder...and louder... Call the service mgr., let him know it's doing it, pick him up for another ride.
Turns out that if I take it to >40 for a while, it's quiet. But sustained driving at 35-40 MPH causes it to get progressively louder, and is now accompanied by a scraping noise. And the svc. mgr. hears it too.
To this dealer's credit, the svc. mgr. voluntarily explained in detail that they checked the CVIs (and explained what it was), quick learn, etc. I was very impressed with how they talked to me like I actually knew something. Kudos to them!
So the tale is to be continued. At least the rental car is nice - Nissan Murano. Not quite the same as the KJ, but I'll tell ya - it's quick, smooth, quiet, handles very well and the CVT is neat. Different beast, but a great vehicle if anyone's in the market for that sort of thing.