@boarder42 You are right about my taxable. About half my savings are in taxable and my situation isn't take cash out to pay off mortgage but more like is it worth taking out another mortgage once this on is lose to being paid off?
Also, do you know how subsidies are enacted for health insurance. I realize there has something to do with 400% of poverty but each state is different.
Next if I need x dollars to live on, I am already pulling from my taxable account to keep taxes low. An addition $28K will likely be taxed at 15% on maybe half of it being capital gains. By pulling that cash out it may stop being worthwhile to do backdoor Roth conversions. Something I am eager to do when retired. Not doing conversions will mean more taxes in the future via withdrawals and increased taxation on SS.
You are right that throwing around random numbers is pointless and may confuse someone who is latching on to the "feeling" that debt free is always the right answer. That's why I think everyone needs to do their own math as the answer may fluctuate widely.
A 3-4% arbitrage on a $300k loan is $9-12K per year and a huge chunk of change. It would take a lot of taxes and loss of subsidies to make it not the most ideal financial decision.