SUCCESS!
Guys, I am immensely thankful for all your help.... The whole darn job got finished up today. The axles went in with a few gentle whacks, my son helped me bleed the brakes, I filled the diff case up with gear oil.
I took her out around the neighborhood, nice and smooth. Then I drove a bit further to get some fresh gas.. Then out onto the highway for 10 miles or so - the sound is completely gone, it behaves magnificently.. I got the end play adjusted right, but the FSM says to check it again after driving so I'll save that for next season..
PS - The rear sway bar is an improvement too - flatter cornering and easy to control onset of oversteer with throttle.. might just need to install some oil pan baffles to prevent starvation when cornering.
Very very relieved to finally be finished before the snow flies - the next several day's forecast is rain & sleet - I got her into storage this evening... saw a DPW truck out salting just afterwards..
Thanks all for your help!
- Art