Looking at the mess of metal chips in there when you first opened it up,
I have
been thinking all along that EVERY bearing in the axle has got to be
damaged.
That GRINDING noise really sounds like confirmation.  If the carrier
bearings
are bad, the pinion bearings have got to be, too.  They spin several
times faster,
too.  This damage may be too subtle to be visibly obvious until the
bearings are
pulled out and the lube totally cleaned off, but the pressure applied at
the contact
points of these roller bearings are huge, and any crud getting between
roller and
race will leave dents.

Jon

Yes, I ordered a real tool, it was not that expensive.

Because I am not sure what the issue it. It is easy enough to open the
diff and pull the axles the second time.

i

Don't do this.

No pins!  A hex fits into the hole of the adjuster.

If you suspect the carrier bearings why not just go ahead and replace them while
you have it open?

beekeep

OK guys... My plan for now is as follows.

0. The noises that I have are of two distinct kinds, a whining noise
that appears when I ease the gas pedal, and grinding noise that I hear
at low speeds.

1. I received the adjuster lock tab replacement from the dealer.

2. I will take off the diff cover again, and will try to adjust the
adjuster lock to reduce backlash to spec, using a dial indicator to
measure backlash. I hope (and would like you to confirm) that I can do
it using a screwdriver through the access hole.

3. If I cannot get a screwdriver through the hole, I could pull the
axle, and make a tool that goes through the axle hole and turns the
adjuster. I would make it out of some materials, I have a welder. What
I will need to know is dimensions of the tool (ie where to place the
pins etc).

4. After I do that, I will drive around to verify that the whining
noise is gone. If not, I will take the truck to a dealer. I realize
that the grinding noise at low speeds may remain, could be due to
trashed bearings.

5. If the whining noise is gone, I will take the diff apart and
replace the bearings that may have caused the grinding noise. I am
not, yet, sure whether it is easy or not to put it back together
correctly.

Does this plan make sense?

i