I picked up a complete set of near new rear end guts on ebay for $25.  They were
changed out when different size wheels were put on the vehicle.  You can get
some real bargains there.

beekeep

You know, that is definitely a possibility. I did spend some time on
some site like car-parts.com or some such, trying to find a rear axle,
and did not find any, and did not pursue this further.

I think that if my attempt at alignment does not work, I will
definitely look in this direction.

i

Jeez, Iggy- instead of fixing the thing on the installment plan, why not
find an axle at a wrecking yard and replace the whole thing?
It's an easy job.

If the gear mesh has been wrong since Day One, then you will wind up
replacing the ring and pinion ($$$).

-Carl

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