I can't help you with the mechanic issue but I'm about to order rebuilds for the front axels. I'll start a new thread when I do so you can track what happens.

I haven't had any TOD issues but my suggestion for the axels would be to check around for a garage that specializes in front end work. I'm lucky because there is such a place not even a tenth of a mile from me. A general mechanic type garage quoted me $500-800 for the install while this place indicated that it would be <$200. They did some work for me before on my TLC and did a great job.

BTW - if the CVs aren't making a noise, you can just replace the boots for less than $100. Use the search function on this site for CV boots or MecaTech boots.