Got everything back together with fresh bearings, races, seals, and FMS 4.10 gearset. The only thing re-used was the Torsen.
I'm happy to report that after 200 miles everything is quiet. I had my fingers crossed as there was no metal in the third member and all brgs/races looked to be in good shape.
One main difference was the gear setup and shimming. The pinion shim and carrier brg shims thicknesses I used were all different than what came out.