So I did some additional troubleshooting:
I checked and changed the fluids in the front diff, transfer case, and rear diff. All looked generally OK. The front and rear differentials were a little low by maybe 1/2-3/4 qt, transfer case was just about full. All have some gunk and very fine metal on the magnet plug, but nothing out of the ordinary and no metal flakes or shards were seen in the old fluid. No change to the humming/whining sound in the subsequent test drive.
I put the rear end up on stands to run it in 2WD while listening under the car, but it didn't tell me much. Without any real load and with Stabiltrak going nuts, I couldn't recreate the sound, at least not for any sustained period. I suspect I would need to try with all 4 off the ground (and in 4WD), or at a garage with rollers, to make it useful.
I also tinkered with gearing some more while driving, and this is what happens with the sound:
- In 2WD the sound is definitely present during acceleration, but winds down if decelerating or put into neutral, although doesn't go away completely.
- In Auto4WD, the sound acts the same as in 2WD as described above.
- In 4WDHi, the sound is a bit louder and more consistent, and does not change much or go away when decelerating or put into neutral. And when the truck drops below 10-15 mph, I almost hear a sandpaper like sound, not real loud, but noticeable, kind of like when brake pads are nearly worn.
The whirring/humming sound certainly sounds like a bearing about to go bad, but I don't see why it would be the wheel bearings again so soon after replacement, why they would be affected by the 2WD/4WD changes, or why the sound doesn't change when turning. Because the sound is affected by 4WD (definitely worse than in 2WD or even Auto4WD), I suspect its a bearing in the front diff or transfer case. So to try and narrow it down before I start tearing things down, what is and is not engaged with respect to the front differential and transfer case in each of these drive settings?
Thanks!