OK, after changing the front diff fluid I found a great big glob of fillings and shavings. At that point I realized that it was probably time to rebuild the front diff. After ordering a new diff from Toddco I was frustrated trying to find instructions online to make the swap. Fortunately I had the shop manual; however they leave out some nuances. Here are the nuances (along with the other pertinent details)…

Use these directions at your own risk.

1. Raise front of vehicle. (Get the front of the vehicle as high as possible as you will need room to work under the truck. USE JACK STANDS!!! Make sure they are rated for at least 2 tons and are in good condition. Chock both back wheels - both front and back.)

WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.

2. Remove front road wheels.
3. Drain oil from differential. (It helps to have the passenger side of the vehicle lower to get out as much fluid as possible)
4. Remove the steering drag rod. (After the nut is removed, place a maul against the back of the housing and sharply strike the housing with a heavy ball peen hammer to break the temper. This may need to be repeated more than once.)
5. If same components to be refitted, reference mark propeller shaft and mating components.
6. Remove 4 nuts and bolts securing propeller shaft to differential. Release propeller shaft and tie aside. (The entire prop does not need to be removed, just the front. The prop can then be pushed to the drivers side out of the way.)
7. Remove the calipers. (Use a bungee cord or string to tie caliper up out of the way.)
8. Remove the caliper carrier. (This will require a 12 point 15 mm socket. Be sure to get the right tool.)
9. Remove LH and RH front brake discs.
10. Disconnect each ABS sensor multi-plug. (Connections are on the wheel wells under hood.)
11. Release each harness from brake hose and hose bracket. (Important - you will need the slack)
12. Remove 4 bolts securing each front wheel hub to front axle. (Expect these to be seized. Have the penetrating oil ready!)
13. Release wheel hubs from front axle. Remove heel hubs and drive shafts from front axle. (These will undoubtedly be seized into the axle and will need to be ‘encouraged’ to come out using a maul. Don’t be gentle.)
14. Remove oil seal from axle casing. (This is recommended, but optional. The seals may leak if not replaced.)
15. Remove 10 bolts securing differential to axle casing. Release and remove differential from axle casing.
16. Gently rock the differential case up and down, left and right until the old seal releases. (The diff is heavy (~55 lb.); be ready to take the weight. There will also be a little bit of fluid left so be prepared.)
17. The differential can the be moved straight back and out of the axle.

What you find when you actually remove and inspect the diff may amaze you. this is what I found. Take a look at the attached pictures. The first picture is the old and new side-by-side. The middle two are of the old diff (Note the spider shaft end). The last is the new diff close up.