[DonC]

At the "cautiously optimistic" stage. Everything is back together and, initially, seems to be working as expected. Sorry about not having any photos but the shop that removed and pressed in the new bearings got them done in a couple of hours while I was off on another errand. I expected it to take longer but they said it was very straight forward. No damage to either the hub or the hub carrier. The outer bearing was very dry and appears to be where the noise was coming from. On the plus side when it happened I couldn't have asked for a better place other than in my driveway when it started to go south.
As is typical with ERA everything came apart and went back together without any surprises. Again, a very straight forward procedure. I did notice that the area around the inner seal had been center punched to help hold the seal in place. Didn't see it till after the seal was removed. The punched areas were peened back in rather than grinding the material away since the aluminum is so soft. Re-punched the inside of the carrier in the same manner but in different places to duplicate the original.
Total out of pocket cost was $110 for a new set of inner/outer bearings, races and seals. $40 to have the bearings and seals pressed on and off. $35 to have the brake rotor turned as long as it was off. Bearing and seals were available from NAPA.
On re-assembly it looked like the existing old spacer was really close to what I needed so reused it and all seems to be well. Really not sure about the 225 ft/lb final torque called for in the manual. Was able to set the initial to 120 on the bench and did my initial checks there. Spun everything up to about 50 mph while off the ground and rechecked for end play. Just barely able to feel any. Put the car back down on the wheels and put a couple of miles on it and lifted it back up to check. Somewhat more axial play than initial which I expected. Tightened the nut to the next castellation and reinstalled the cotter pin. Got 25 to 30 miles on it last night and will get the car up and check the axial play again today.
Don't know what the final torque value is on the nut (my wrench only goes to 150 and it was slightly beyond that) but getting that last castellation lined up is as tight as I feel comfortable with.
I'll update this afternoon with what I come up with.
DonC