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That was a good catch ! You where so lucky, since it would not take long to destroy all the bearings and seals and shafts in a situation like that !

When you check the "backlash" on the front axle you carefully turn the flange until you "feel" it make contact with the other gear. You can feel this, you just need to turn it slowly.

Good to hear that the advice we "first" gave you worked. ;)

The way your describing the "sound /vibration" now is pointing to the transmission not the driveline. Can you take the transmission cover off and do a quick check ? You have checked all the fluid levels of the transmission and transfer-case right ?

When you push against the pinion flange (upward movement) there should be "ZERO" clearance. The only play should be the backlash which is usually .008" to .016" on a gear like that. You measure that by "twisting" the flange.

I agree with "fsearls92" here. You actually need to torque them, not just put a wrench on them and assume they are tight. I had several that where "tight" but when I actually torqued them they where way off ! Also how are the 'U' joints ? When was the last time you lubed them ? Lube them now and...