I pulled off the driver side grease cap again, loosened the nut one notch, and with the up/down test, I could feel play in the bearings. So they must have been just right as-is. I'm going to leave everything alone here and move on.

I think the heat in the caps is transferring after stopping the car ...

OK. I readjusted, using the steps you provided. I did a similar test drive. There is much less heat to be sure. But the grease caps are still hot. To where I can keep the back of my hand on them, but barely. I'd estimate 90-105 degrees Fahrenheit. I can do the adjustment again, and err towards the ...

I got the bearings replaced, and adjusted. I am a little confused on the adjustment because the Bentley manual says to tighten to 41 ft-lb then loosen 1/2 turn. Meanwhile the Haynes manual says to tighten to 50 ft-lb and loosen 1/3 turn. I tried the Bentley method and the wheel spun quite freely ...

Yes they 'look' fine to me as well. And I can tell they were installed with loctite previously. I'll do the same for now. Next time I order parts I'll get some caliper bolts just for peace of mind, but I won't make it a necessity for this job. Thanks!

I didn't disable the vacuum sensor. It's still wired normally.

I bypassed the on/off/thermostat switch/knob by putting a toggle across the green/green wires (on/off), and shorting the two leads that go to the thermostatic switch. Now I can force the system to run anytime. Hopefully next week I'll have time to take it to a shop for a leak down test. That will ...

Should be getting parts/tools today. Something I was unable to put into my FCP Euro order was brake caliper bolts. The manuals say to replace them. Should I be able to find them at an auto supply store?

I got my brass punch in the mail and quickly knocked out the inner/outer races from the hubs. I get now why these punches are brass. The brass will deform while the aluminum will not. Cool.

Now just waiting on my new bearing parts and bearing press tools.

As another note, the right disc and hub ...

Eh, paralysis by analysis... I just went ahead and whacked it out with a run of the mill hammer. I put an expendable lug nut on the broken one, set it on some concrete (on top of a rag) and it took five hits or so. I don't believe I caused any damage to the hub.

I already ordered the replacement stud. It should arrive on Friday or Monday. So would you recommend that I get it professionally done and not do it myself with a big hammer?