What exactly happened to the hard drive, what were the problems with it, and who did what with it before? Because something was clearly done wrong, as an unreadable 0x32 module alone would not have brought the hard drive to this state. Upload all modules and everything you copied from the service area of the hard drive.
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is translator regeneration (format with P-list) the missing step?
It would be worth a try, the only question is whether anyone has done anything stupid with the hard drive before.
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with MOD 32 unreadable the translator can't load, hence all-LBA ABRT
No, these Western Digital hard drives have a static translator. It's possible that with a damaged P or G list, the drive would refuse to access the data, although it seems like you can erase all the defect lists on these drives and, as long as the translator module itself is intact, the data will be accessible. With an empty translator, the surface will still be accessible, although the drive will find a ton of defects. I can't say for sure, but with a damaged 0x32 module, the drive should allow access to the data. It's just a relo list. It does not affect data addressing, but unreadable sectors are added to it for further processing. As a possible source of problems with module 0x32, I'd point to either a mismatched version in the header, which is unlikely, or a module that's correct from your perspective and the software's perspective, but invalid from the hard drive's perspective. There's also a VSC for cleaning this module, so you don't have to edit it manually; after cleaning with the command, some data appears in the module. By the way, there have been problems with this: if you try to load a supposedly "clean" module from another disk that meets all the parameters, then because of this data, the disk rejects it and the firmware crashes as soon as it finds a bad sector and tries to add it to the RELO list.
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Is there any documented way to trigger it with VSCs, or is a paid tool (WDMarvel/Arch7, MRT, PC-3000) the only route?
There is a free version of wdmarvel (2.3 beta), but it is quite old and requires a computer from its time (i.e., any 20-year-old piece of junk with Windows XP and a SATA port). But it does have the ability to recalculate the translator and run internal formatting. The VSC for internal formatting and recalculation of the translator were on the fzakbar forum (hddoracle) and I saw them somewhere else. I won't search and I won't be able to find it. The problem with all this is that all these functions are already implemented in paid and not so paid programs, and no one does it manually anymore.
There's a current demo version of WdMarvel that will let you read modules and create a restore point. It offers far more free features and is much more convenient than the opensuperclone script. You'll only need to use the script when you need to write modules.
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What are MOD 148 and 4002 on ROYL/Trails, and could their being unreadable block LBA access? Is there a safe way to rebuild them for my drive rather than copying a donor's?
These are most likely empty modules or some junk left over from the factory scan. It only takes a few modules to get the hard drive ready. So, these modules are 100% not the cause; on brand-new drives, fresh from the factory, it's not uncommon for several modules to be unreadable. You can try reading them sector by sector, or you can try reading a copy from a different head. But then again, take at least the demo version of WdMarvel; you're creating half the problems for yourself by struggling with manual input of the VSC and OpenSuperClone.
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Do MOD 02 sections 0x0C / 0x19 / 0x27 matter here
It doesn't affect anything. You can safely use module 0x02 from a hard drive with the same firmware version and, if desired, correct its identity to match the data on the sticker. Within the same firmware version, the module is identical. These few bytes that are different are the APM settings, the inactivity timer, and so on.