Hi GC,
I am 13 months out from my HR. Personally, I think you are returning to work too soon. I took 6 weeks off, which might be more on the extreme side, but I think I would have liked at least a month; both for my physical as well as mental state.
Yes, I had a ton of swelling, even at 2 weeks. My leg was at least TWICE the size as my other (and purple!). I kept it elevated most of the time, with plenty of ice packs. Are you able to do this at work? It is very important.
As far as the snapping... I remember when I did one particular PT exercise that involved lying on the floor, and sliding my operated leg outward then inward (back beside my other leg) while in a straight position, it would feel like one of my muscles was "catching" on something. I told my Dr and he said it was nothing to worry about. Have you consulted your Dr about your "snapping"?
Eventually, it all went away. Now I occasionally have the "thunking and clunking" noise/sensation( not painful) discussed here, but no snapping or catching any more. Overall, I am doing great and am very happy I had it done.
I think you are probably worried a little too much for the amount of time that has passed since your surgery. It took me many months to heal, and I am still in the process.
Be patient, talk to your Dr about your concerns, do not do too much too soon. Good Luck, Lu