Had never noticed the Polish husband -- nice catch. I know there were a few recasts during the series run -- like in Season One, Pussy's wife is a larger woman, and Silvio has a different wife as well. Tony's sister Barbara was an actress named Nicole Burdette from Seasons 2-3, and an actress named Danielle Di Vecchio in later seasons. Nicole was a slight, slender woman, whereas Danielle was built more like Tony and Janice.

The Polish maid's last name was mentioned in Mr. Ruggerio's Neighborhood as Wosilius. That's more of a Lithuanian name, IMO.

I noticed the Green Grove tapes discrepancy as well -- the only conceivable way they could have caught that conversation was on a parabolic microphone, but even then, it was very windy in that scene, so the sound quality would have never been that good as it was when they played the tapes for Tony.