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Ok the stereo/bitrate settings seems to solve the audio sync issue, at least for the most part.
I took a 41.3mb, 5:01 minute .avi resized to 320x240 with DivX 3.03 encoding at 250 kbps (higher than I'd previously been using) and this time, rather than converting to 8 bit mono at 22050Hz with the MPEG Layer 3 codec, I chose the LAME MP3 codec set to 44100Hz at 128 kbps stereo.
The resulting file was a bit larger than most, at 13.5mb. Though to be fair, I then re-encoded another version of it, this time using the old mono audio settings, and it turned out to be 10.1mb so overall not that big a difference.
As far as I could tell, the stereo version stayed in sync the whole time, while the mono was immediately out of sync by approximately 1 second, as usual.
Considering this, plus the fact that all movies play in sync on the desktop, I'm thinking it's simply a matter of DivX being CPU-intensive while low bitrate mono MP3 is not. So find a combination where both the video and audio take the same CPU resources, and things should equal out.
I'll continue experimenting with other settings as I find the time and motivation... :)
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