The crux of this is that there uncountably many reals but only denumerably many names.
But it's difficult to reply point by point to your post, because it's too tangled and knotted up. It would be much better to just start from the beginning. That would be to move step by step through a textbook treatment of this subject in mathematical logic.
It's like when the cables among a lot of electronic components are so tangled and knotted that you can't tell what is connected to what, so you have to just unplug everything and then reattach all the cables in a methodical way.
But I'll address a few points anyway, reiterating some of what I've already said:
First, just to be clear: 'countable' doesn't meant 'finite'. Rather, 'S is countable' means 'either S is finite or S is 1-1 with the set of natural numbers'. And then 'S is denumerable' means 'S is 1-1 with the set of natural numbers'. So there are finite countable sets and infinite countable sets. And a denumerable set is an infinite countable set. And, 'S is uncountable' means 'S is not countable'. Lastly, 'uncountable' doesn't just mean 'infinite'. Yes, if S is uncountable, then S is infinite, but also S is not 1-1 with the set of natural numbers.
"PLUGGING IN"
Because we are grappling with the notion that there are uncountably many real numbers but only denumerably many names, we need to be more exact in what we mean by 'plug in'. This gets pedantic, but it's necessary:
An equation is a syntactical object. So when we substitute a constant symbol for a variable, we are not "plugging in " a number. Rather we are plugging in one symbol (a constant symbol) for another symbol (a variable).
The constant symbol STANDS FOR a real number, but it is not itself a real number.
Recognizing that fact helps to dispel bafflement about the fact that there are uncountably many reals in the solution set but only denumerably many substitutions we can make for the variable.
BOTTOM LINE
There are uncountably many real numbers.
So the solution set for
x+1 = 1+x
(where '+' is defined as the addition operation on the set of real numbers)
is an uncountable set.
But there are only denumerably many names, so there are uncountably many unnamed real numbers, so there are uncountably unnamed real numbers in that solution set.
And, since there real numbers that don't have names, there are no names for those real numbers to plug into the equation.
FURTHER EXPLANTION:
SYNTAX
Ordinary mathematical languages have a denumerable (countably infinite) set of symbols.
The syntactical objects are the terms ("names") and formulas ("statements").*
Every equation is a formula.
Every term and formulas is a finite sequence of symbols.
With only denumerably many symbols, there are only denumerably many finite sequences of symbols. So there are only denumerably many terms and denumberably many formulas.
So there are only denumerably many names and denumerably many equations.
The terms with no free variables are the closed terms.
Every closed term can be abbreviated with a constant symbol per a definition for that constant symbol. For example, we can provide a formulation that is a definition for the constant symbol 'pi':**
Ax(x = pi <-> Ecmd(c is a circle & m is the circumference of c & d is the diameter of c & x = c/d))
And there are only denumerably many constant symbols.
The formulas with no free variables are the sentences.
A theory is a set of sentences closed under deduction.
By 'theorem of a theory' we mean a sentence that is a member of the theory.
Usually, with a theory we also mention an axiomatization of that theory. So a theorem is a sentence provable from those axioms.
In our usual mathematical theories (i.e., any of the usual extensions of Z set theory), we have this formulation that is a theorem:
{x | x is a real number} is uncountable
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SEMANTICS
For a given mathematical language, we provide the "meaning" for the terms and formulas through the method of models. A model is a function from the set of symbols:
To the universal quantifier, the model assigns an non-empty set, which we call the 'universe for the model' or 'the domain of discourse' for the model.
To each n-place operation symbol, the model assigns an n-place function on the universe.
(a constant is just a 0-place operation symbol)
To each n-place predicate symbol, the model assigns an n-place relation that is a subset of the universe.
(a sentence letter is just a 0-place predicate symbol)
The model does not assign anything for the variables. It shouldn't, because variables are not supposed to have a fixed designation. But we can make a separate assignment for the variables and then we have a model plus an assignment for the variables.
Then, for closed terms, the model assigns members of the universe, inductively per the assignment for the operation symbols.
And, for sentences, the model assigns a truth value, inductively per the assignments for the operation symbols and the predicate symbols.
For open terms, the model plus an assignment for the variables inductively assigns a member of the universe.
For open formulas, the model plus an assignment for the variables inductively assigns a truth value.
A model M is a model of theory T if and only if every theorem of T is true per model M.
Now, per a given model, a mathematical object is a member of the universe of that model.
Each real number is a mathematical object.
Our theory says has the theorem:
{x | x is a real number} is uncountable
Now, for any model of our theory that is also a model that "correctly captures"*** the "intended meaning" of 'uncountable', the subset of the universe that is mapped to from the predicate symbol 'R' (for "is a real number") is indeed uncountable.
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SOLUTION SETS
For example, the solution set for the equation
x+1 = 1+x
(where '+' is defined as an operation on the set of real numbers)
is
{x | x is a real number} = R
and we have the theorem:
R is uncountable
And, looking at it semantically, if we have model in mind that "correctly captures", then 'R' maps to the set of real numbers (or an isomorphic variant), thus the model maps R to an uncountable set.
In general, for a formula P with free variables x1....xn, the solution set is:
{<x1 ... xn> | P}
where n=1, we may drop the tuple notation and just say:
{x | P}
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REPLACEMENT SET
As far as I can tell, that is a notion used in beginning informal high school algebra or instruction at that level. I don't know of an actual serious mathematical definition in this context. For the purpose of this discussion, I recommend just forgetting about "replacement sets". It is not needed for any explanatory purpose and only clutters an otherwise rigorous exposition of this topic.
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* To be more accurate, only terms with no free variables are names, and only formulas with no free variables are statements.
** Throughout, I use some English in the formulations to facilitate exposition. In principle, these formulations would be just symbol sequences of the formal language.
*** To get avoid certain cases provided by Lowenheim-Skolem.