It's impossible to say what the crowds will be at this point. I thought a 7 am flight on a Saturday from Toronto to Newark on Continental would find no one in the Toronto airport....I arrived and it was total craziness there although most of the people seemed to be lining up for the charter or low fare airlines...still, it really "plugged up" the security and customs lines and I was a little concerned about missing my flight....get there extra early!
Overall, the Toronto Airport experience for fliers to the US is just about as nasty as it can get...I know that there is renovation/construction going on there but right now as far as people flow, line-ups, overall comfort it's horrendous. The Terminal 1 building looks like it's going to fall down (there are chunks of concrete missing from its support beams (no joke)....it's possible to hurt your hand using the door handles at Terminal 1 - they are very square and very sharp at the corners!
It's a shame that the people of Toronto (with such a great city to call home) have had to deal with such a lousy airport....I carefully weigh any opportunity to just use Buffalo or Detroit airports when visiting the area (both of those are new, well-organized, comfortable, and just sparkle!) Many people on these boards who "discover" Buffalo, Detroit, and Flint airports always seem to have the highest praise for them, probably because their reference airport is Toronto!
Good luck...I know its tough even when healthy to deal with small children in any airport, Toronto may not be a lot of fun....keep thinking about making it to the plane, then hope your child falls asleep there!