Thanks guys. As sixstring asked, and hoping this is where he wanted me to put it, here's a little bit about me:
I'm a semi-retired locomotive engineer. I still work a few days a month in Huntsville, AL, but have more or less returned to the construction biz, and have been working near Globe, AZ. I used to have a '97 F350 SRW 4x4 7.3, but sadly sold it in '06. After getting supremely stuck in a 2wd in the Tonto NF in AZ for 9 days in December, I decided I needed to go 4wd again.
So rather than doing the smart thing and buying a new truck, I wanted to go, uh, vintage. I bought a well worn (out) '95 F250 4x4 with a ZF-5 for cheap. It's even XL trim, crank windows!!
I started at the front bumper, and am moving my way back. I plan to be rolling west to AZ in this beast in early Feb.
So far, I have welded up some weird stress cracks in the front radiator support sheet metal, rebuilt the power steering gear and pump, new lines, etc. And now I am into rebuilding the front knuckles, including the upper and lower ball joints, tie rods & ends, u-joints and axles seals. New calipers, rotors, brake master and booster are done too. I'm procrastinating adding some Warn hubs before I move on.
I have all the stuff on order to rework the fuel delivery system, and install a South Bend clutch to replace what appears to be the original dual mass clutch. That's next week's work. I fear the transmission needs to be rebuilt too, as there have been some issues getting into reverse and some syncho wear symptoms.
'95 F250 4x4 ECLB 296k - ZF5, Southbend, 4.10, van pedestal, EBPV & CCV delete, 1.0 ex housing, 3" DP, 4" exhaust, BFAF, 6.0 fan, 140v IDM, Autometer, MagHytec diff cover, HD ft springs, 16x8 alloys
'95 F-Superduty 4x2 CM 12' Flatbed 47k - E4OD, 5.13, Banks intercooler, van pedestal, EBPV & CCV delete, 1.0 ex housing, 3" DP, 3/5" side dump exhaust, BFAF, PHP tunes, 6.0 fan, 140v IDM, TruCool, MagHytec diff/pan, Dieselsite exl trans filter, Autometer, 180w LED bar