I had a problem with my lines that I couldn't get them properly bled and the back rotor was all sorts of warped. Turns out it was a brake line that had been installed backwards putting too much strain and causing a minor defect. Once I replaced the line and the rotor it's been great.
In an update to the Eaton/Detroit Trutrac(tm) that I put in the rear of my 1998 Expy. I just got the truck back from the shop after having to put $2600 into another axle. The gears are a hair out of spec and the torque from spinning an axle/tire for 15k miles took its toll.
There is only a...
I didn't realize adjustable pedals were an option. I've got a setup from an excursion I was going to put in an F250. Wonder how similar they are.. I can check my shop manual for troubleshooting options if you need.
Both my manifolds ended up cracking and then finally broke apart. Once they were replaced the noise and ticking (valve noise I believe) went away or at least was silenced.
I had the Bilstein 5100s on my F250 and I hate them as well. I ended up putting a set of Zone Offroad shocks on it and I liked them a whole lot better.
http://zoneoffroad.com/product-shocks?ma=7&mo=134&ye=1998 . These are the ones for our truck.
I'm a big fan of Nitto Tires myself. If you're mostly dry pavement and some off-road their TerraGrappler would be a good fit, If you see sand and deserts they have a DuneGrappler but its wet performance is mediocre.
It also comes down to if you like the look of the vehicle and if fuel prices...
Have you checked the clutch packs in the rear differential? I had an issue with them and ended replacing with a LSD from Eaton.
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