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4l80/85e are both 4 speed as well. You need to step up to the 6l80/85/90 to get 6 speed. GM is now making a 4l75e that is a very heavy duty bolt in replacement/upgrade to the 4l60/65e.

I hadn't seen the Luverne...thanks for the lead on that, I'll check them out. I did find that CARiD has the Aluminess steps for less than $800 which is a helluva lot less than on their own site.

I'm looking at options for side steps. I want full length. I'm not interested in "rock sliders" just a good looking nerf bar drop step that will fill the entire 118" span. I have seen that Aluminess makes some but have read mixed reviews on fitment but like the low weight feature of aluminum...

I think the GMT-600 Vans share a lot of front suspension parts with the GMT-400 Pickups and SUVs...do a little searching on that and you may find some low cost solutions.

maybe some help here...appears that the pickup spindle will provide some lift http://www.sportsmobileforum.com/forums/f12/lifting-a-2wd-dodge-b350-van-23089.html#post243171

yeah, a little easier to fab to that design...diff case would be a one time purchase and there are just as many of them on the road now as the older ones...if it was a wear item I'd probably be more critical..

a couple views in those links, you can see the drivers side has a flat bolt flange on the newer models

yeah, I think the only change was how the center section was cast and how it mounted https://www.midwesttrans.com/chevy_gm_9.25_front_centersection.html

while I didn't look closely into it, the GMT-900 front diff is reported to be a much easier to retro-fit design and allows more clearance at the driver-side mount, it might fit your desire for drop out capability better..

starting with a donor that had a lift on it would be helpful, using the bolt on drop cradle and torsion bar relocators could reduce fabrication quite a bit. I'd stay with the entire stock GM spindle, unit bearing ect... and just solve the tone ring issue. you have the room for wheel adapters so...

cool project...way to blaze a new trail! with the extra weight the 4.10 gears would definitely be a blessing..

Maybe some help in this guys videos...looks like he posted a bunch on it. https://www.youtube.com/user/MyREALstories/videos I didn't watch them but I expect that he used spacers. Any more than a couple inches on that A-arm coil spring design will in fact reduce droop travel, ball joint life...

no adhesive I've ever heard of on them...maybe one of their famous clamp washers with the locking teeth on it?

unless you got under your rig and removed some sections of the exhaust heat shield you don't have all the fasteners removed

That's for a GM 8.5" rear axle, it may work in a 1500 (I'm not familiar with what axles came in them) but most 2500's that I have seen have the semi-float dana60 (9.25")

I'd rethink the bed-liner on the bumper, the textured surface will be a nightmare for cleaning out bugs/road debris. Honestly, other than the lower rockers, bed-liner pretty much sucks on the exterior. I've have it (for 10yrs)on the Safari top of my Jeep and some other surfaces, I hate it, it...

04 Ram 3500 wheels with the factory 2000 Express centers. Tires on it now are some roached out Nitto's, LT285/75R17, I have new tires, same size that I need to swap on..

If I were looking for just some lift I'd get the spacers that Weldtec has and keep the stock rate springs so the ride stays comfortable.

3500's will be better for build-able axles as many have full floating axles, look for Dana70 full floaters(decal on the axle tube), they have good aftermarket support. Steer clear of the 2500's with the semi-floating dana60's there is only and OEM limited slip available for those and they are...

I don't think the static height is much different, the rate is heavier so I'd bet you wouldn't get much lift at all, just a rougher ride..