Another 5k miles on the van, still working out a few bugs, mostly due to user error though.
Left upper control arm had one pivot slip in a bit. Messed up my alignment, did a quick reset in the bush, but need to redo the alignment when we do a maintenance stop. If I had to do it again, I may switch to the ford camber washers. Getting the forward bolt tight is a pain due to the brake line location.
The diff shifts a bit when I really load up the drivetrain, such as tight turns in 4PT. I need to reset the yoke angle, as its moved down several degrees. I probably didn't get the rear mount bolt tight enough. If I was doing the design again, I would probably add about 1/4" more lift at the front, for better diff clearance.
My new engine mounts are settling a bit, so I need to change the rear axle shims, this big poorly balanced driveshaft is limiting my top speed to about 65mph due to vibration. I am getting a bit fed up, if I can't get it right with shims, I will just order a new shaft $$$$$.
Speaking of shafts the front temporary shaft still works fine. However the slip has more friction than I would like, so when the shaft is really loaded, engine vibration gets transferred to the chassis. If I am moving its not noticeable, but at low speed its annoying. I may get a new shaft built at some point $$$.
I have been using the 4wd a fair bit, snowy roads, sandy tracks, etc. 4WD is no substitue for airing down, and I think my air compressor needs an upgrade after all the usage its been getting.
Here is the van getting buried in a sandy wash. Frozen crust on the top, and windblown sand below. you can see we were just drifting down the 20% slope Lockers and 4WD are a great way to dig yourself into a deep hole, experience has taught me that MOAR POWER usually doesn't help. 20Psi rear and 15psi front combined with lockers made for an easy drive out.
As far as the 4wd bits go, everything just worked when I needed it. On the fly shifting between 2HI, 4PT and 4FT is seamless, ESP and ABS work fine. Ride is quite good with correct air pressure. I still have a knock left side, which may be a loose bolt on the LCA. So after the alignment everything is getting retorqued.
I also need to do a third, and hopefully final, clearance at the front of the wheel wells. Still getting a bit of rubbing, so hopefully a sledgehammer can remedy that.