Just for the sake of time, only listing what's been done.
Exhaust manifold issue has caused 11 straight days of wrenching, two of which I had to run the garage off of an inverter (no power). I went with dropping the 2.9 back in with an extensive rebuild. Rationale of keeping the 2.9 is that I need my truck back, and I keep reminding myself this may not be my truck in the future. Driving a borrowed Ford Fusion four banger is a daily reminder that I REALLY hate sedans.
Summary of modifications made to the engine: 1986 throttle body, JBA stainless headers, J & C Enterprises "improved" 2.9 heads with (I think) larger valves and (I know) much heavier springs, sealed power lifters, new pushrods, free floating rockers (will post exact dimensions of spacers my machinist came up with so others may use), have spare intakes from the 1990 to port and polish as time allows, 3g alternator, rebuilt injectors, new timing chain with ratcheting tensioner, new pickup tube for oil pump, CLEANED THE ENTIRE INSIDE OF THE ENGINE, electric fan, stupid cone filter intake, bosch O2 sensor, bosch iridium plugs (go ahead and yell at me), cap, rotor, and wires, msd coil (stock was cooked), set timing to 12 degrees, new capacitors in the ECU, and probably some other crap I'm forgetting. Went through the bottom end, replaced the rear main and crank seals, all gaskets that I could find blue fel pros to fit have been replaced with them. All other gaskets changed.
Have a weirdo ECU that came out of the 1990. Moates/others list the 1990 ECU as fitting a 2.8. No idea why. Going to make sure it works on my stock one first, then see what the difference is. Photo is attached of the 1990 box. Anyone recognize it?
I was extremely impressed with the guts of this motor. ZERO wear on cylinder walls. Literally zero. No signs of re-bore or hone use either. Just no wear. Every Mopar 440/383 and Jeep 4.0 I've torn down is in way worse shape than this was internally. Maybe from more extreme use. No idea. Found a whole 'buncha nasty in the oil pan and pickup tube. Something came apart in this engine at one time. No telling what it was though. No other damage found either. Crank, bearings, pistons, rods, etc. all healthy.
The 1/4 inch thick carbon cake I found in the entire lower intake tells me two things. One, sea foam doesn't do anything. Two, I had a problem.
M5OD has a new shifter kit. Guts checked out good. 1354 transfer case was full of water. It is now rebuilt. Both filled with Mobil 1 synthetic dex/merc. New clutch, slave cylinder, etc.
11 straight days of wrenching 8-14 hours a day. Many new problems found I need to ask about. I'm f*g exhausted and my knees are probably going to need replaced. My retired father (former Chrysler employee) is now hoarse and unable to speak from 11 straight days of chanting "this is why I don't like Ford."
Not going to mess with the Dana 35 yet. Still need to replace body bushings. I'm tired. I'm taking a break.
Oh, and because I really hate myself, keeping the 1990 axles in the truck, pushing it outside on gravel, and covering it. Because I'm starting the hunt for a V8.