FIRST- VACUM HUBS-The single biggest problem and until they produce metal warn type manual Locks the problem will continue. I changed to AVM. They work but I don't think they will stand up in heavy off roading ? Wheres the best place to shut off the vacum on the hubs? I removed the vacum hose from the hub and plugged it with a rubber cap from Auto Zone. They have the asst pack thats best. I also used one of these plugs from the asst pack to close off the hose I removed from the hub.
Second-Brakes- The rear brake drum hardware design is not good and hard to get on straight.
Third -Front Suspenion, Ball Joints and A arm bushings .Mine are shot, big problem and I cant find a good guided illustration to repair. There are so many squeaks I can't tell where the noise is coming from.
It sounds like a bunch of short legged Beagles in high water !!!!!!!!!!!!
Forth- Clunking drive shaft or somewhere in the driveline? Have not fixed yet.
Fith- A grease seal behind the front bearing assy ? Can't Find ? It squeals.
Sixth-Everytime I read this forum I trust this truck less.
First - AVM style hubs are you only choice for the 98-mid 2000, and no other companies are going to make them. The only other option for these year models are either swap in a solid axle (research it) or swap in the cv joints, knuckles, and hubs from a later model. Doing the former is alot of work to get it right but you'll have strong lockouts, the latter is easier but you'll have live axles. There are a lot op people out there that have put the AVM hubs through some tough stuff, and they have held up well.
Second - The rear drum brake is the exact same design that had been used on nearly every Ford since the 80s probably longer than that. You're the first person that I've heard complain about it. IF you really don't like it later model Rangers came with disks, as well as Explorers since 96. The axles can be swapped, or some of the brakes can be swapped onto your axle.
Third - Already discussed, but I'll say it again. Get a Chilton's manual form the auto parts store.
Fourth - Somebody in the other thread already mentioned that one. There's a slip yoke in the rear drive shaft that needs greased.
Fifth - Not sure about that one. Reference number three.
Sixth - Maybe stop reading the forums? Only solution I can think of for that one.
If you got any more questions about these I'd recommend searching or creating new threads in the proper forum.