The truck is up and running! It was 110% worth it. It is soooooooo much better to drive now. This is proper work/play gearing for a truck and how it should've been from day 1. First gear dropped from 3.7 to 4.45, reverse from 3.4 to 4.0, and low range from 2.48 to 4:1.
I had to modify the cross member slightly and used a jeep transmission mount instead of the ranger mount. The rear driveshaft was lengthened by 5" and used a neapco 1310 driveshaft kit to build the front shaft. For the hydraulic clutch connections, I used an advanced adapters TJ jeep -3an fitting in the master cylinder and I tig welded a -3an male onto a VW clutch line quick connect end that just happened to match the JK slave perfectly. An all star performance 24" -3an line with a 45 on one end was the perfect length and on the shelf at the local auto value.
As it turned out, the factory ranger master didn't have enough fluid displacement to fully disengage the jeep slave/clutch. Browsing rock auto, the ranger master is a 16mm bore and the jeep slave was paired with a 19mm bore master. Poking deeper on rock auto, all 2000 era f150-f550 used the same appearing master cylinder as a ranger but with an 18mm bore. It installs in the same way as the ranger master, but I found out the hard way that the square shape on the F150 master that twists into the bracket is .100" larger than the ranger master was. I used a flex shaft dremel with an aluminum burr bit to open up the square in the bracket and it twisted right in. Once bled, the clutch now fully disengages!
For the transfer case shifter, I whipped up a linkage using some 1/4" rod ends and other bits laying around the shop. Rummaging in the scrap bin, I found a nice 1.25" chunk of round that made a perfect shift knob. The pivot has a teflon bushing pressed in riding on a stainless shoulder bolt and it works very smoothly without being floppy. Last things to do are connect the reverse lights, cut holes in the 2wd auto floor plate, install junkyard sourced 2wd auto rubber floor mat in place of nasty carpet, and install the chevy squarebody shiftboots. Just happy to have my truck back!
2 Hi shifter position
4 low shifter position
Here's a video running up through the gears and showing just how low the crawl ratio is now.