I do have an update, by the way. I went ahead and pulled the bed off yesterday, removed my lift blocks, and flipped the rear shackles. I haven't put the bed back on yet (the fiberglass bedsides are much worse than still when you're alone), but I did get the truck up to about 50-55 around my house with zero vibration - just the big, hard bumps from the front suspension. Once I put the bed on, I'll report back with how everything runs. My suspicion is that the yoke angle was so royally screwed up that it was starting to cause the rear, and possibly front, U-joint to fail. Correcting this angle seems to have put it back into a happy place for now but I don't doubt that I will be replacing it sometime soon.
The next project I'm looking at is the front suspension. I'm keeping lift no matter what so here are the choices I'm down to:
1. SAS swap - Not 4x4, not worth it
2. Leave it alone - I personally think this is a horrible idea but hey, it's out there now
3. Return to stock springs and put a spindle lift under there - I'll have to buy the lift but it's not the worst, I suppose.
4. Fabricate custom upper control arms - I don't want to do it all that bad and a shop quoted me $400 for just the uppers. That's too much for what i'd get.
5. Fabricate, or locate, lift brackets - just to relocate the control arm mounting points. I'm actually pretty comfortable working something like that up. I would, however, like to find some that are already made for my truck if I can.
6. A guy I know has an '05 Ranger Edge that he is currently in the middle of a SAS on. He has offered to sell me his entire front suspension (Steering setup, control arms to wheels, front diff/driveshafts, torsion bars, trans bracket, so on/so forth. I would love to do this (even if I don't make my truck 4x4 for a while, I can throw manual hubs up front and leave it disconnected) but I think I may have found a few problems. Looking in AllData, it appears that our engine bay crossmembers are in different places and mine would get in the way of the differential. It also looks to me like the 4x4 truck has a shorter lower control arm that mounts more to the outside of the frame than the 2x4. Can anyone confirm this? (05 4x4 vs 01 2x4). The shocks also mount differently but that's nothing I can't just relocate in one way or another.
Now let's hear your opinions. Any additional options (besides returning to stock)? Maybe knowledge of where I can get some lift brackets or something similar? Possibly someone selling 3" lift spindles and stock 2x4 springs? I'm open to anything!