Thanks bracker8040!
I enjoyed meeting and talking with you, also tell your brother the machine we purchased from him is doing a great job.
NetKarts: Thanks!
Mine isn't completely tuned but averages 10-12 mpg hauling the loads I pull which is all local with 3.73 gears, once I get it completely tuned to my liking it should gain a couple mpg empty and have a little lower egt's, I have the fuel set to a max of 1250 degrees egt at full throttle loaded.
Don't expect to gain any mpg loaded with final tune but should gain a little more pulling power at the same mpg.
These are the loads I normally pull, gcw runs from 25-30k lbs
I'm not sure about the F-450 2wd chassis but all 99-04 4x4 chassis came with the larger Dana S110 rear axle.
3.73 ring & pinion, bearing set and new tone wheel cost me $1700 and I did the work, 4.10's cost more.
While the front axle was apart for gears and seals it was also a good time to replace the ball joints, axle u-joints, hub units and inspect all of the steering linkage.
By the time we had it back together I'd spend around $3k on parts for both axles.
If I was building a 2wd I'd go with 4.10's or 4.30's.
With 4x4 I can use low range in the t-case for off road use and for the mostly local 55 mph driving I do the truck runs 55 mph in 5th direct at 2200 rpm.
Rpm's are a little high just cruising along in direct but I can pull most small hills and overpasses without needing to down shift.
For those that do more interstate driving where they'd be using OD most of the time 4.10's or 4.30's would be better towing gears.