Batteries sold were too small (2-450cca)
Replaced both batteries with 2-900+cca & starter. 3 years later I over-cranked & warped the plates replaced with 2-27s 1100ca. 4 years later I replaced them with 2-1000s. Replaced them Feb 05.
First starter went bad quickly. Next starter lasted 2 years so I went to a high torque, It lasted two years & was replaced under warranty. Next one lasted almost 4 years. Last one lasted about 5 years. Replaced with a reduction-drive unit from Autozone with lifetime warranty. Basic cost is about half. It is longer, lighter and just and just as powerful.
Replaced both locking hubs in 91 and replaced intermediate bearing and drive-shaft universals. The dealer sold it as having 145000 on it... He lied.
Replaced exhaust in 92 to a Banks complete N/A system. Made additional repairs to exhaust in 04.
Installed custom front seats and lift kit for rear seat in 92.
Engine block pitted through in 93 so I rebuilt the engine with a new block. Cam was worn so I replaced it as well and rebuilt all of the injection nozzles and had the injection pump calibrated. Had the injection pump repaired once about 5 years later and replaced fuel transfer pump once. No other engine work.
Glow plug cycler is unreliable, I keep a wire in the door to manually cycle for 7 seconds. I have also started it with either if too many glow plugs are burned out. I replace 2 or three of them each year.
Tires twice, shocks once. Front end work once. Front & rear brakes 3 times, but rear brakes are vulnerable to parking brake cable failure. Do the cables every time and make sure they are not kinked! Master cylinder twice and this year brake booster, master cylinder and vac pump.
Installed US Gear 1.25:1 two speed auxiliary trans between the 4spd and xfer case during engine rebuild. Best thing I ever did to this truck! Also added a dash tach from an 85. 4 speed trans and 3.55:1 axles were too tall for good towing capability. Now have 8 speeds and unit has been very reliable. Had to replace a control box this year (05).
Added Air-lift helper springs in 96? with twin gauge dash panel and compressor. Compressor has been unreliable, but bags work great.
Had tank selector valve fail in 94. Replaced valve and added an electric priming pump with switch under hood. Replaced water separator with a Raycor unit.
I use this truck for camping, towing, boating and off road. Truck weighs 7000 empty, 9500 with camper and will tow a 5000-7000 trailer well with the camper on-board. It is and extended cab and has one ton axles front and rear, 34 inch rubber, and tachs 2100 or 2600 at 60 MPH. It is a little light on power with a heavy load on the long hills over 60 MPH, but if you are running under 50 mph this truck will get the job done! It gets about 18 MPG empty and about 12 towing heavy.
I paid 6500 for it in 91. I bought it because of the engine, one ton axles and extended cab. It looked good, but it had been rode hard and put away wet. It was previously equipped with a fifth wheel hitch that had bowed in the bed and both front hubs were torn up. I put about 4000 in it in 93 but have rarely spent more than 600 a year on it since.
It is starting to show age poorly now and rusting under the fenders and all along the hood and some of the gauges don't work. It may be a bucket of rust, but it is paid for and as long as it runs I am going to drive it.
If I ever sell it I'll get one of those 345HP fords.