Driving it in 4WD wasn't as wonderful as I was hoping. Despite the center differential relieving drivetrain bind, the front axle U-joints are pretty noticeable, especially accelerating around a corner. That could be cured by using axleshafts with a CV joint in it--RCV or similar. Those are a BUNCH of money...and combine that with the little driveline vibration I have, made the next choice easy. The driveline vibration is because I totally nailed the pinion angle when assembling the axle. It's perfectly wrong for both a standard U-joint shaft, as well as wrong for a double cardan driveshaft.
So, part-time 4WD here we come!
@cruiseroutfit had the kit in stock for me, which I picked up yesterday at the BBQ. Here it is after I pressed the bearing onto it:
Installation is pretty simple--basically, take the back half the transfer case apart to access the center diff. Replace the rear half of the differential with this spool. Reassemble. This pic is as far as it gets disassembled...ready to start putting it back together.
Here it is with the spool bolted on, ready to put the case parts back:
All buttoned up. I'll give it overnight for the silicone to cure before filling with oil and getting it back on the road.
Now, the former Center Diff Lock button on the dash will engage front-wheel-drive instead. Hubs are easy on this axle--for now I have the stock Ford locking hubs on it, but they're pretty ugly so I'll replace them soon.