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I believe by 2002 all steering boxes were 32 spline (i.e. 4 X 8 spline segments). I think it was only 1999-2000 that either/or was used. However, to answer your questions.
1.) See this here on how to do it with the steering box on truck and the pitman arm installed.
2.) Yes if you change the pitman arm I don't see why you couldn't use whatever box you wanted.
3.) I don't really see any advantage over one or the other that is worth even messing with. I would use whatever box I had the pitman arm for.
Monster-4, thanks for the info. I saw your thread after writing the post. I am thinking of getting one of the Red-Head boxes. The truck I just bought has 35" tires so I am sure that contributed to the wear of the box.
My dad and I took turns turning the wheel a bit and it was pretty evident the box has some backlash. I don't want to tighten it down as a band-aid.
I am going to downsize to 285/75-16s. I primarily bought the truck to haul my family around towing a 5th wheel, so I desire a more quiet ride.
It has a 6" lift, so stock 265/75-16s would look a bit funny. It rides nicer than my stock 1999 F250, so I guess the longer springs provide a lower spring rate.
I thought about taking the lift kit off, but I am going to keep it for a while and see how it performs. The 6" on the 2WD is equivalent to about a 4" lift on a 4WD from what I have read.
Rezvani's Latest Post-Apocalyptic Monster Is a Ford F-150 Raptor Underneath
Slideshow: Called the Fortress, the 850-horsepower pickup combines Raptor underpinnings with military-inspired features, survival equipment, and a starting price of $285,000.