Once again, thank you FTE for excellent tutorials. Pain free. Let me summerize, and add a few personal observations.

I ordered the Airtex waterpump for roughly $80 online. Whatever site was recommended here, I can't remember the name. Perfect match.

Searching locally for HD ELC coolant, no one within 30 miles stocked it. Everyone had ELC but I don't want to mess with the test strips. Napaonline says my local store had it in stock, but the guys there couldn't find it and ended up ordering it. Zerex for $18.88 a gal. I think the name has changed from "Zerex EXTREME HD ELC" to just "Zerex HD ELC" specs are same on the bottle, good for 300,000 miles, OAT technology. I looked it up the Valvoline website and they don't mention "Extreme" now.

I started the process by cleaning the engine. I bought the truck in 2006, a 2002 7.3PSD with 80K on it and now have 178K. Never cleaned the engine and it was filthy. Started by covering the alternator and 6637 filter with bags, then sprayed Gunk engine cleaner, rinsing with garden hose, then two more baths with Zep degreaser. What a difference. I spent maybe an hour or more on this and wiped down the underside of the hood too. It's like christmas under the hood now, seeing all the red and green wires compared to the dirt gray before.

After cleaning, I just followed the disassembly process described on here and the youtube videos. Big thumbs ups for using the scaler to get the fan off. An air scaler is $9.99 at northern tool with bits. Highly recommended. A note: It takes a few seconds for the fan to loosen. When the fan didn't immediately start backing off, I was scared I was going the wrong direction or it wasn't working. I went and watched the video and noticed the guy held the scaler on the nut for a few seconds. Threads are conventional. I went back, tried it and it worked perfectly. That was my biggest worry. A tip here: When you loosen the fan shroud, I would put a piece of cardboard between the fan and radiator. Saves you from damaging the radiator fins because you WILL bang the fan against it trying to pull the shroud and fan out together. I didn't do this, thought of it after noticing the dented fins.

Everything else was easy. Reused the thermostat and cleaned up the cover. It had been leaking and I see why. The o-ring was hard as a rock and crushed. Face of the motor had quite a bit of scale on it so I took time and cleaned it up good. Lucky the o-ring that came with the new pump fit tight and I did not have to use sealer to hold it on. I cleaned up and reused the flange for the lower radiator hose as it was different than the one that came with the new pump. The threads for the fan come with a plastic cover. I would leave this cover on until all your bolts are tight just in case you bang it while tightening everything. Once again, I didn't do this and got lucky and didn't damage the threads.

After reassembly, I started flushing the cooling system. Only about 3? gallons of fluid drained when I started the process. So I filled the bottle with hose water, ran it, drove it and drained, doing it 3 times. All I did was loosen the drain on the radiator and remove lower radiator hose. Didn't want to mess with block plugs because they looked tough to do.
Then I did the same thing with distilled water. By doing it this way, I was adding 4-1/2 gallons of water to the radiator each time. Finally, this morning when I picked up the coolant I did a final drain, added 4 gallons of coolant and topped with distilled water. I'll keep checking the level for the next couple weeks.

Hope this helps someone else. Now on to my oil pan and POR-15. Got pretty rusty since the last time I was rolling around under the truck.