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I agree with you, the next project will be the ZF5, the turbo will have to wait. More bang for the buck with the tranny than what a turbo would ever give me.
Note, I did get a quote for a ZF6 (early version, no polished gears) for only about $300 more than the ZF5, although the cost would probably be in trying to make it fit with my T.C. or the cost of a new T.C., shaft mods,,,,,etc....
If I am going to buy a donor truck I probably would consider rebuilding the a ZF5 myself to save some $$$. Depends on the shape of the core I guess. I heard some horror stories of ZF5 with cracked casings (due to abuse no-doubt).
I also like your note on the Synthetic ATF, I actually added some Duralube Tranny additive awhile ago to both the tranny and the transfer case on my 93.
I have used the Duralube in my turbo diesel engine since I bought the truck in 93 and it has kept it as clean as a whistle and does not use a drop of oil after 210,000 km's
The ZF 6 would need the transfer case that was behind the ZF 6 originally.
NP 283 if I remember right.
The BW 1356 transfer case you have now would not fit, input shaft is way to small.
The swap is not that big a deal, well since you have an automatic it will take some work with the pedals.
You will have the same thing with any manual though.
What is a deal is you have no speedometer.
The trucks that had the ZF 6 had the speedo pickup in the rear axle.
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