The passenger rear upper ball joint and lower control arm have been replaced. The upper ball joint moved easily, but I felt no play. The lower ball joint was not easy to move, but it was sticky. It would not move and then kinda stutter as it moved so I suspect the grease had dried up. I only took it for a 3mi test drive, but I think this may the end of the drivetrain vibration. I sure hope so. I'll know better after driving to work this week and then.
I still have to reinstall the front driveshaft. I left it out to ensure the driveshaft and front axle weren't part of the problem.
Here's the parts and tools list in case anyone is interested. Everything was replaced with Motorcraft parts unless otherwise stated. Most everything contributed to minor vibration that added up to major vibration. The front driveshaft u-joint created extreme vibration at times.
IWE's (one failed to hold vacuum) $105
Tires (it was time, so another set of General Grabber HTS60) $950
Front wheel bearing hubs (286k miles just barely starting to develop play) $210
Fuel pump, Bosch $160 (just happened to fail during this lengthy adventure)
Changed rear diff gear oil (was gonna change it in 2-3 months anyway) $30
Rear driveshaft u-joints, slip yoke, straightened and balanced (slip yoke splines excessive play and front u-joint just a tiny bit of play)(Dana SPL non-greaseable u-joints all around) U-joints all 4 $80, slip yoke $125, straighten and balance $300
Front driveshaft u-joints, clean and re-grease slip yoke.(rear u-joint rusted cup keeping driveshaft off center)
Transfer case new bearings and seals (rear bearing for front output shaft ruined by driveshaft u-joint) (USA Standard Gear overhaul kit) Bought 2 kits, 1 salvage yard T-Case and a Motorcraft front output seal. $400
Transfer case shift motor (was causing errors for the 4wd module and other modules on the bus and improperly engaged the clutch coil)
Water pump(weeping a bit and just a little play) $60
Fan clutch(just a bit of play and a little easy to turn) $80
Rear diff torque arm/support bracket (bushing had 3/16" play up, no play down) $205
Found transmission cooler lines rusted while replacing water pump. Cut out the rusted parts and replaced with rubber EVIL ENERGY 5/16" Transmission Hose. Only because I could not find a full set of 5 new lines. $20 (just happened to find during water pump replacement)
Battery failed, Interstate. $125
Harmonic damper. $143
Front main seal. $16
PCV grommet. $10
Rear upper left knuckle ball joint, Moog K80212. $52 (local parts store)
Rear lower left knuckle ball joint, DELPHI TD4312W. $21 (rebranded Dorman garbage)
Rear upper left knuckle ball joint/bushing, Moog K80212. 2 more $64 (I messed up the first 1)
Rear lower left control arm. $306
Rear lower right control arm. $345
Rear toe link. 2 of them $275
Rear struts, Rancho. Warranty replacement, $16 return shipping to RockAuto
Front struts, Rancho. Warranty replacement, $28 return shipping to RockAuto
$3,916 parts total
New tools and supplies purchased during this adventure:
12 point 12mm impact socket for driveshafts, Sunnex. $10
E-Torx impact socket set to replace transfer case front driveshaft protective cover studs, Duratech. $20
Line flaring tool to flare transmission lines, OTC. $40
Deburring tool for transmission lines, General. $10
Transmission line quick disconnect tools (seat the tool and listen for lock release, pull both tool and line out together and the line will unseat), ZKTool. $15
Low profile creeper 'cuz I'm struggling to slide in/out from under the vehicles, ATD. $105
Ratcheting crimp tool for single ear hose clamps for transmissions lines/hoses, iCrimp. $20
Single ear clamps, Oetikar. $25
Transmission fluid for T-Case and transmission lines, Amsoil. $70
Coolant, Prestone. $35
Front main seal installer. 3D printed
Ball joint press, Maddox. $55 (rental units at the local parts stores are just abused)
Foaming intake manifold cleaner, Amsoil. $14
Digital angle meter to set camber properly, Klein. $30
$449 tool total, though I'm sure there's brake fluid and a few other minor costs as well.
Total $4,365