I’m wondering how it’ll handle on a highway. Can I roll comfortably at 70mph? Can I use it to haul other project vehicles?Why on earth are you trying to find out how fast a Power Wagon will go lol? That isn't what it's designed for.....if the engine is stock, SLOW with a smog era small block in a full size pickup.
Suspension is solid. Is there a way I can swap out my transfer case to where I only have part time 4 or would that not be advised?As long as the suspension is good it'll be fine. You may have issues depending on the gearing getting moving initially with a load (I know some of them came with 3.55's but not sure what other ratio options were that year) but should be fine at speed. You'll want a drop hitch since they tend to be on the high side.
Definitely making me feel better, thank you. I’ll see if I can find that thread.Yes you should be able to easily swap for whatever the available part time case was that year and yes, I'm reasonably certain an A518/46RH would fit; it will bolt to the engine no problem (it's basically and A727 with lockup TC and OD). You would most likely need custom length driveshafts, as the mid-section is chunkier and might be longer (I'm not sure) or later ones from a truck that was built with a 518 might work. You'd need to check the tunnel to ensure trans clearance, need a custom mount and you'd need to wire up the lockup and OD, either with manual switches or there is a kit available to make it happen automatically. It was linked in a post somewhere in this forum not too long ago. That would be the easiest, keep in mind anything beyond that and you're going well into the realm of custom.