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If you can swing it and are going to install new engine oil cooler lines, install an engine oil bypass filter. I install a T in the return line brother engine oil cooler to supply the bypass filter and return to the engine oil fill neck

My old 1991 International 4700 is probably to far and probably needs too much work to consider. The best I can say is, it was running when parked

Looks normal to me

If somebody, not in the know reads this thread the battery bolt mod requires 3/8-16 thread bolts or Allen screws. If you use an Allen screw, it has to be flat on the ends. I like stainless or brass. I haven't had issues mixmatching those metals. I usually use grade 8 nuts on.a stainless Allen...

I never had an issue with the side posts. I run group 34/78 dt, Dual Terminals I've always used -1-1/4" long Allen screws for the battery bolt mod. Make sure the screws are flat ended. Pointy screws will strip.

Yes It's a fusible link. It's never a bad idea to upgrade the cables on about anything GM or any other manufacturer. They're all built to the minimum standard to save a bean or 3. Also upgrade the wire going to the load center.

I would try Hot Shot's Stiction eliminator

Have you checked the switch that dims the interior lights to see if the lights are turned down?

I went back to ACDELCO

On the Honda it definitely made a difference in oil dilution and oil consumption

I've had success with it in the Honda...

I ordered 2 or 3 sets of junk front wheel bearings from them. For the K1500s and K2500s. The best longevity was maybe 20,000 miles. After that when somebody was bragging a part up, I tried to remember to ask.how many miles, not how many years

Glad to hear you healed enough to grt back at things. Sounds like a fun project

I seem to have had good results with Hot Shot's Stiction eliminator I don't know if it helps, if it's just imagination or if it's just snake oil. https://www.amazon.com/gp/aw/d/B0053YFDNM?psc=1&ref=ppx_pop_mob_b_asin_title

Don't lose the studs. If you don't want extra. Sell them to somewhat does

Extensions. A thin wrench to get on the studs behind the nuts. Get the starter and brace while you're there. Slave cylinder. Get the whole clutch and flywheel. Be careful. Those transmissions are heavy. There's know way I could get one at a pick and pull by myself Is there an option of...

I use these cigarette lighter volt meters https://www.amazon.com/gp/aw/d/B01N00I4TM?psc=1&ref=ppx_pop_mob_b_asin_title

Yep. I got all 3 sets, years ago. I try to get a set of service manuals for everything. Picked this up 20 some years ago for, I think $2400. I don't remember. Might have been less. It had coolant in the oil. Turned out one of the freeze plugs on top of the head had a pencil lead sized...

Could the transfer case be in neutral?

I wouldn't rule out the PMD or resistor even though they're new. Where did you get your parts? There's also thevfuel fill cap and the optical sensor noise harness to investigate and rule out.