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I don't think you should view these trucks as any different than any other 25 year old car when it come to repairs and maintenance. As with any 25 year old car that has seen hard life it will need a lot of attention. Would you be willing to own a 25 year old car and expect it to be reliable as a...
The fusible link protect the wiring. The links are usually sized one wire size smaller than the wire it is protecting. So, if you are using 8awg then the link should be 10 awg. I think that you over sized your wiring though. Size the link off of the original if you are concerned.
If you are using a fuse that is your problem, you need a fusible link. The correct fuse size would be over 100 amps. They are not the same. Get the right link or just delete it completely.
Well, when you let the magic smoke out it usually won't work any more.
It sounds like a bad connection- since it worked before. I would disconnect everything you did, wire brush or clean the connections, make sure the wire is in good condition - not coming apart at the lugs. Check the grounds...
You may have fixed the charging problem with the work you have done, but the 20v on the rear battery is a problem. I suggest charging the rear batter for a while and see if it works.
Glow plugs operate like a light bulb that gets very bright, so like lights they sometimes can just burn out for no reason - nothing wrong. The problem with the way the stock wiring to the plugs is done is that if you lose one plug, either it burns out or bad connection at the plug, the voltage...
Can you point me to the where in the TM it says to "Pull a few out and look at them" at the glow plugs when troubleshooting? Don't waste your time looking at them- that is not how you troubleshoot glow plugs. You need to start actually troubleshooting. There have been many good suggestions...
What does this mean? Starting fluid? If so you most likely still have a glow plug problem- even though you said you did all of the tests.
What is the voltage on the plugs when the key is first turned and the wait light is still on?
I'll take a guess, before the wait light goes out, if you measure 12V at the glow plug side of the resistor then the resister, relay, and glow plugs are working.
If the lights used to work before you changed the bulbs, you probably have a bad connection or ground. Now for your brights, it could just be a bad bulb- or bad connection. The sockets that connect to the bulbs are 25 years old and prone to corrosion. Turn your lights on and wiggle each...