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Did you use a GPS for that speed reading? When you start swapping parts, things get missed. There is a plastic gear in the transfer case that is specific to tires size, diff ratio, etc. That is a whole different topic.

The 218 uses a u-joint at the rear, the 242 uses a slip yoke. So shortening won't fork.

Is the tranny you may buy from a humvee? or at least an H1? I would check into if the torque converter needs to be for your truck. I don't know for sure.

On the back of the transfer case is a round metal tag with red around it. There is a build date on that. It is next to the plug with two wires in it. Can you post a pic of that?

It is better than the 218 that comes with the old 3-speed. The 242 has two cooling line ports on the front of it. A revised version will have a blue band on one or both of those tubes. That is the preferred one to find. The non-banded one had some issues with leaking the cooling fluid into...

Are you going to install a 242 transfer case with it?

The crossmember is replaced with the one made for the 4l80e. Propshafts do not need to be made. You just buy the correct ones.