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I used Permatex Red on my 8.25 diff and it leaked. Switched to Permatex Copper, and no leaks yet. Changed fluids a month ago. I did the exact same install and prep procedures for both. I will only buy the copper RTV from now on. A buck or two is worth it to me.
I just replaced my evap core Memorial Day weekend on my 2001. It took about 7 hours total. Got the evap from Murray's for about $150.00. I got it apart and noticed the heater core was leaking a little bit - it had some corrosion near the top, so it was not caused by condensation in the heater...
I have on '01 and had the same problem. I replaced all the U joints a couple a weeks ago and put a nice coating of wheel bearing grease on the slip joint that comes out of the transfer case. That took care of all my "clunking" issues.