glad that's a step towards improving life behind the wheel.

I know how much those can suck to line up sometimes.

 

how's the frame/subframe rust condition looking? I've seen a few posts over the years of subframe welds breaking/splitting.
I've also seen recently one truck that pulled the mounting plates off of the Idler arm tower on the RH frame rail


Wondering if you have something more major going on? Fingers are crossed that you don't have major frame issues

 

A couple things came to mind while reading thru this. First wheel bearings- You really seem to be doing them way too often Maybe a Moly 3% is in order. In the wayback machine Ford was one of the first to recommend Special Hi temp Grease. I like Tetrimoly for that.
Next is Other things related to your "Feel". As in you comment about the cab moving around- Looked at cab mounts closely? No play in the steering wheel and dancing through potholes you should feel in your hands as much as your butt unless the truck is changing directions a foot at a time or more. Rear leaf springs? Broken spring, loose U Bolts, Missing leaf centering pins, rear bushings. A little movement in the back is alot in the front six feet away. Older I get harder it is to localize a noise. At 60 with windows down heard it loud and clear,just didn't find it on first try. Good luck and keep us posted what you find.

 

This is my go-to grease:

https://www.amsoil.com/p/synthetic-m...se-nlgi-2-glc/

 

Valid points, Leaf bushings are often overlooked