I will admit I haven't read this thread in detail today, but have been following it since it started... don't recall if the existing axle gear ratio is known or not, but I have extensive backround in '73-'87 chevys. A 2wd dually often came with 4.56 gears, and for good reason. Even with the granny low in the stock (T-10, I believe) truck 4 speed manual trans, you needed low gears when towing and hauling. No top speed, but without the ability to drop into low range like a 4X4 would have, they made up for it with low axle gears.
OP, check yer gears... if you have 4.10's or (ouch) 3.73's, you might just be geared too tall. If you have the GM 14 bolt axle, it's an easy swap if you find a complete donor axle, can be done in an hour with basic hand tools. And you don't even have to jack up the truck to do it.
Where are you in PA? Be willing to help if you're close enough and want to stop by...