I rebuilt my ZF on my 1990 last winter. I bought some of my bearings from Napa and bought the rest of the bearings and synchro rings from a local driveline shop that sells actual ZF parts. I notice that you can get parts from broncograveyard on the net and even on ebay you can find complete overhaul kits that include the synchros. As far as seals frost plugs shifter bushings and gaskets i just went to the local Ford dealership. All parts in total came to around $400. Since I had to change the rear housing (where the transfercase bolts to) I had to dink around with shims to come up with correct bearing preload. But I'm assuming you are going to be using your original cases, so you may not need to have to change your shims, it should be really close. As far as jigs, i did it on a clean part of the garage floor on top of a large piece of cardboard. You will need a tiny set of heel bars to pull the bearing races out of the blind holes (the biggest pain) unless you have the propper puller on a slide hammer. The only puller around that was small enough, that I can find, was from snap-on. But I wasn't prepared to buy a tool that was going to cost more then my trans overhaul. And if you are going to adjust bearing preload, you need a dial indicator with an attachment that allows you to use the indicator at right angles. Because you have to go in through your PTO port to measure your countershaft endplay you need this attachment. For the input shaft/mainshaft you can use the dial indicator in the regular old fashioned way. A set of torches is nice to have to slighty heat up the synchro bodies to remove them from the shaft becase they are a press fit and I borrowed a bearing heater from work to install them. Don't use silicon on assembly of the two case halves, use an anerobic sealant, its almost like a gel that dries in absence of air. You do not want strings of silicon flipping around in your fresh trans !! The most important tool is the workshop manual. I'm lucky that both of the trucks I had prchased used came with a full set of factory manuals from the original owners. So this should be enough information to get you started. When you get into it, if you do, just keep this post going so we can help you along ! Good Luck.
Side note- I re-read my manual, and for some reason I thought we needed endplay for the shafts on this trans. It turns out you need to measure the endplay (no shims behind the bearing races) then claculate the number of shims required to obtain 0.00079"- 0.00434" preload.
