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You may want to go 3/4 ton.
The GM 14 bolt 10.5 full float axle is a lot tougher than the old 8.5 inch semi float.
If you have a TH700 you don't have to have 3.73 gears. The first and second gear ratios in a TH700 are numerically higher than a TH400.
Best thing to do to make it greener is put a turbo on it. A big turbo, not the sorry factory excuse for a turbo only designed to get the new trucks off the dealer lot, because it sounds like you tow a lot and could be at higher elevation.
A turbo will increase fuel economy, power and reduce smoke output.
And if you have the engine apart get the heads machines for valve seals.
The exhaust valves on the 6.2 motors don't have any seals and the seals on the intakes I would barely even call them seals.
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1984 chevy suburban, custom made 6.5L diesel turbocharged with a Garrett T76 and Holset HE351VE, 22:1 compression 13psi of intercooled boost.
1989 firebird mostly stock. Aside from the 6-speed manual trans, corvette gen 5 front brakes, 1LE drive shaft, 4th Gen disc brake fbody rear end.
2011 leaf SL, white, portable 240v CHAdeMO, trailer hitch, new batt as of 2014.
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