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PSR use there own Balljoints, however some people say that you can grind the OD of the OEM balljoints to make them fit

Couple of notes, with your Allison trans, id assume its in a Light or Medium Truck, if so they have retained alot of serviceability due to their use scenarios. And as for ATF being "bright red", not always the case, and not always an appropriate manner in which to gauge fluid quality

Unfortunately (I think) ZF also pioneered the "Lifetime Fill" method for transmissions. Basically saying dont touch it, if it ain't broke.

From memory, the only patrol box that was the same, was fitted to the RD28. So likely you'll have to swap box aswell to the larger FS5R50? found on Other patrol motors

From what I've seen, browsing wreckers, google and parts websites, NO D22 ever came with a pollen filter. If @Tecah has a pollen filter i would also greatly appreciate a photo. As for damp sweaty socks, likely you've got a bit of mold or mildew in the AC box, theyre easy enough to pull out...

Not uncommon for early VP pumps to give up the ghost randomly. The VP is not a great pump to play around with, but if you narrow it down to that, call a Bosch injection specialist for unfo and diag

Depending on your geographical location you may not even be able to do it from a legal standpoint, due to the engines complying with different emissions. General rule of thumb is, newer motor, older car. Cant do older motor, newer car

This wont work with a ZD D22 as they dont run OBD @Estoricnomad

You won't be able tondue to the different Emssions regulations of the motors

I have seen people install R32/33? calipers on the front, they're a 4pot fixed caliper so some work needs to be done to fit. But with the extra clamping force thay do pull up very quickly. I however would not modify brakes on a vehicle with ABS or TCS as it can cause issues due to different...