should I go ahead and try the adjustment procedure or just put a new one on? I have the $$$ for a new one, just don't want to part with it.

Also I am curious if I happen to tighten this box up, what stress will that put on the pump? any issues with the pump when installing a new box?

recommendations for fluid? I might as well change the fluid while it's off. I was thinking Royal Purple, but the manual simply says Chrysler power steering fluid.

Adjustment procedure is free, aside from the fluid.... so, it won't hurt to give it a shot. Flushing out the system, and putting in new fluid isn't a bad plan either. There are no other issues with this adjustment. (or a new box for that matter....) Don't waste the money on synthetic fluid. It isn't worth it. (IMHO)

If you aren't happy with it after the adjustment, go for the new box.

is it easier to take the fan shroud off or dont bother with it?

I didn't. But, I only did the one adjustment. (there are actually two, to do it 'right'....) Procedure is outlined in the service manual. (which you can download for free from the faq section.) They want ya to take the box off the truck though. This is something I had in mind for some time this summer......

The reman boxes are a waste of $$, been there/done that

Just talked to Rick at Red Head Steering Gears and ordered my new gear. Cost

gear $286
Core $125
ship $32

and they pay for shipping your core back, at which point they will refund the core charge.

Part# 2869
for a 98 ram 4x4 2500 5.9l 8800 gvw

I didn't think this was too unreasonable seeing how the reman boxes are $150 plus core

He also said they use synthetic fluid to test their gears

anyone know of any ill-effects on the rest of the power steering system by switching to synthetic?

Just flush out the rest of the system really well, and you should be fine.

any suggestions on what to flush it out with? chemical cleaner, power steering fluid?

Power steering fluid.