Something doesnt add up
Jyro,
Do you have a fuel pressure gauge?
I think we need to find out for sure what fuel psi you have before we can really go any farther. If you dont have one, and dont want to mount a permanent on in the cab. Get a test gauge. If nothing else, I will send you mine, as long as *I GET IT BACK*, assuming it will work with your schrader valve, and you can hook it up, tape it to your windshield and go for a good long cruise. Then, noting what you see for pressure at various throttle positions and rpm's, we can go from there.
It is possible, that you WILL hear your lift pump working, but not producing any pressure. This was the case when my pump went bad.
I was lucky enough to have an incab gauge to *watch* mine die in a matter of about 20 miles when it went. About 2 weeks before it offically died, I had noticed a 3# fluctuation in fuel pressure during normal operation. And, once in a while it would drop dramatically under any rpm's, like close to zero. All the while I could always hear the pump run before start up.
On a side note, a friend came to me last summer with a terrible miss and several puffs of smoke at about 2200 rpms. I drove the truck around awhile to note this myself. It had never quit on him, but the "stumble" was quite evident. Upon checking his lift pump, it never even ran while bumping the key, and he had less than zero (it actually drew a vacuum when we started it), but the truck still seemed to run and idle fine, with the exception of the high rpm stumble. FYI