It's finally 100% ready to leave now. It's not done, but it's as ready as we can make it for small a trip this weekend. The wheel bearings were good & repacked, have 2 new seals in place & a spare set of bearings & an extra seal as well, just in case.
About that problem with the marker lights, I can't believe I missed it. The symptoms, erratic & strange marker lights, blinking, not running at all, one side not working, then the other (it was screaming at me the whole time). The tail lights were fine & working as they should have. They both feed from the same wire up front at the truck. I finally looked into it tonight after I got the trailer home from work. Powered up the markers from the back where they meet with my test battery & they were fine. I tried from the front junction box & they were not running. I thumped on the tongue box & then they came on. I thumped again & they went out. What the h... is wrong now? Finally stopped & ate dinner. CLICK!
I had tied everything together at the PD4045 & grounded everything to the battery in the rear (solar panel, cabin lights, galley, marker lights, etc). The front box was grounded from the harness & truck with a bolt & a wire the box is welded to the frame. What I had forgotten to do was connect the front ground from the truck to the power panel ground buss in the rear in the PD4045, & then tie the whole system together at the back as well as the front! Since the marker lights were sharing a ground in the back with the battery, they had no connection to the front where the source for the lights came from (the ground from the truck was missing at the back). I had provided a + side to them, but not the - to make them work. When I tested, them I was supplying power to both the hot & the ground from the back, so they worked fine when tested.
Ah well, we always get it right eventually! Fortunately it only took a couple of hours to find (?????). Ready to leave now on Thursday. Will report back next week with some new pictures & a few tales to tell.