"Granted the will save is factoring in that the Rangers push forward against all odds, I could easily substitute this with iron will and be done with it."
Just about any warrior can easily be said to "Push against all odds." I don't think there's anything about being a woodsman that makes you more likely to be strong willed than a soldier, or a holy warrior, but using Iron Will is deifnitey better than giving them a good Will save.
Kyramus: As I said in the post above. Changing the better will save to iron will is doable.
"Unarmed fighting vs Animal friendship. By level 10 the ranger's animal friendship total is 10 HD. let's see. What's the difference?"
The difference is that first of all, a 10th level ranger only gets 5HD worth of animal companions... And being able to make FOUR attacks for 1d10+STR damage at will is a lot more powerful than that.
Kyramus: from the SRD "At most, the character can have animal friends whose Hit Dice total no more than twice the character’s caster level (though the demands of adventuring generally restrict a character to half that number)." Which means a 10th level ranger cann have 10hd. his casting level is 5. twice that is 10. Let's see Dire Lion is 8hd. it has 3 attacks with a possible pounce and rake. claws do 1d6+7, bite does 1d8+3 and rakes do 1d6+3. the claws have +12 to hit, the bite has +5. If the bite hits it gets to rake.
at 10th level unarmed fighting we have...+10/+7/+4/+1 to hit with damage of 1d10 +str bonus.
tiger does 4 attacks (assuming bite hits) damage for 2d6+14, 1d8+3, 1d6+3 and has it's own hp and can flank a target with the ranger. avg damage is 37.
VS this ranger who can hit a possible 4 times, though the last 2 are harder to connect and a damage of 4d10 + str(assume a +2). avg damage is 32.
Who's repalcing spellcasting and Ambidex/TWF with Unarmed Fighting? You're replacing Ambidex/TWF with Flurry of Blows, Improved Unarmed Strike, and one other feat (forgot the name, lets you stay conscious longer.)
Kyramus: if you mean determined soul. that was a feat they can take, not a bonus feat. it requires them to take toughness as well.
That means you're replacing the potential spellcasting ability with a better Will save, more skill points, an extra feat (since it only takes two to make up for Ambidex/TWF, although it's a stretch to say those are actually worth anything), and an absurdly powerful (Fighter BAB, monk iterative attack progression and damage die, lets you wear armor) unarmed combat ability.
There's not even a semblance of balance... And it's not going to get better as long as you insist on giving one core class the unique ability of another.