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First, armies are limited to 16 units and/or 960 men, but in the battles they can use 16 units regardless of the total man count. Is there a way to get rid of or modify the 960 man-per-army cap?
Yes, there is. You can make the stack take 120x16=1920 men(huge units stack).
Look here:Increase number of men in stack

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Second, I have lost the tech tree mini-poster that came with MTW. Does the VI Xpac have another one? If not, are there scans of one that I can download and print out or something? I already have the Yas utility, but I'd like a hardcopy.
VI xpack only have the tech-tree for VI add on, as a PDF-file. However, I thnk you will find the MTW tech-tree in the file-vault of the ORG:FAQ's and Documents downloads

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Third, I have found the crusaders_unit_prod11.txt file. For several columns the author of the text file makes reference to a "unit def and summary file" and recommends any changes be made in them, as the data in the unit_prod file links to those other two files.
a) I can't find either a "unit_def" or "unit_summary" file. Where are they?
b) Which file is the one I need to change in order to change unit stats and such?
Don't bother with those "unit_*" files, it's in the crusaders_unit_prod11.txt file that you change stats. You can do this in WordPad, but I do recommend that you use the Gnome editor to avoid problems.
Dowload Gnome from: Tools Downloads