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IIRC, the stock exhaust piping is 2-1/4". Regarding which muffler it's always a personal preference.

Factory V8 not available for 2001-05 first gen. https://en.wikipedia.org/wiki/Ford_Explorer_Sport_Trac

Looks great Todd. What treatment did you use? I've been using Stoner Trim Shine aerosol spray for years with great results although it must be reapplied every couple of months depending on how much it rains. I stock up when it's on sale for around $5 a can...

Cool. Just by replacing body mounts, sway bar, and end link bushings should make it feel and handle like a "new" ride. Congrats!

Five hours isn't bad for the driver side if you replaced A thru D and have any corrosion. Rearmost bed bushings can be a real PITA to separate with those internal locking tabs. Hardest part for me was getting the parking brake cable out of the way. Got it slack, but couldn't get it the cable...

I've heard nothing but praise for K-Seal coolant sealer, even from tech gurus that usually frown upon any type of "fixes in a bottle". Even heard reports of it permanently fixing head gasket leaks. Definitely a last resort for me, but I'd try it before pulling an engine.

If you used aftermarket lower control arms such as Moog or Raybestos, improper indexing or a loose fitting t-bar "hex" may have contributed to slightly lowered ride height. See both links in post. https://www.explorerforum.com/forums/threads/replace-torsion-bar.475840/post-3729593

Sounds like the tailgate trim "tabs" are not replaceable. Nothing new. Door panels, bumper pads, etc. Personally, I prefer E-6000 glue. Best adhesive I've ever used, and I've tried most. https://www.explorerforum.com/forums/threads/tailgate-emblem-and-tailgate-top-molding-replace.404176/

Also do this. One time and it's done. Thanks. Add or Change Vehicle Details

Just keep in mind camber and toe change when the torsion bolts are adjusted. Reputable alignment shops are difficult to find (at least in Hawaii) and usually well over $100 for a recommended rear thrust alignment. Also check ALL your body mounts if you haven't yet.

First gen 2001-05? Is the tire rubbing the fender liner, sway bar, or both? Alignment checked? If Gen 1 it's not real common, but I'd guess a weakened drivers side torsion bar or misaligned torsion screw in the key dimple. Were the screws ever adjusted for ride height? Shocks will have little or...

It was fine.... until making a turn. LOL Entering inclined driveways with lot's of cab flex were the worst.

Well done. What did you end up torquing the bolts at? Agree, there's nothing worse than metal to metal noises. Brake pad rivets on rotors come to mind. Can you imagine me driving with these "flared" cab bushings over a year? Yes, that flare was caused by rubbing the cab sheet metal...

That's correct. Washers under the bolt heads. IIRC, no factory torque spec was given for the upper bolts. Uppers are threaded into extruded u-nuts similar to the frame bushing brackets that rarely come loose. There was a TSB for new design end links and the torque spec was increased to 55-59...

VERY likely the fuel pressure sensor. Check the Bosch FPS in post #20 from the thread below. https://sporttrac.org/threads/shifting-problems.122714/

@blert Did some research re: Prothane 6116 body mounts. I believe the torque confusion comes from the Daystar vs. Prothane instructions. Daystar specifies 45 ft/lbs. for the cab mounts. Pretty vague, and no mention of "A" bushings torque...

Press is the best way. Too much chance for damage with a chisel or saw. Remember to use the supplied lube. BTW, the blue Moog bushings are garbage thermoplastic rubber just like their old style front end link grommets. Polyurethane FTW.

Sleeves must be removed for ES bushings.

Attn OP- Apologies for hijacking/derailing this thread. Just wanted to share this and will delete if requested. Recently I was behind a black, but identical MB AMG C63S hot rod being driven by a young and very inexperienced driver that was 100% throttle and sideways after every stop. Worse yet...

^ Eddie, OP's first sentence. : ) BTW, nice blue pony.