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What I have:
03 explorer housing and back cover

2 MK VIII knuckles

31 spline Torsen T2 (OEM) I've been told it won't work with IRS)

What is coming:
2 03 Cobra hubs

Tbird half shaft

03 Cobra half shaft and extra 03 diff side (31 spline) stub/CVJoint

Currie Johnny joint is a spherical bearing which is rebuild able, they have one version that the outer shell is 2" diameter 1.5" width and the trunion is 2". this appears to be a pres in fit for the knuckle bushings and would considerably cut friction/bind they are $37 ea but if a GB might be able to knock price down a bit.

What I'm trying to find out:
Will My T2 fit an IRS housing

What are the differences between the Cobra 28 & 31 spline Tbird/MK VIII and Explorer half shafts?

The best/cheapest way to put big brakes on the Tbird/MK VIII knuckles

How good/bad an idea is using ABS on this light a car

Flange to flange width of 03 Explorer, 03 Cobra, and Tbird/Mk VIII, The Explorer is 48" inside of tire to inside of tire.

What I'm working on:
I'm talking with a shop that builds half shafts that has stopped breaking shafts & stubs for drag 03 Cobras. He will get a set of Explorer half shafts in the next week and should have some answers on differences. He has different length of shafts in stock they cost 99 and moved the breakage to the outer CV stub shaft. he has a heavier level that replaces the outer stub and hub assy with 35 spline that appears to have moved the breakage to the tie rod on 03 Cobras. I'm working up a cost for a 28 spline that fits Cobra/Tbird/Mk VIII hubs and Explorer 31 spline diff.

I have found a source for reasonably priced Explorer diffs and rear covers.

What seems to be the best mix:
Tbird/MK VIII knuckles
Currie Johnny rebuildable joints instead of bushings
03 Cobra hubs
Cobra rear brakes
Cobra/Super Coupe/MK VIII diff housing (allows 2 front mounts and has mounts for 4 channel ABS)
03 Explorer rear cover (better mounting)
Rock Krawler .75 shank rebuildable suspension joints
Stock Car Products threaded steel tie rods to build A arms

I will pass on info as I get it and would appreciate any comments.