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I sent you a PM on the wheels, I run 17" Dodge wheels on my uncut with BFG all terrains, the Explorer has been converted to 5x5.5" bolt pattern and runs 16" Dodge wheels with 265 75'16 Goodyear Duratracs. I'm thinking the back spacing is about 5" on both the 16" and 17" wheels.
I've done a few of the conversions and have a used a couple of different master cylinders, my current set up on my uncut Bronco has manual brakes with a newer dodge truck master cylinder. Currie has most of the other parts you'll need like re-drilled rotors, the spacer you'll need for correct...
As a Ford technician the best thing I can say about the 10R80 is to use a 6R80 instead, they're finally getting one of bigger issues with the 10R80 taken care of but it's taken Ford years to get that done.
The recall for the wiper slow down issue takes less than a half an hour to complete, I'm a Ford technician (36 years now) and to tell you the truth there really hasn't been any huge problems that I've seen, the seven speed noise is one but there are very few manuals out there and I'll blame that...
My mild rig, built to tow behind my Class A motor home. 32' tires, 4.56 gears, 5sp manual with a manual t-case, front and rear traction devices as well. I've done quite a bit of suspension work and the Dana 35 in the front has been converted to Dana 44 outers.
I mount quite a few tires at work (Ford Technician) and with a good machine it shouldn't be an issue but I've seen and had folks complain about the smallest little nicks that were already there. We had a guy a few weeks ago complain that we bent a wheel by dropping it while it was being mounted...
My thought as a Ford technician that it can void your warranty depending circumstances or dealerships, I've had both cause issues and no start conditions in various vehicles that ended up not being covered by Ford.