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GM seems to have similar issues with their Direct Injection gas engines.

The Evap core is in that corner, not sure where the drain is, I remember seeing water spots on the top of the muffler heat shield when I upgraded the exhaust.

Please see enclosed:

The first set could have been damaged while being shipped if the car was strapped down by the control arms. Second set, improper install techniques, the manual is full of warnings regarding this. Yes you should be able to have the parts shipped to you.

I would contact the Speed/Performance shops and ask for installer recommendations.

Did you contact repair or FORD Performance/Speed shops?

My first tire change on my F150 went with the same, last month thought I would try something different, I hate driving it now, wish I had just went with the same old. Not sure with to do next.

My first thought was an exhaust or intake leak, did not sound like a mechanical issue.

I placed my 23ST into brake service mode using Forsan and could not return to normal mode using Forscan, the Above procedure will not work with newer Explorers, the procedure below worked. This happened about 6 months ago, hopefully Forscan has been upgraded.

Bad AWD module ground?

Guess I'll add that to my monthly inspection routine.

Thanks, was just wondering if I needed to stand behind it and remote start in order to check for smoke.

Can any of this smoke been seen while sitting inside using the rear view mirrors?

Try Googling "dc motor brush dust", we have the very same issue with DC motors at work, the brush dust shorts out the commutator, sometimes the dust causes arching and blows fuses. If you catch it in time the motor can be cleaned and reused.

Tried Leftover in several different languishes none sounded just right. 23' was a good year, Ford corrected most of the issues, I installed a diff brace just because. Good looking ST, congratulations.

you could try this: https://www.explorerst.org/threads/keyfob-has-extra-flexible-pcb-between-battery-and-contacts.7031/ EDIT: Or an OBD II Port Lock https://www.amazon.com/Connector-Prevents-Vehicles-Computer-Material/dp/B0BTW92ZPS

What type of oil do you use?

Not sure if the Dealer can do anything unless they can find a trouble code. https://static.nhtsa.gov/odi/tsbs/2023/MC-10240240-0001.pdf https://www.explorerst.org/attachments/ford-tsb-23-2061-pdf.21518/

What type of oil are you using? I found that synthetic blend leads to a smoother cold start up, at least with my ST.

Welcome, You picked a good one, nothing was deleted like my 23'.