O77 your truck sounds really good, BUT when your at cruise speed (2200-2500RPM) what is the tone like? That is the part that give me the head aches.
As for pipe size ide say more then likely I am going to go with 2.25" since that is what is recommended for the Vortec 5.7.
I know there is a difference in sound from a fuel injected exhaust as compared to a carbeurated exhaust system.
If I go with Glass packs then more then likely I am going to be looking at somewhere inbetween 18-24" packs, HOPEFULLY that wont be excessivly loud.
As for the torque bar being the cause for busted Transfer cases. WELLLLLL that is kind of iffy in my opinion, USUALLY there are 2 main causes for this poor oiling system (low fluid or broken pump), also is pure abuse, rocking back and fourth forwards and backwards.
C4 Ide love to hear a clip of your truck.