Will do... I also got a PM from another member that had the same issue... sounds like you are right on track. Haven't got a call back from FT, but in the mean time, I did call David over at Northridge and he gave me additional input as to how to get the thing aligned and tightened properly. I'm gonna take the ball end off and tighten the crap out of the jam nut, then put it back in... that sounds like it'll take care of it.

 

While step #38 of my write-up indicates that you should "tightening the jam nut against the track bar arm finger tight." This is only done so that you can make additional adjustments with ease prior to securing everything in place. Now, if you read my instructions carefully, you will have see that in step #41, I specifically state that you should "Use a crescent wrench to secure the rod end jam nut in place..." With the track bar secured to the frame mount, you should be able to get a lot of leverage to tighten up this jam nut and it really shouldn't come loose. At least, mine hasn't in the almost 9,000 miles I have put on my Jeep and a majority of those have been playing hard on the rocks.

 

Correct... this is what FT said as well. Thanks for the replies...

 

Just some concluding remarks... Dropped the track bar down and tightened the $hit out of it. Worked out beautifully. It was kind of bound up in there, so it took some work to get it out, but did get it out and now it's tight. I also adjusted the track bar a little... had a little extra tire sticking out on the passenger side. Of course after I did that, the steering wheel was cocked over to one side when the wheels were straight. Needless to say when I test drove it and went around a [very] slight bend at 30mph the computer thought I was driving like a mad man and turned on the traction control ... so as was stated in many prior posts, make sure your steering wheel is straight... went back and straightened it up and presto... worked beautifully. No more noise, everything is great!

Thanks again for all the replies!