Thank you for your ideas. I agree there was nothing I changed to start all of this. It just started a couple months ago and has been getting worse and now is predictable to start at 50-55 after going over the slightest bump every time. There is nothing obviously loose but something is clearly wrong. My new track bar may not be compatible with my RC drop bracket... I'll post some detailed pictures of everything on Monday and post them here. Maybe I'll call Rough Country and get their track bar to go with the rest of the RC suspension to eliminate the track bar as a possible culprit?
"something has crept up. A fractured weld , an elongated hole, an undertorqued bolt on the track bar"
This could be the issue. We didnt look that deep or thoroughly into every bolt/hole yet. We have focused on eliminating the tire possiblity and looking for anything loose then replacing parts. As of today there is nothing obviously loose when doing the dry steering test.
Here is how to make a rough country track bar perform:
Replace the factory bushings before you install it , the are made in Mexico and are too soft and the sleeve is nearly tear shaped.
Sit them on the floor and build a wall around those little Mexican bushings. Don’t let them out , they will have your shop sheetrocked in about 2 hours.
Now go to o Reilly’s and get their oem replacements, they are about 17.99 each .
The rough country track bar is otherwise stout and has a good curve over the chunk , so it works well.
Going by your op, my guess to what has happened is something has worked loose or a weld is failing at the mount .
We have seen many cases where proper torque on a track bar bolt ended death wobble immediately....even if a mount hole is elongated , all you need is more holding strength than the pressure the front axle exerts on the track bar.
Most death wobble is a 2 week diagnosis and a 5 minute fix.
The track bar has a two fold job..to allow the axle to move (vertically) but not move (horizontally)....at least excessively.
Don’t be discouraged , it will be fixed.
We are not afraid of death wobble on here ...when we have the monthly cookouts at Chris’s house one of us always slips out front and loosens somebody’s front end pretty good...they may have a terrible wreck, but deep down inside they think it’s a good joke .