Opening a can of worms here but doesn't the rough country bar have a shape very much like the stock bar as it pertains to diff clearance?
It can be oversized if it's just a bigger bolt vs smaller bolt. You can't put the factory bar on a drilled out hole because it's a tapered rod end and without the taper seat there's nothing to seat against. It would at least ruin the grease boot and have no capability for misalignment, and might just pull the rod end out of it's socket.
If the hole is still small enough for a washer to seat against and have some meat to grab onto, it's fine.
If you have a Dana 44 with only 2 inches of lift, hate to break it to you but the Currie Rockjock front track bar will also cause massive interference on the front diff. How much bumpstop are you currently running?
Sorry for the late reply. I added 2 inches of bump stop on top of the welded Rubicon bump stop pad. I had 1.25" previously. It kept my tires out of the fenders, but the stock diff cover would come in contact with the TB at full stuff.
In that case, you're not too far off from what may be needed for the Currie Track bar. Not sure which ranchos you're running, but I'm using the 55239 up front which have 9.5 inches of travel. In order to run the Currie Rockjock trackbar I had to have 2.5 inches of bumpstop, which in conjunction with the Rubicon welded bumpstop is a total of 2 and 7/8ths bumpstop. This resulted in me losing the 1.5 inches of travel, and being at the stock 8 inches of travel despite a 3.5 inch lift. It works but it wasn't ideal. I tried bending the track bar to get more clearance, it was a pain since it's chromoly. I also ended up cutting the gusset clean off along the way...
The best solution would have been if I kept the lift at 2 inches and used stock bar, or I went to a 4 inch lift/and or adjustable control arms. The taller lift would require me to run longer shocks which would fully compress before trackbar interference. The control arms would have allowed be to dial things in better and get the axle further back.
Neither the Currie/RockJock track bar and steering require 2" of bump stop extension. Mine never did.
According to my results from cycling before drilling the mounts it seemed I needed a minimum of 2 inches of bumpstop. After bending the bar I was able to get it down to 1.75. Then after drilling the mounts I needed 2.5 (on top of the welded pad). The only thing I can think of is when I bent the bar it somehow made clearance worse. Either that or my front axle wasn't centered properly during cycling, but I tried almost every adjustment point within reason.
There must be some variation in the manufacturing process of our Jeeps.
Yes. This is why, when you get adjustable control arms, we'll tell you not to waste your time setting the arms on both sides to identical lengths. You set one side and adjust the other side to fit. If you measure them after the fact it's not at all uncommon to have them different by 1/4".
Agree.
On the other hand, most of our Jeeps run the first decade or two of their lives with identical length OEM control arms.
Things that make you say "Hmmmmmm?".
Agree.
On the other hand, most of our Jeeps run the first decade or two of their lives with identical length OEM control arms.
Things that make you say "Hmmmmmm?".
Agree.
On the other hand, most of our Jeeps run the first decade or two of their lives with identical length OEM control arms.
Things that make you say "Hmmmmmm?".
Hey, when you get $4,000 per inch then it really gets expensive, I have 5.5 up and 6 down with the lj and the rs5000x shocks. Look at new upper mounts for the front and outboard the rears.