Yep. I always torque my suspension pieces including the track bars with the Jeep sitting on all four tires on flat ground. When I put all the pieces together I used white lithium grease on the frame end of the bar and some anti-seize on the axle end threads. I use the same white lithium grease when I take it off to re-grease it when it starts popping. I was pretty sure I did everything correctly, and after looking at your article I know I did. I wish I knew something else that would fix it so I could just keep it.

 

Yes I think you are correct. I remember the steel sleeve being narrower than the width of the bushings, so the clamping force is pretty much all on the bushings. I wonder if my sleeve was cut too short, or if the end of the track bar was too wide, which would make the sleeve too short for the installed width of the bushings?

 

Well that would explain a lot and I bet if you could just get your hands on a sleeve that is the correct lenght or just a hair longer, your problem would go away. If you are willing to pull your track bar and get an exact measurement of the sleeve, please let me know what it is. I have a bunch of extra parts laying around and if I can find one that is a bit longer, I would be more than happy to send it to you for free.

 

Thanks for the help! I had no idea the sleeve was supposed to be marginally wider than the installed width of the bushings. I'll be pulling it off this week because it started popping again last week. I'll PM you the width of the sleeve and the installed bushing width. Thanks again!

 

Yeah, give all your factory components a look and you will notice that the sleeves on them protrude ever so slightly out beyond the rubber bushings. In fact, I would be willing to bet that even if the length of your sleeve was exactly the same width as your bushings, you would not be having any problems. The fact that it's shorter is reason enough for me to suspect that it is the source of your popping.

I'll start digging around for my spare parts and see what I come up with

 

Wow, cant get service like that just anywhere!