IRO caster adjuster
 

Purchased an IRO 5.5 critical path system complete and did the install the other day. Parts are very solid and beefy, but I plan on welding it in also (crossmember). I am having some troubles with it though. First issue was the front driveshaft not clearing the crossmember. Turns out Jeep used a different trans mount after 99 that was centered differently, after finding this out and swapping in a new mount from an older year its clears fine. Now th eproblem is the caster adjuster is hitting the front diff, anybody else having any issues like this? The bushing is brand new btw, replaced it while the axle was loose.

So after looking closer at mine, it looks like it has worn on my new d30... Same location as yours. Looked at the last one (both from 99s) and it had no marks whatsoever. I can't find anything different between the two or the setup.. Makes no sense to me lol.

My advice is take an angle grinder to the ear a little bit so it wont rub. Doesnt look like you need to grind too much.

Problem is that pic is when it's sitting on flat ground in the shop, I know it moves a little when you flex and or hit bumps, so I'm afraid grinding will only help while it's static

Honestly considering cutting the upper link off the arm, and making it adjustable and ditching the adjuster altogether.

That is pretty much the solution I've come up with too.. Putting a Johnny joint and 1/2 inch bolt in at the same time... Only thing that has me perplexed is I can't figure out why it was fine one the last one but not on this one... The arm isn't bent or anything... Brand new bushing... Unless the old bushing was different?

Ya lost me man, what was fine on the last one? The IRO stuff is brand new, wasn't on the last one. The front diff came from the last one, but the IRO is new and the busing is new.