Hopefully, we found the cause of my DW. I asked my mechanic friend if I could come over to his shop after work and go through it all with me present and helping. So he and I went back thru stuff and here is a break down of what we found.
We had found a clunk in my steering when doing the wheel back and forth exercise and found that my drag links needed replaced which we have done.
We did not notice any movement in the track bar during that exercise and the bolts were really torqued down. However, when we removed it we did find the frame end bracket holes to be rounded out. Not drastically but definitely could tell it. The axle end bracket bolt holes appeared to be ok. If they are rounded any, it is very, very slight...to the point of not being able to see it with the naked eye.
Tie rod ends seemed to be good.
Ball joints did not show any movement/play in them.
Bearings and other components at the wheels appeared to be in good shape as well.
Wheels have been rotated and balanced along with an alignment.
We did notice what seemed to be some very, very slight movement in the sector shaft when turning hard, but it was almost not even noticeable.
Hard to believe that the front track bar bolts holes being a little off while still having the front track bar bolts torqued down can cause or allow so much movement. But when you think about the fact that the front track bar is the only thing holding the body and frame with the weight of the engine right over it centered over the axle and the forces it has to counteract, I guess it makes sense.
So, I went ahead and ordered the synergy track bar frame brace, sector shaft brace, track bar and steering stabilizer HD relocation bracket. I went with the synergy HD steering stabilizer relocation bracket because it mounts in similar fashion to the Teraflex track bar gusset plate and it would also relocate my steering stabilizer as well. Synergy also provides the bolts to mount it. Teraflex just provides the plate. I also went ahead with the Synergy track bar because I figured if my RK track bar ends up not working with the braces, I'll have it right there on hand rather having to wait again on parts. Surely, I will be able to sell one or the other once we get everything figured out.
Parts came in last night and I got them dropped off to my mechanic friend first thing this morning. Hopefully, I will know something by tonight. Keeping my fingers crossed, hoping and praying.