Short version: Does a poor alignment cause stress on other components like the track bar?
Ok, here's the longer version that involves my 2009 JKUR and please bear with me, as I'm trying to do some investigative work to determine the failure point. Ever since it was stock and when I took it in for an alignment, all of the shops that I have taken it to have never been able to get my passenger side in alignment (the amount of caster has never fallen into specs). Which lead to some death wobble but nothing I couldn't live with at first.
-After a lift and a couple of years later, I looked at the track bar mount on the frame and noticed the hole had wallowed out. So I added the brace from Synergy and that worked really well for a couple of years.
-Fast forward and one day in the parking lot I hear metal on metal and come to find out that the Synergy track bar bracket was moving back and forth as I turned the wheel lock to lock. So I had a shop weld on the bracket to the axle tube and all is well for about a year
-I then go wheeling yesterday and while driving on a dirt road, my steering wheel turns 90 degrees but I'm still driving straight. Get out and take a look and find that almost the entire trackbar mount has been ripped off. The welds from the shop still held, it was the mount itself that failed. Where it didn't fail, it was cracked and the cracks look like they've been there a while.
From what I can figure, it seems that the failure points started on the track bar mount on the frame, then to the axle mount and then the mount/bracket itself failed. So the question then is, if the UCA and LCA mounts on the passenger side are off (either bent or welded incorrectly at the factory) would that cause that kind of stress over time? and if so, would it be better to have them cut off, re-welded on or just say screw it and get a new housing?