Mystery solved: The sway bar on this JK Rubi (and others) hits the front crossmember tube on both sides. When I saw that some time ago I used an angle grinder to take off enough of the tube on both sides to stop the rub. It took off just enough to stop the interference, but that was enough to let the sway bar slide to the right enough for the pitman arm to contact it at full left lock. The only way to stop this is to some way prevent the sway bar from sliding side to side, or to grind some of the bar away.
I went by the dealer this AM and looked at half a dozen new Rubis sitting on their lot. Sway bars on every one of the bastards hit the crossmember tube on both sides. More great Jeep engineering!
Last edited by SoK66; 09-11-2010 at 07:58 AM.