This has been an interesting read, although to be honest I did not read all 45 pages. Two years ago my local shop offered me a great deal on a RE1600 tack bar that they had ordered for a customer that never showed up with the cash. My first trip into the dirt was filled with all kinds of new clunking noises, when I finally stopped to look it was my new track bar banging on the diff. I took it back, they looked at it and acknowledged that they screwed up - they assumed because I was running 33's that I had 4" lift necessary for the RE track bar they sold me (I run 2" BDS springs with the supplied bump stops plus a 1" BL). Last year my DW returned, and my local alignment shop pointed out that my track bar was loose at the adjustment collar. I took it back over to the offroad shop, they tightened everything back up again, has been good ever since. I have a fairly noticeable groove in my stock D30 cover, but no clearance issues with the gears. Other than working it's way loose that one time, no other issues, and in fact it doesn't clunk any more now that it has clearanced itself. I just had the track bar out a couple of weeks ago when I temporarily swapped in another D30 - mine is going back in this weekend, and I plan to rebuild the heim joint on the track bar while I have it all apart. I'll take some pictures and post them after I get it all apart again.
My Jeep is driven daily, ~18k miles per year so I have roughly 30k on this set up. I also beat it on the rocks on occaision, and when running trails to perform trail maintenance I am frequently hitting "whoops" and berms hard enough to launch us out of our seats and sometimes catch air under the front axle....OK maybe 25-30mph down an ATV trail is a bit excessive I'll admit, but just reinforcing the fact that despite my significant diff cover contact, I have not had any significant issues. Maybe just luck?
Paul - 2005 Wrangler Unlimited