Sorry for taking so long to get back. It has been a long week already.....
Ill try and respond in line as best I can below.
[snip]One thing I notice about the basic design approach is bothering me a bit and that is how the wear of the urethane bushing face will be affected by the slotted mounting hole in the frame mount. TC's instructions say to dry install the bushings to the arms and then grease the ID and the steel insert with appropriate grease. This leads me to believe that the slip surfaces will be the bushing to insert interface and the bushing to frame mount interface. Basically the face of the bushing will be rotating against the slotted frame mount and I think that could be bad.
Another user, MXNDRINKS had a problem like this due to the angles or tension of the inboard mounting bolts which caused damage to the inboard bushings. Mxn, was this due to the tension in the mounts or the angularity?
Any pictures anywhere or post you could direct me to?
I looked through my pictures and I dont have any pictures to provide. What happened with me is my local Firestone couldnt align my truck if their life depended on it. The first time they aligned it my passenger wheel would rub on the UCA at full lock. When I had them do it again, you could visibly see that the UCA was tweaked towards the rear of the car and during suspension cycle, the arm would rub on the opening for the inner UCA mount. I think I had them try one more time with not much better success. So, I went through Total Chaos to find a local shop they recommended to do the alignment for me. They are the only shop I have do work on my rig now. Even though, I think I was the first 100 they had done the TC UCA's on, so we decided to set it up similar to the numbers they do on the Tundras. Everything was good from there on.
After about 9 months, I was trying to lubricate the inner bushings, and couldnt get grease into one of the zirks on the inner bushing. Then the Zirk broke off. So I pulled it (this was the passenger side that Firestone could get right) and the bushing face was all torn up. So, after 9 months of use I found myself having to rebuild my UCA's. I was not happy about it. When I pulled my drivers side it was fine. But, seeing I was rebuilding one... I just did both and a bearing repack, and replaced my lower ball joints at the same time. So, I think they can work with a proper alignment and proper maintenance.I do think there is a lot of room for improvement here though. I have not had any issues in 1-1.5 years now.....
Now I'm wondering if this will happen regardless due to the design of the inboard urethane bushing and hardware.
In the case of the Tacoma/4-runner UCA, the upper arm is not adjustable. Only the lower control arm is adjusted and therefore the upper frame mounts have just a hole, not a slot. On the 100 this is reversed so the lower pivots are fixed and the uppers are adjusted and for this reason the upper is slotted. It seems to me that this design that works great for the other platform may need to be re-engineered slightly for the 100. For example, perhaps a heavy washer should exist between the Urethane and the frame mount to protect the urethane against extreme misalignment or damage from the slot (this washer would need to be keyed to the steel insert so as to not rotate against the frame mount.
The stock design does not bear against the frame mounts because it is a cast rubber bushing and there is no slip, only shear deflection in the rubber.
Anybody know if JT's use the same approach as TC?
It's going to be interesting to see how these wear compared to the set on my Tacoma.
Any other thoughts or experiences? MUD? Mxndrinks?
Like I said above, I think there is a lot of room for improvement. The washer idea is a great start, But, I think the whole inner joint needs a long hard look at. I havent had many problems with squeaky UCA's... but for the last year I have been regulated to street driving only (soon to change). I know others that have complained about having to grease them multiple times on a trip. Once I get back out there, if I start having issues again, they will be pulled and I will go back to OEM unless some one comes up with a better solution that has less maintenance.
Hope this helps!