These are my notes on my RE1600 track bar hitting an aftermarket Dana 44 differential cover on our ’97 Wrangler with a 3.5″ suspension lift. I originally started this as a post on a forum-style website, asking for some advice on how to diagnose and resolve this issue. But I decided to keep my detailed notes here instead for follow up. I think the trackbar issue is the only thing left unresolved from my “initial wave” of working through issues after purchasing this Jeep.
I have a Rubicon Express RE1600 adjustable track bar on my 97 Wrangler with a 3.5″ lift (RE7003) that supposedly “works on vehicles with 3.5″ – 4.5″ of lift” (https://www.quadratec.com/products/16311_602_07.htm). However, my Wrangler appears to be making contact between this track bar and my aftermarket front aluminum differential cover (Part number: 40-2033AL). This was first pointed out to me by a user on the forum website. The axle is also a Dana 44 that came off a 2004 Rubicon, which might change the geometry a little too.
I’d be willing to buy/install a new track bar, but I’m hesitant to do so since the track bar is “supposed” to be OK (not hit the diff cover). I’m guessing that the aftermarket G2 cover is a little thicker and just enough to “stick out” and make contact under certain conditions. I’m not sure how often (or “how bad”) this is occurring. I can just see the scuff mark where the track bar has made contact with the diff cover at some point.
My initial impression is that contact between these two parts is probably not occurring often and likely not impacting hard enough to cause functional issues. But I don’t want to regret dismissing this issue. I also don’t want to buy parts that have the same specifications. To help monitor things, I’ll probably “mark” the trackbar somehow to help determine if/when the track bar makes contact (leaving ink/paint transfer on the differential cover).
Recommendations from the original forum post included cycling the suspension with the springs out to help evaluate the issue, putting the passenger rear tire on blocks and jacking up the driver side of the front axle for further inspection, and replacing with a Currie Rock Jock front track bar (e.g., https://www.rockjock4x4.com/CE-9120TJS), Another user suggested that if I have upper and lower adjustable control arms, I could move the entire axle “back” a little. I’ll keep this in mind when I have some time to look at this issue again. I’ve put this issue on hold for now because I am already aware that I need to do some additional suspension work “soon” (e.g., replace my shocks). When I work on the suspension, I’ll probably also look a little closer at this track bar issue. In the meantime, I’ll try to be careful and monitor if/when contact seems to be occurring between these parts.