Sway bar end link contacting lower control arm

1. I have been through the gauntlet of TRD PRO alignment nonsense. I’ve burned through multiple sets of stock falken tires (Toyota has replaced them) and had multiple alignments to no avail. I decided to ditch the stock tire and get the real Falken wildpeak at4’s 35’s and brought it back to Toyota for alignment. When they tried to return the truck to me the front wheels were still bull dogged, too much chamber. The manager was great about it and said he understood the nonsense I’ve been through. My luck the alignment lift broke so they gave me loaner and had it “fixed” the next day. After driving a bit I began to hear a creaking sound. I crawled underneath later to discover the sway bar end link making contact with the lower control arm. Brought it back to the dealership, they said they think it’s because of correcting the chamber as to not destroy the tires. Of course their alignment lift is down so they want to send it to a different shop and hope to correct it. My question is, have any other PRO owners had this problem after adding larger tires or is this just the dealership not being able to balance the camber and caster? They say the tie rod is maxed out on one side. Or do I need to get after market UCA’s? Thanks
   
   
   
2. 
   Current alignment specs

 

Tie rod is maxed out, I would say something is wrong or bent? I had a 3.5 inch lift and never had an issue with tie rods or end links hitting. Something doesn't seem right. You could go with the Rough Country extended links to get back the angle of the sway bar.

https://www.roughcountry.com/product/sway-bar-links-10917

 

Thanks Rod, I’m not sure extending it isn’t just going to push it further into the control arm on both sides.

 

Your first picture there makes me curious, if you can find another pro or someone else here with a pro,
have them take a picture of the same area, i am wondering if the swaybar link is installed backwards, if its even possible can't see the whole thing

 

Doubtful, the sway bar hasn’t been touched since production.

 

doesn't rule out being installed incorrectly from factory in my opinion, still wouldn't hurt to look at another and compare though

 

Picture from motor trend shows same orientation of sway bar end links

 

And almost touching

 

Could you loosen the center sway bar brackets and move the sway bar towards one side or the other to even it? What does the other side of your sway bar look like?

 

My passenger side one has some good wear on it.

 

I haven’t taken it apart so I’m not sure if the bar moves freely or has some thing in place to stop it from sliding. Since the dealership is willing deal with it this next week I don’t want to mess with it. I’m just trying to figure out if any other pro owners have come across this or I’m just lucky and have the isolated problem.

 

It will move freely, but only when loosened. I would look at the other side and see if it's leaning away. Might just need to recenter. If that's the case, 5 minute fix tops. Good luck

 

I had another look at mine the end link is touching the control arm and it’s squeaking sometimes. I measured the sway bar and it appears to be even on both sides. Picture shows space on the driver side and none on the passenger. I have the 3” trd uca and 295/70 tires