I set it up to have as much positive caster as possible on both sides (matching the side that had the least max caster) and then re-adjusted to get the camber to match for both wheels. (all checked with the suspension settled etc.) I haven't measured the toe-in yet so that could be an issue although it looks pretty straight (I'm going to get in trouble for that one LOL).
One of the issues when I first installed (7 years ago) my 14" rims on the disc brake front end is that it shaved off the weights on my first drive LOL. So RustyRatRod, you are correct, those weight are definitely shaved off and were hitting the caliper causing them to shave the caliper shape out of the weights. But I have driven it with those weights on the vehicle for years without issues and this problem suddenly started last year.
My new tires and rims are finally mounted and balanced, so pretty soon I'll be able to rule those variables out.
Is it possible that a tie-rod end only starts having play under heavy load and not when you are normally turning the wheel etc.?
Before I take it in for the alignment I have decided to order new inner and outer tie rod ends and a new idler arm so at least I'll know that all front end parts are brand spanking new except for the pitman arm.
